Cateye ergociser EC-3200 User manual

CATEYE ERGOCISER
MANUAL LOAD-CHANGE TYPE
Applicable Models: EC-3200/EC-3500
SERVICE MANUAL

Cateye Ergociser Series 3000 Service Manual
2
EC-3200 EC-3500
Applicable Models
INDEX
INTRODUCTION
• How to Use This Service Manual -------------------------------------------------------------------------------------------------------------------------------------------------- 3
• Name of Parts
1.(EC-3200) Upright Type --------------------------------------------------------------------------------------------------------------------------------------------------------- 4
2.(EC-3500) Recumbent Type --------------------------------------------------------------------------------------------------------------------------------------------------- 6
3.(EC-3200B) Belt Drive Type --------------------------------------------------------------------------------------------------------------------------------------------- ADD-1
• Circuit Diagram------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 8
PART A
Symptoms and Cause of Problems ----------------------------------------------------------------------------------------------------------------------------------------------- 9
PART B
Repair and Adjustment Methods
EC-3200 EC-3500
D-1 Removing the Frame Covers -----------------------------------------------------------------------------------------------------------11
E-1 Replacing the 7P Cable Set -------------------------------------------------------------------------------------------------------------12
E-2 Replacing the CDC Sensor--------------------------------------------------------------------------------------------------------------13
E-3 Replacing the Workload Sensor Set --------------------------------------------------------------------------------------------------14
- E-4 Replacing the Button Panel -------------------------------------------------------------------------------------------------------------15
M-1 Replacing the Workload Unit------------------------------------------------------------------------------------------------------------16
M-2 Replacing the Chain-----------------------------------------------------------------------------------------------------------------------18
M-3 Replacing the Belt and Pulley "B" Set ------------------------------------------------------------------------------------------------19
M-4 Replacing the Pulley "A" Set ------------------------------------------------------------------------------------------------------------20
M-5 Replacing the Idler Set -------------------------------------------------------------------------------------------------------------------21
M-6 Replacing the Crank Set -----------------------------------------------------------------------------------------------------------------22
M-7 Replacing the BB Set ---------------------------------------------------------------------------------------------------------------------24
M-8 Replacing the Magnet Set ---------------------------------------------------------------------------------------------------------------25
M-9 Replacing the Workload Shift Lever---------------------------------------------------------------------------------------------------26
- M-10 Replacing the Post Spacer --------------------------------------------------------------------------------------------------------------27
- M-11 Adjusting the Spacer Spring-------------------------------------------------------------------------------------------------------------28
- M-12 Replacing the Inner Pipe Spacer-------------------------------------------------------------------------------------------------------29
- M-13 Replacing the Vertical Pipe Spacer ---------------------------------------------------------------------------------------------------30
- M-14 Replacing the Seat Post Knob----------------------------------------------------------------------------------------------------------31
- M-15 Replacing the Lock Pin -------------------------------------------------------------------------------------------------------------------32
M-16 Replacing the Caster & Level Adjuster -----------------------------------------------------------------------------------------------33
- M-17 Removing the EC-3200 Center Cover ------------------------------------------------------------------------------------------------34
- M-18 Removing the EC-3500 Center Cover ------------------------------------------------------------------------------------------------35
M-19 Replacing the Handlebar Grip ----------------------------------------------------------------------------------------------------------36
PART C
List of Genuin Parts --------------------------------------------------------------------------------------------------------------------------------------------------------------------37
INDEX

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
3
Applicable Models
How to Use This Service Manual
This service manual describes how to repair and adjust the Ergociser of manual load-
change type which utilizes a permanet magnet.
The manual consists of Part A, Part B and Part C. Part A refers to trouble-shooting which
allows you to identify the cause and areas to be fixed depending on typical symptoms. Part
B shows how to repair and/or adjust specific defects. Part C lists up all genuin parts and
corresponding part numbers that will be necessary for replacement or stock. Also, please
refer to Operating Instructions which comes with the Cateye Ergociser.
Whenever any problem has occurred on the unit, take the following actions to repair or
adjust it.
1. Check and identify the cause by referring to Part A.
2. Identify the part name by referring to Name of Parts.
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.
How to Use This Service Manual

