Cateye ERGOCISER EC-3600 User manual

CATEYE ERGOCISER
AUTOMATIC TYPE
Applicable Models: EC-1200/EC-1600/EC-3600/EC-3700
SERVICE MANUAL

Cateye Ergociser Series 1000 Service Manual
2
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
INDEX
Repair & Adjustment Methods
EC-1200 EC-1600 EC-3600 EC-3700
ES-1: Replacing the Wiring within the Frame ----------------------- 24
ES-2: Replacing the 5P Cable ---------------------------------------25~26
ES-3: Replacing the Power Supply Board----------------------------27
ES-4: Correcting the Position of Solenoid Coil--------------------- 28
ES-5: Replacing the CDC Sensor --------------------------------------- 29
--ES-6: Replacing the Panel Keyboard ---------------------------------- 30
--ES-7: Replacing the Button Panel -------------------------------------- 31
--ES-8: Replacing the Printer ----------------------------------------------- 32
--ES-9: Adjusting the Printing Darkness-------------------------------- 33
--ES-10: Paper Jamming in Printer ----------------------------------------- 24
--MS-1: Replacing the Workload Unit (w/o Flywheel) ----------35~37
GMS-2: Replacing the Workload Unit (w/ Flywheel) --------------- 38
--MS-3: Adjusting the Flywheel--------------------------------------------- 39
MS-4: Replacing the Chain------------------------------------------------- 40
MS-5: Replacing the Free Wheel Set ----------------------------------- 41
MS-6: Replacing the Derailleur Set-------------------------------------- 42
MS-7: Replacing the Idler Set --------------------------------------------- 43
MS-8: Replacing the Crank Set --------------------------------------44~45
MS-9: Replacing the BB Set ----------------------------------------------- 46
--MS-10: Replacing the Post Spacer---------------------------------------- 47
--MS-11: Adjusting the Spacer Spring ------------------------------------- 48
--MS-12: Replacing the Inner Pipe Spacer-------------------------------- 49
--MS-13: Replacing the Vertical Pipe Spacer ---------------------------- 50
--MS-14: Replacing the Leg Cover ------------------------------------------ 51
--MS-15: Replacing the Caster/Level Adjuster -------------------------- 52
--MS-16: Replacing the Seat Post Knob----------------------------------- 53
--MS-17: Replacing the Lock Pin -------------------------------------------- 54
MS-18: Replacing the Crank Cover --------------------------------------- 55
--MS-19: Replacing the Center Cover of Upright Type --------------- 56
--MS-20: Replacing the Center Cover of Recumbent Type --------- 57
MS-21: Replacing the Handlebar Grip ----------------------------------- 58
--MS-22: Replacing the Printer Cover -------------------------------------- 59
--MS-23: Replacing the Paper Cutter --------------------------------------- 60
PART C
List of Genuine Parts -------------------------------------------------------------------------------------------- 61~65
INDEX
INTRODUCTION
• How to Use This Service Manual
• Name of Parts
1. Upright Type (w/o Flywheel)---------------------------------------------------------- 4~5
Upright Type (with Flywheel)--------------------------------------------------------- 6~7
2. Recumbent Type (EC-3600 & EC-3700) -------------------------------------------8~9
3. Belt Drive (EC-1200B, EC-1600B, EC-3600B & EC-3700B) ----------ADD.1~2
• Circuit Diagram ----------------------------------------------------------------------------------10
Part A
Symptoms of Problems & Causes
T-1: No Display on Control Unit after Power ON-----------------------------------11~12
T-2: No Display of Cadence --------------------------------------------------------------------13
T-3: No Display of Pulse Rate -----------------------------------------------------------------14
T-4: No Printer Operation -----------------------------------------------------------------------15
T-5: No Loading -------------------------------------------------------------------------------16~17
T-6: No Pedal Rotation (Locked) -------------------------------------------------------------18
T-7: Unusual Noise
1. Continuous and Increasing. -------------------------------------------------------19
2. Periodical.--------------------------------------------------------------------------------20
3. Noise occurs when the pedal is rotated with a large loading. ---------21
Part B
Removing the Frame Covers
D-1: Upright Type (EC-1200 & EC-1600)----------------------------------------------------22
D-2: Recumbent Type (EC-3600 & EC-3700) ----------------------------------------------23