Cateye Ergociser Series 3000 Service Manual
4
EC-3200
Applicable Models
Name of Parts Upright Type (EC-3200)
Connector Cover
Pulley B Mounting Nut / S Washer 1q
Workload Shift Lever
Idler Spring
Plane Washer
Name of Parts (EC-3200) Upright Type
PostSpacer
Handlebar Post Fixing Screw
Cable Holer (L)
Copper Plate
7P Cable
Magnet Set
Slit Plate Link Mounting Set 39w
Frame
Pulley B
Slit Plate Link Set
Cable Holder (L)
7P Cable Connector
Caster Pipe
Caster
Post Spacer
Spacer Spring Adjust Nut u
Crank
BB Set
Crank Nut
Cross-Recessed Head Hexagon Bolt r
Workload Unit Aluminum Frame
Rear Leg with Level Adjuster
Cable Holder (S)
Level Adjuster
Pulley A Fixing Set 1q
Workload Unit Fixing Bolt (4 pcs.) 8wt
2P Connector
Workload Sensor
i
8wt
2
o8wt

EC-3200
Cateye Ergociser Series 3000 Service Manual
5
Applicable Models
Cable Holder
Handlebar Post
Seat Post
Frame Cover
Center Cover
Crank Cover
Idler
Workload Unit Reinforcing Metal Plate
Timing Belt
Workload Shift Lever Fixing Bolt Set 0p
Name of Parts (EC-3200) Upright Type
Large Gear
Gear Crank
Chain
Crank Cap
CDC Magnet
CDC Sensor
Pulley "A"
Idler Fixing Screw 0
Free Wheel
Workload Frame Metal
Workload Shift Lever
Handlebar Post Fixing Screw
Stopper Metal Plate
Frame
Joint Bar
Magnet Set
Joint
Magnet Mounting Base
Leg Pipe Fixing Screw (4 pcs.) d
Rubber Base
s
a1
f
6ey

Cateye Ergociser Series 3000 Service Manual
6
EC-3500
Applicable Models
Pulley "B" Mounting Nut/Spring Washer 1q
Name of Parts Recumbent Type (EC-3500)
Name of Parts (EC-3500) Recumbent Type
Crank
Hanger Pipe
Crank Nut
Workload Unit Fixing Bolts 8wt
Cross-Recessed Head Hexagon Bolt r
Workload Unit Aluminum Frame
Frame
Idler Spring
Plane Washer
Copper Plate
Pulley "B"
Magnet Mounting Base
Slit Board Link Set
Slit Board Link Mounting Set 39w
Caster
Caster Pipe
Magnet Set
BB Set
7P Cable Connector
Workload Shift Lever
Cable Holer (L)
7P Cable
Joint Fitting
Cable Holder (L)
Pulley "A" Fixing Set 1q
2P Connector
7P Connector
Workload Sensor
Workload Unit Fixing Bolt (3 pcs.) 8wt
2
i

EC-3500
Cateye Ergociser Series 3000 Service Manual
7
Applicable Models
Frame Cover Control Panel Cover
Center Cover
Crank Cover
Seat Pipe
Rear Support Pipe
Inner Pipe
Name of Parts (EC-3500) Recumbent Type
Stopper Metal Plate
Workload Shift Lever Mounting Bolt Set 0p
Workload Shift Lever
Joint Bar
Large Gear
Chain
CDC Sensor
Crank Cap
CDC Magnet
Free Wheel
Pulley "A"
Workload Frame Metal Plate
Workload Unit Reinforcing Metal Plate
Idler
Idler Mounting Screw 0
Gear Crank
Pulley "B"
Frame
Timing Belt
Magnet Set
Joint
Joint Bar
Leg Pipe Fixing Screw (2 pcs.) d
1
6ey
0p

EC-3200B
Applicable Models
Cateye Ergociser Series 3000 Service Manual
ADD-1
Name of Parts (EC-3200B) Belt Drive Type
Crank Pulley 1-A Teethed Timing Belt (PM8x15-896)
Idler A SetPulley 1-B
Pulley 2-A
Pulley 2-B
Idler B Set
Idler A Reinforcing Plate
V-ribbed Belt (280-J6)
Idler B Spring
Belt Drive

EC-3200 EC-3500
Applicable Models
CN1 CN2
1
2
3
4
5
6
7
1
2
PH3 PH2 PH1
LED3
R3 LED2
R2 LED1 R1
Cateye Ergociser Manual Load-Change Type Circuit Diagram
7P Cable
Slit Board
CDC Magnet
CDC Sensor
Workload Sensor Circuit Board
7P Connector 2P Connector
Common
LED Control
CDC Signal
Circuit Diagram
To Control Unit
Workload Level
Position Signal
Cateye Ergociser Series 3000 Service Manual
8

EC-3200 EC-3500
Applicable Models
Symptom of Problem Check Method/Cause of Problem Remedy
The display of Pedal Rotations, Current Speed and/
or Distance remains at zero (0). Possible causes include: 1) Faulty connections (at three points)
2) Defective control unit
3) Defective CDC sensor
4) Breakage of cable
Check the cause as per the following procedures.
1. Ensure if the 7P connector, which is on the back
side of the control unit, is securely plugged.
If a correct display is restored, the control unit will not be
defective. However, ensure firm plugging of the connec-
tor.
2. Check if normal operation is restored when the 7P con-
nector is plugged to a new control unit. If a correct display is restored, the control unit will be de- fective. Replace the control unit.
3. Remove the frame cover, and check if the two2P and
7P connectors are securely plugged to the workload
sensor.
If a correct display is restored, the control unit will not be
defective, but the plugging of two connectors (2P) and (7P)
are insufficient.
4. Disconnect the 2P connector from the workload sensor.
Place two probes of a multimeter across the two termi-
nals of the 2P connector. Rotate the pedal and check if
the two terminals are conductive.
The CDC sensor will be defective if the two terminals are
not conductive once per revolution of the pedal. Replace the CDC sensor. Refer to Section E-2 "Re- placing the CDC Sensor."
7P cable will be broken if the two terminals are conductive
once per revolution of the pedal. Replace the cable set. Refer to Section E-1 "Replac-
ing the 7P Cable Set."
Workload Shift Position Mark will not be displayed.
Workload Shift Position Mark will not change. Possible causes include: 1) Faulty connections (at three points)
2) Defective control unit
3) Defective CDC sensor
4) Breakage of cable
Check the cause as per the following procedures.
1. Ensure if the 7P connector, which is on the back side of
the control unit, is securely plugged.
If a correct display is restored, the control unit will not be
defective. However, ensure firm plugging of the connec-
tor.
2. Check if normal operation is restored when the 7P con-
nector is plugged to a new control unit. If a correct display is restored, the control unit will be de- fective. Replace the control unit.
3. Remove the frame cover, and check if the 7P connec-
tors is securely plugged to the workload sensor.
If a correct display is restored, the control unit will not be
defective, but the plugging of the connector (7P) are insuf-
ficient.
4. Disconnect the 7P connector from the workload sensor. Place two probes of a multimeter across the end terminals
of 7P connector to check the conductivity.
* Place the probes at the connector slots of the same No.
both across the large and small connectors.
If all the seven wires are found conductive, the
workload sensor will be defective. Replace the sen-
sor. Refer to Section E-3 "Replacing the Workioad
Sensor."
Replace the cable set. Refer to Section E-1 "Replac-
ing the 7P Cable Set."
The cable will be broken if a specific wire of the cable
shows no conductivity.
The operation of workload shift lever will not result in
correct display of the workload shift lever position. The position of the workload sensor is incorrect. Adjust the position of the workload sensor. Refer to Section E-3 "Replacing the Workload Sensor Set."
Symptoms and Cause of Problems 1
Cateye Ergociser Series 3000 Service Manual
9