EC-1200 EC-1600 EC-3600 EC-3700
Cateye Ergociser Series 1000 Service Manual
3
Applicable Models:
R
EC-3700
ON
OFF
EC-1600
RESET
MODE
ADV
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
Whenever any problem has occurred on the main unit, take the following actions to repair or adjust it.
1. Check and identify the cause by referring to Part A.
2. Identify the parts name by referring to Name of Parts.
3. Perform repair or adjustment in accordance with the instructions in Part B.
4. Replacement, if required, should be done by using genuine parts as specified in Part C.
How to Use This Service Manual

Cateye Ergociser Series 1000 Service Manual
4
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Name of Parts for Upright Type (w/o Flywheel)
Post Spacer
Lock Nut
Frame
Cable Holder
Large Gear
CDC Magnet
Connector Cover
5P Cable Connector
5P Cable
CDC Sensor
Frame
Leg Cover
Leg Pipe
Leg Pipe Fixing Screw
Caster
Levelling Knob
Adjust Screw
Spacer Spring
Crank
Crank Cap
BB Set Post Spacer
Lock Nut
Adjust Screw
Spacer Spring
Seat Pipe
Timing Belt
Inlet Metal Base
Power Switch
Copper Plate
Idler
Idler Fixing Bolt [M6x16]
Idler Metal Base
Idler Spring
Wiring within Frame
Levelling Knob
Workload Unit
Solenoid Coil Mounting Base
Solenoid Coil
Power Supply Board
Name of Parts for Upright Type (w/o Flywheel)
Plastic Pulley
9
6
8
4
0
9
6
qSW Nut (M6)
Power Supply Board Fixing Screw
[Tapping Screw(2) 4x12c]
Workload Unit Mounting Base
[Screw Set (+) (M6x16)]

EC-1200 EC-1600 EC-3600 EC-3700
Cateye Ergociser Series 1000 Service Manual
5
Applicable Models:
EC-1200
Inlet Metal Base
AC Adapter Inlet
Chain
Workload Unit Reinforcing Metal Base Nut
Workload Unit Reinforcing Metal Base
Leg Pipe Fixing Screw
Leg Pipe
Lever Cover
Cable Holder
Handlebar Post
Seat Post
Center Cover
Frame Cover
Crank Cover
Workload Unit
Fixing Bolt
Free Wheel Set
Hexagon Head U Nut
Solenoid Coil
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
Derailleur
Crank Nut
Levelling Knob
Derailleur Spring
Name of Parts for Upright Type (w/o Flywheel)
Power Supply Board
2
Hexagon Nut (M8-3)
1
4
3
9
Screw Set(+) (M6x16)
4
Tapping Screw (4x12) with Washer
5

Cateye Ergociser Series 1000 Service Manual
6
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Name of Parts for Upright Type (w/ Flywheel)
5P Cable
Post Spacer
Adjust Screw
Cable Holder
Large Gear
CDC Magnet
CDC Sensor
Frame
Caster
Leg Pipe Fixing Screw
Leg Pipe
5P Cable Connector
Lock Nut
Flywheel Mounting Metal Base
BB Set
Crank Cap
Crank
Power Supply Board
Power Supply Board Fixing Screw
[Tapping Screw(2) 4x12c]
Post Spacer
Lock Nut
Adjust Screw [M8x10]
Spacer Spring
Seat Pipe
Flywheel Metal
Flywheel Fixing Screw [SW Nut(M6)]
Flywheel Metal Base Fixing Screw
[Screw Set (+) (M6x16)]
Inlet Metal Base
Power Switch
Copper Plate
Idler
Idler Mounting Bolt [M6x16]
Idler Metal Base
Idler Spring
Timing Belt
Wiring within Frame
Leg Pipe
Levelling Knob
Workload Unit Mounting Base
[Screw Set (+) (M6x16)]
Plastic Pulley
Workload Unit
Solenoid Coil Mounting Base
Solenoid Coil
Name of Parts for Upright Type (w/ Flywheel)
qSW Nut (M6)
04
4
q
9
6
4