EC-3200 EC-3500
Applicable Models
Symptom of Problem Check Method/Cause of Problem Remedy
The control unit will be defective. Replace the control unit.
The pulse rate reading remains at zero (0), and it
does not count. Follow the section "Checking the Pulse Sensor" in the Operating Instructions to check if the pulse
sensor works correctly.
When the check revealed any breakage or damage of
wires, the pulse sensor is defective. Replace the pulse sensor.
Replace the control unit.
No workload. Remove the frame cover, and check the following points. Refer to Section D-1 "Removing the Frame Cover."
Replace the chain if it is broken. Refer to the Section M-2 "Re-
placing the Chain."
2. Check if the free wheel is idle-running. *Rotate the pedal, and check if the belt rotates.
4. Check if the pulleys are damaged. Replace the pulley "A" set if it is broken or worn out. Refer to the
Section M-4 "Replacing the Pulley "A" Set."
1. Check if there are any problems with the chain.
Replace the pulley "A" set if the free wheel is idle-running. Refer
to the Section M-4 "Replacing the Pulley "A" Set."
3. Check if there are any problems with the belt. Replace the belt if it is broken or worn out. Refer to the Section
M-3 "Replacing the Belt and Pulley "B" Set."
Replace the pulley "B" set if it is broken or worn out. Refer to the
Section M-3 "Replacing the Belt and Pulley "B" Set."
Seat post slips down abruptly. Incorrect adjustment of the spacer spring. Adjust the spacer spring. Refer to the Section M-11 "Adjusting
the Spacer Spring."
Abnormal sounds in the unit.
The operating noise (continuous) has become larger.
Adjust and set the tensioning as specified. Refer to the Section
M-2 "Replacing the Chain."
Noise occurs periodically.
1. Noise occurs once per rotation of the pedal.
2. Abnormal noise is heard while the pedal is being
rotated. The copper plate contacts the magnet set. Adjust the position of the magnet set. Refer to the Section M-8 "Replacing the Magnet Set."
Symptoms and Cause of Problems 2
An "All Clear" operation will not rectify abnormal dis-
plays.
In case the pulse sensor is normal, the control unit will be
defective.
Grease the chain. Greasing of the inner surface of the belt
(mading surface with the pulley) will also contribute to reduce the
noise level. Refer to the Section D-1 "Removing the Frame
Cover."
Incorrect tensioning of the chain.
Fasten the pedal onto the crank with a No. 15 wrench.
Replace the pedal.
Fastening of the pedal is loose.
Bearings of the pedal are defective.
Lack of chain lubrication.
Cateye Ergociser Series 3000 Service Manual
10

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
11
Applicable Models
D-1
D-1
When any repairs or adjustments of parts within the frame cover is
required, remove the frame covers in the following procedures.
àREMOVAL
(1)Remove the pedals at both the left and right sides.(Fig. 1)
(2)Remove the crank cover fixing screws. The narrow-width area of
the crank cover should position in between the frame cover and the
crank.(Fig. 2)
(3)Remove the leg pipe fixing screws.(Fig. 3)
* You do not have to remove the leg pipe itself.
(4)For the upright type (EC-3200), disassembling should be made in
the following procedures:
1. Detach the rubber base at the seat post lock knob from the cen
ter cover.
2. Loosen the center cover fixing screw a little, and lift the center
cover upward. (Do not remove it.)(Fig. 4)
* In the case of the recumbent type model, no center cover fixing
screws are available.
(5)Remove the frame cover fixing screw with a screwdriver before re-
moving the frame cover.(Fig. 5)
àASSEMBLING
(1)Place the frame covers onto the frame at both right and left sides,
paying attention to the position of the crank.
* In the case of the recumbent type model, the center cover
should be placed in between the right and left frame
covers when the two covers are to be mated each other.
(2)Fix the right and left frame covers with frame cover fixing screws.
(3)Set the center cover to the frame cover correctly in position, and fix
it with the center cover fixing screws.(Fig. 4)
* This procedure is for the upright type model only.
(4)Pass the crank through the hole on the crank cover, and fix the
crank cover onto the frame cover with screws.(Fig. 2)
(5)Set the rubber base at the seat post lock knob, and then mount the
right and left pedals.
Removing the Frame Covers
No. 15 Wrench
Crank
Pedal
Removing the Frame Covers
Crank Cover
Center Cover
Lift upward.
Leg Pipe Fixing Screw
Center Cover
Fixing Screw
Frame Cover
Fixing Screw
Frame Cover
Remove the frame cover
sideways.

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
12
Applicable Models
E-1
E-1
Fig.1 Fig.2 Fig.3
Fig.4 Fig.5
Fig.6 Fig.7
Control Unit
78cm for Upright Type
Fig.8 Fig.9
Replacing the 7P Cable Set
(1)Procedures are different depending on the type of model as shown
below:
TUpright Type (EC-3200)
Remove the 7P cable connector to the control unit, and then re-
move the cable from the cable holder of the handlebar post.
TRecumbent Type (EC-3500)
Remove the control panel cover before taking out the control
unit, and disconnect the 7P cable connector.(Figs. 2,3)
(2)Remove the frame cover, by referring to the Section D-1
"Removing the Frame Cover."
(3)Remove the 7P cable connector to the workload sensor.(Fig. 6)
(4)Cut the two cable clips which fix the cable to the frame, and remove
the existing cable.
(5)Mark the brandnew cable set as per the following procedures.Fig.
7)
EC-3200: Mark the cable at the position 78cm from the large cable
connector.
EC-3500: Mark the cable at the position 36cm from the large cable
connector.
(6)Apply a cable clip at the position marked in step (5) above, and fix
the cable to the square pipe at a position just below the welded
area. (For EC-3200: Fig.8, EC-3500: Fig. 9) Also, fix the cable at
the lower part of the square pipe. To apply a cable clip, strongly
pull the clip by using a plier, and cut the excessive part.
(7)Firmly connect the 7P cable connector (smaller) to the workload
sensor.(Fig. 6)
(8)Pull the cable out of the center cover through the hole on the cover,
and connect the 7P cable connector (larger) to the control unit.
Check if the control unit operates correctly.
* In the case of the recumbent type model, pull the 7P cable
connector out of the center cover through the hole on the cover,
and tentatively hold it with an adhesive tape so that it may not be
retructed.
(9)Reassemble the frame cover, by referring to the Section D-1 "Re-
moving the Frame Cover."
(10) Connect the 7P cable connector to the control unit.
TUpright Type (EC-3200)
Set the connector cover, and fix the cable holder to the handle-
bar post.
TRecumbent Type (EC-3500)
Mount the control unit to the frame along with the control panel
cover.
Cable
Connector
Cable Holder
Control Panel Cover
Cable Connector
7P Cable
Workload Sensor
Workload Sensor
7P Cable
7P Connector
Workload Sensor
Cable Connector (L)
36cm for Recumbent Type
Mark
7P Cable
Cable
Holder
EC-3200 EC-3500
Replacing the 7P Cable Set
Cable Holder
(at marked position)
Cable Holder
(at marked position)

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
13
Applicable Models
2P
Connector
E-2
E-2
Fig.1 Fig.2
Fig.3 Fig.4
Fig.5
Fig.6 Fig.7
CDC Sensor
CDC Sensor
Replacing the CDC Sensor
(1)Disconnect the frame cover, by referring to the Section D-1 "Re-
moving the Frame Covers." (Figs. 1,2)
(2)Disconnect the 2P connector from the workload sensor.(Fig. 3)
(3)Cut the cable clips which fix the CDC sensor cord to the workload
unit aluminum frame.
(4)Loosen the screws which fix the CDC sensor (defective) to remove
the sensor. Mount and fix a brandnew CDC sensor.(Fig. 4)
(5)Perform the following adjustment:
1. Align the line on the CDC sensor with the center of the line on the
CDC magnet. (Figs. 5,6)
2. The clearance between the CDC sensor surface and the magnet
surface should be approx. 2mm. (Fig. 6)
* When the specified clearance has not been established, bend
the metal base to have the celarance.
(6)Firmly connect the 2P connector to the workload sensor.(Fig. 3)
(7)Rotate the crank, and check if the number of pedal rotations is dis-
played on the control unit.
(8)Fix the CDC sensor cord to the workload unit aluminum frame by
using cable clips.(Fig. 7)
(9)Assemble the frame cover, by referring to the Section D-1
"Removing the Frame Covers."
CDC Sensor
Workload
Sensor
Line on CDC
Magnet
Line on CDC
Sensor
Line on CDC
Sensor
Center of CDC
magnet
Cable Clip
EC-3500EC-3200
Replacing the CDC Sensor
Approx. 2mm clearance between CDC sensor
and CDC magnet