EC-1200 EC-1600 EC-3600 EC-3700
Cateye Ergociser Series 1000 Service Manual
7
Applicable Models:
CDC Magnet
Flywheel
Flywheel Fixing Screw
Flywheel Metal Base Fixing Screw
Flywheel Metal Base
AC Adapter Inlet
Inlet Metal Base
Plain Belt
Chain
Workload Unit Reinforcing Nut
[Hexagon Nut (M6-3)]
Workload Unit Reinforcing Metal Base
Flywheel Mounting Metal Base
Power Supply Board
Hexagon Head U Nut
Free Wheel Set
Workload Unit
Derailleur
Spring
Workload Unit Mounting
Bolt (M6x16)
Derailleur
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
Solenoid Coil
Handlebar Post Cover
Seat Post
Center Cover
Frame Cover
Crank Cover
Name of Parts for Upright Type (w/ Flywheel)
2
Hexagon Nut (M8-3)
1
43
Crank Nut (M10x1.25)
7
Screw Set(+) (M6x16)
4
Tapping Screw (4x12) with Washer
5

Cateye Ergociser Series 1000 Service Manual
8
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
R
Name of Parts for Recumbent Type (EC-3600 & EC3700)
Wiring within Frame
Flywheel Metal Base Fixing Screw
Flywheel
Flywheel Fixing Screw
Flywheel Metal Base
Plain Belt
Power Supply Board Fixing Bolt
Power Supply Board Crank
Crank Nut 5P Cable Connector
5P Cable Set
Cable Holder
Frame
BB Set
Copper Plate
Timing Belt
Idler
Idler Metal Base
Idler Fixing Bolt
Idler Spring
Plastic Pulley
Workload Unit
Solenoid Coil
Solenoid Coil
Mounting Base
Frame Cover
Center Cover
Crank Cover Rear Support Pipe
Inner Pipe
Seat Pipe
Leg Pipe Fixing Screw
Name of Parts for Recumbent Type
4
q
0
7
8
4
Workload Unit Mounting Base [Screw Set (+) (M6x16)]

EC-1200 EC-1600 EC-3600 EC-3700
Cateye Ergociser Series 1000 Service Manual
9
Applicable Models:
ON
OFF
Cable Holder
Chain
CDC Sensor
Workload Unit Reinforcing Nut
Workload Unit Reinforcing Metal Base
Workload Unit
Hexagon Head U Nut
Free Wheel Set
Derailleur
Solenoid Coil
Derailleur
Mounting Bolt
Power Supply Board
Cable Holder
Flywheel
Plain Belt
Flywheel Fixing Screw
Flywheel Metal Base Fixing Screw
Inlet Metal Base
AC Adapter Inlet
Power Switch
Front Leg with Casters
Caster
Name of Parts for Recumbent Type
CDC Magnet
Workload Unit Mounting Base
[Screw Set (+) (M6x16)]
4
4Screw Set (+) [M6x16]
3
4
q
2

EC-1200B EC-1600B
Applicable Models:
Belt Drive
Name of Parts for Belt Drive Type
Teethed Timing Belt (P8M15-1192)
Pulley 2-A Set
Idler A Set
Idler Spring A
Pulley 1-A Set
Pulley Flange
Pulley 1-B
Workload Unit
Teethed Timing Belt (P8M15-1192)
Pulley 2-A Set
Pulley 1-B Idler A Set
Workload Unit Idler Spring A
Pulley 1-A Set
Pulley Flange
EC-1600B EC-1200B
Cateye Ergociser Series 1000 Service Manual
ADD. 1