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
14
Applicable Models
E-3
E-3
Fig.1 Fig.2
Fig.3 Fig.4
Fig.5
Fig.6
Workload Sensor
7P
Connector
2P
Connector
2mm
(1)Remove the frame cover, by referring to the Section D-1
"Removing the Frame Covers." (Figs. 1 , 2)
(2)Disconnect the 2P and 7P connectors from the workload
sensor.(Fig. 3)
(3)Remove the workload sensor by loosening screws. Do this step
carefully not to damage the slit board.(Fig. 4)
(4)Insert a brandnew workload sensor into the slit board.(Fig. 5)
(5)Set the workload shift lever to Point 8. Adjust the position of the
workload sensor set so that the center part of the slit board pro-
trude approx. 2mm from the low end of the workload sensor set.
Fix the slit board with screws.(Fig. 6)
(6)Connect 2P and 7P connectors to the workload sensor.(Fig. 3)
(7)Check if the control unit operates properly.
(8)Assemble the frame cover, by referring to the Section D-1 "Re-
moving the Frame Covers."
EC-3500
Workload Sensor
EC-3200
Workload
Sensor
Workload Sensor
Workload Sensor
Slit Board
Workload Sensor
Slit Board
Replacing theWorkload Sensor Set
Replacing the Workload Sensor Set

EC-3200
Cateye Ergociser Series 3000 Service Manual
15
Applicable Models
E-4
E-4
C
Fig.1
Replacing the Button Panel
(1)Insert a thin cutting knife, while paying cautions not to damage
the control unit,in between the button panel and the unit, and
carefully peel off the damaged button panel.(Fig. 1)
(2)Clean the adhesive agent, if any, on the control unit before
placing a brandnew button panel.
* Sufficiently press the button panel thus placed.
Button Panel
Replacing the Button Panel

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
16
Applicable Models
M-1
M-1
Fig.1 Fig.2
Fig.3
Fig.4
Fig.5 Fig.6
Workload Unit
EC-3200
Workload Unit
EC-3500
Joint Bar
Joint
Joint Nut
Nut Pulley "B" Shaft
Pulley "A" Shaft
Bolt
Workload Frame
Metal Base
Bolt
Workload Unit Reinforcing
Metal Base Frame
Aluminum Frame
Workload
Unit
Workload Fixing Bolt
Replacing the Workload Unit 1
(1)Remove the frame cover, by referring to the Section D-1
"Removing the Frame Cover." (Figs. 1 ,2)
(2)Remove the joint nut, by using a wrench, which is located just
below the joint bar that connects the workload shift lever and the
workload unit.(Fig. 3)
(3)Move the workload shift lever to remove the joint bar from the joint.
(Fig.3)
(4)Remove a nut from the pulley "B" shaft and two bolts from the
pulley "A" shaft and the frame, and remove the workload frame
metal base together with the workload unit reinforcing metal
base.(Fig. 4)
(5)Use a screwdriver to loosen the cross-recessed head hexagon bolt
which presses the workload unit aluminum frame to the hanger
pipe, until the leading edge of the screw is concealed by the alumi-
num frame.(Fig. 5)
(6)Use a hexagon wrench to loosen the four (three for EC-3500)
workload unit fixing bolts which fix the workload aluminum frame to
the main unit.(Fig. 6)
Caution: Never remove these bolts, but just loosen them.
- to be continued on the next page -
Replacing the Workload Unit
Cross-recessed
Head Hexagon Bolt
Workload Unit Fixing
Bolt

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
17
Applicable Models
M-1
M-1
Fig.7
Fig.8
Fig.9 Fig.10
Fig.11
Upper Part of Large Gear
Chain
Workload Sensor
2P
Connector
7P
Connector
Workload Unit Fixing
Bolt
Workload Unit Fixing Bolt
Upper Part of Large Gear
Chain
Slack of 3 to 7mm
Replacing the Workload Unit 2
(7)Slide the workload unit aluminum frame toward the side of the
hanger pipe to loosen the tension of the chain, and remove the
chain. The entire chain can be removed when it is first removed at
the upper part of the large gear, and then rotate the crank
forward.(Fig. 7)
(8)Disconnect 2P and 7P connectors from the workload sensor.(Fig.
8)
(9)Remove four workload unit fixing bolts which has been loosening in
step (6), and remove the workload unit from the frame.(Fig. 9)
(10)Mount a brandnew workload unit. Mounting of the workload unit
can be done in the procedures opposite to disassembling.
(11)The chain should be first set on the free wheel, and then on the
upper part of the large gear. A forward rotation of the crank will
enable the complete setting.(Fig. 10)
(12)Adjust the tension of chain. Fasten the cross-recessed head
hexagon bolt to press the aluminum frame to the hanger pipe. The
tension of chain should be adjusted as illustrated in Fig. 11.
* Be careful about excessive tensioning of the chain. After com-
pleting the adjustment, fasten the four (three for EC-3500)
workload unit fixing bolts with a hexagon wrench.(Fig. 9)
(13)Fix the workload frame metal base to the pulley "B" shaft with a
nut, and to the pulley "A" shaft with a bolt, fix it to the frame with
bolts.(Fig. 4)
(14)Connect 2P and 7P connectors from the workload sensor.(Fig. 8)
(15)Assemble the frame cover, by referring to the Section D-1 "Re-
moving the Frame Covers."
Replacing the Workload Unit

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
18
Applicable Models
M-2
M-2
Fig.1 Fig.2
Fig.3
EC-3200
Fig.4
Fig.6 Fig.7
Fig.5
Chain
Chain
Replacing the Chain
(1)Remove the frame cover, by referring to the Section D-1 "Remov-
ing the Frame Covers." (Figs. 1 ,2)
(2)Remove a nut from the pulley "B" shaft and two bolts from the
pulley "A" shaft and the frame, and remove the workload frame
metal base together with the workload unit reinforcing metal
base.(Fig. 3)
(3)Loosen the cross-recessed head hexagon bolt which presses the
workload unit aluminum frame to the hanger pipe, until the leading
edge of the bolt screw is concealed within the aluminum frame.(Fig.
4)
(4)Loosen the four (three for EC-3500) workload unit fixing bolts which
fix the workload unit aluminum frame to the unit, by using a
hexagon wrench.(Fig. 5)
Caution:Never remove the workload unit fixing bolts, but just loosen
them.
(5)Slide the workload unit aluminum frame toward the side of hanger
pipe, and loosen the tension of chain to detach it. First, detach the
chain at the upper part of the large gear, and then rotate the crank
forward to detach the entire chain.(Fig. 6)
(6)A brandnew chain should be first set on the free wheel, and then on
the upper part of the large gear. A forward rotation of the crank will
enable the complete setting of the gear.(Fig. 7)
(7)Adjust the tension of chain. Fasten the cross-recessed head hexa-
gon bolt to press the aluminum frame to the hanger pipe. The
tension of chain should be adjusted as illustrated in Fig. 8.
* Be careful about excessive tensioning of the chain. After com-
pleting the adjustment, fasten the four (three for EC-3500)
workload unit fixing bolts with a hexagon wrench.(Fig. 5)
(8)Fix the workload frame metal base to the pulley "B" shaft with a nut,
and to the pulley "A" shaft with a bolt, fix it to the frame with
bolts.(Fig. 3)
(9)Assemble the frame cover, by referring to the Section D-1
"Removing the Frame Covers."
EC-3500
Nut
Bolt
Workload Frame
Metal Base
Bolt
Pulley "B" Shaft
Pulley "A" Shaft
Frame
Aluminum
Frame
Cross-recessed
Head Hexagon
Bolt
Workload
Unit
Slide
Workload Unit
Fixing Bolt
Workload Unit
Fixing Bolt
Upper Part of
Large Gear
Chain
Upper Part of
Large Gear
Chain
Fig.8
Approx. 3 to 7mm slack
Replacing theChain
Workload Unit
Reinforcing Metal Base