EC-3600B/EC-3700B
Applicable Models:
Name of Parts for Belt Drive Type
Teethed Timing Belt (P8M15-1080)
Pulley 2-A Set
Pulley 1-B
Workload Unit
Idler A Set
Idler Spring A
Pulley 1-A Set
Pulley Flange
Belt Drive
EC-3600B/EC-3700B
Cateye Ergociser Series 1000 Service Manual
ADD. 2

EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
CN4
+ –
C1 –
+C2
R8
REG
R1
TR1
R2
TR2 R3
IC1
R7 VR1
D1
CN3
CN2
CN1
–
+
–––
+
Circuit Diagram for Automatic Type Cateye Ergociser
AC Plug
100V AC
AC Adapter
12V DC*
DC Connector
*Fluctuate depending on the electric load
About 16V when the load is zero. AC Adapter Inlet
Black Cable (-)
Red Cable (+)
Wiring within Frame
Switch
CN4 (Connector 4)
DC Power Supply
(Connector 4)
Power Supply Control Circuit
for Printer
Solenoid Coil Current Control Circuit
Power Supply Board
Cadence Sensor
Magnet
5P Cable to Control Unit
Common Line
Cadence Signal
Control Unit Power Supply
Solenoid Coil Current Control Signal
Printer Power Supply (+5V)
Metal Pulley
Coil
Timing Belt
Electromagnet Copper Disk Plate
Plastic Pulley
Chain
Free Wheel
Cadence Sensor
Magnet
Large Gear
Crank
Circuit Diagram
Pedal
Cateye Ergociser Series 1000 Service Manual
10

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
11
T-1
T-1
Black Cable
No Display on Control Unit after Power ON. (1)
Check the power is available at the wall socket before proceeding to
checking of causes.
[1] Checking the AC Adapter
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.
3. Using a tester, measure the voltage at the plug which will be
connected to the main unit. (Fig. 1)
tThe 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.
tWhen the measured voltage is 0V, or less than 14V, the
AC adapter will be defective.
Note: Never short-circuit the plug of AC adapter. This will
damage the AC adapter.
[2] Checking the Wiring within the Frame
1.When the 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)
2. Remove the 5P cable which is connected to the back of the
control unit. (Fig. 2)
3. Connect the AC adapter, and turn on the main unit.
4. Using a tester, measure the voltage across the terminals 1 (-)
and 3 (+) of the 5P cable. (Fig. 3)
tThe 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.
Fig. 1
Normal for 14V thru 19V
Red Cable
DC Connector
Fig. 2
Cable Connector
Fig. 3
Normal for 14V thru 19V
Black Cable Red Cable
5P Cable
Terminal 1 (-)
No Display on Control Unit after Power ON. (1)
Replace the AC adapter.
Replace the control unit.
Terminal
3 (+)

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
12
T-1
T-1
No Display on Control Unit after Power ON. (2)
[3] When the meter reading at step 2. is 0V or less than 14V, check the
main unit in accordance with the following procedures:
1. Remove the frame cover. (See sections D-1 and D-2
"Removing the Frame Covers.")
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)
tThe 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.
tWhen the measured voltage is 0V, the wiring within the
frame is defective.
tWhen the problem cannot be remedied even if the 5P cable
is replaced, the power supply board may be defective.
Fig. 4
Correct for 14V thru 19V
Power Supply Board
Black Cable
Red Cable
Fig. 5
Power Supply Board A
Fig. 6
Power Supply Board B
No Display on Control Unit after Power ON. (2)
Replace the 5P cable. (See the Section ES-2
"Replacing the Frame.")
Replace the Inlet Metal Base Set. (See the Section
ES-1 "Replacing the Wiring within the Frame."
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board. "Fig. 4