EC-3200 EC-3500
Cateye Ergociser Series 3000 Service Manual
19
Applicable Models
M-3
M-3
Fig.1 Fig.2
Fig.4 Fig.5
Fig.6 Fig.7 Fig.8
Fig.3
Pulley "A"
Pulley "B"
Replacing the Belt and Pulley "B" Set
àREMOVAL
(1)Remove the frame cover, by referring to the Section D-1
"Removing the Frame Covers." (Figs. 1,2)
(2)Remove a nut from the pulley "B" shaft and two bolts from the
pulley "A" shaft and the frame, and remove the workload frame
metal base together with the workload unit reinforcing metal
base.(Fig. 3)
(3)Remove the idler spring from the latch of the idler metal base.(Fig.
4)
(4)Move the workload shift lever to the Point 8 to position the magnet
horizontally.(Fig. 5)
(5)Remove the bolts which fix the magnet to the magnet mounting
base, by using a hexagon wrench, and remove the magnet set.(Fig.
5)
(6)Detach the gear crank and chain, by referring to Steps (3) thru (8),
"Removing the Gear Crank", Section M-6 "Replacing the Crank
Set." (Do not remove the crank at the left side.)
(7)Remove nuts from the pulley "B" shaft and the pulley "A" shaft at
the aluminum frame side, and then remove belt, pulley "A" and
pulley "B" in this order.
àASSEMBLING
(1)Set a plane wahser to the pulley "B" shaft, and mount the pulley "B"
and pulley "A" to the workload aluminum frame in this order, by
using spring washers and nuts. Then, apply a brandnew belt.
(2)Mount the gear crank and chain, by referring to Steps (1) thru (5),
"Assembling the Gear Crank", Section M-6 "Replacing the Crank
Set."
(3)Put the magnet set on the magnet mounting base, and make
position adjustment against the copper plate in the following
procedures:
1. Place the magnet set so that the inner side of the magnet side
can be positioned approx. 2mm inward of the outer edge of the
copper plate.(Fig. 7)
2. The copper plate should position at the center of the gap of mag-
net. * Rotate the copper plalte to check if it does not contact the
magnet at any position during the rotation.(Fig. 8)
(4)Fix the magnet set to the magnet mounting base, by using a cap
bolt, a spring washer, and a plane washer.(Fig. 5)
(5)Hang the idler spring on the latch of the idler to give tension to the
belt.(Fig. 4)
(6)Fix the workload unit frame metal base to the pulley "B" shaft by
using a nut and to the pulley "A" shaft by using a bolt, and then fix
the metal base to the frame with bolts.(Fig. 3)
(7)Assemble the frame cover, by referring to the Section D-1
"Removing the Frame Covers."
Pulley "B"
EC-3200
Timing Belt
EC-3500
Timing Belt
Pulley "B"
Workload Unit
Frame Metal Base
Pulley "A" Shaft
Pulley "B"
Shaft
Idler Metal Base
Latch
Idler
Spring
Magnet
Plane
Wahser
Approx. 2mm
Copper Plate
Replacing theBelt and Pulley "B"Set
Workload Unit Reinforcing
Metal Base
Magnet The copper plate aligns with
the center of the magnet. The copper plate contacts the magnet.
Magnet Mounting
Base
Hexagon
Wrench