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
13
T-2
T-2
Line on CDC Sensor
Power Supply Board
No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.)
[1] Checking the Control Unit
1. Turn off the power. Loosen the four screws on the handlebar
stem to remove the control unit.
2. Remove the cable connector which is connected to the back of
control unit.
3. Slowly rotate the pedal while measuring the resistance across
the connector terminals 1 and 2 of the 5P cable. (Fig. 1)
tWhen there is one short-circuiting (resistance becomes
zero) during one rotation of the pedal, the control unit is
defective.
When there is no short-circuiting, proceed to the following check
procedures.
[2] Checking the Main Unit
1.Remove the frame cover. (See the Section D-1 and D-2
"Removing the Frame Covers.")
2. Remove the CN-3 connector on the power supply board. (Fig.
2)
3. Slowly rotate the pedal while checking shortcircuit across the
two terminals of the CN-3 connector by using a tester to see if
there is one short-circuiting during one rotation of the pedal.
(Fig. 3)
tIf short-circuiting is found, the 5P cable which connects the
power supply board and the control unit is defective.
When there is no short-circuiting, proceed to the following check
procedures.
[3] Check the positional relation between the CDC sensor and the
magnet of the large gear. (Fig. 4)
1. Align the line on the CDC sensor with the center of the CDC
magnet. (Fig. 5)
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.
tWhen a short-circuiting is found, the positional relation
between the CDC sensor and the CDC magnet of the large
gear is incorrect.
tWhen there is no shortcircuit, the CDC sensor is defective.
Fig. 1
Fig. 2 Fig. 3
Red Cable
Black Cable
Fig. 4
CN-3 Connector
Line on CDC Sensor
Center of CDC Magnet
Fig. 5
Gap of 2mm between CDC Sensor and CDC
Magnet
No Display of Cadence
Replace the CDC sensor. (See the Section ES-5
"Replacing the CDC Sensor".)
Replace the control unit with a brand new one.
Replace the 5P cable. (See the Section ES-2
"Replacing the 5P Cable.")
4
5
1
2
3
Terminal 2
Terminal 1
Red Cable
Black Cable
5P Cable
The case a short-circuiting is found. One zero (0)
is detected during one rotation of the pedal.
The case of no short-circuiting
The case of no short-
circuiting
The case a short-circuiting is
found. One zero (0) is detected
during one rotation of the pedal.
Center of CDC Magnet

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
14
T-3
T-3
Replace the pulse sensor with a brand new one.
Replace the control unit with a brand new one.
No Display of Pulse Rate
1.Turn on the power to display the in-training screen (any
exercise program).
2. Install a brand new pulse sensor, and check if pulse rate will be
displayed.
tWhen the pulse rate can be displayed, the pulse sensor is
defective.
tWhen the pulse rate cannot be displayed, the control unit is
defective.
No Display of Pulse Rate

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
15
MODE
ADV
RESET
10 1
10 1
TIME
T-4
T-4
123
ON
OFF
4
Printer Symbol
Back of Control Unit
Paper Cutter
Fig. 1
Control Unit
Fig. 2
Select Switch
Fig. 3
Tweezer
Printer Cover
Fig. 4
Cable Connector
Fig. 5
Power Supply Board
Fig. 6
Normal when zero (0)
Connector Terminal 5
5P Cable
Connector
Terminal 5
No Printer Operation
In such cases as display of the LCD panel, etc. operate without
problem, but the printer does not operate, the following cases are
possible:
[1] Checking the Control Unit
1. Check that the printer symbol is displayed on the LCD panel
and the printer is in a working status. (Fig. 1)
2. Check if the setting of control unit is in the setting that the
printer is not used. (Check if the No.4 select switch on the
back of the control unit is in the "OFF" position.) (Fig. 2)
3 Check if the thermal paper is not jammed at the printer head.
tRemove the thermal paper if it is jammed. (Fig. 3)
4. When no other problems are found, replace the control unit
with a brand new one.
5. With the new control unit installed, check the printer operation.
tWhen the printer works fine, the control unit is defective.
When the printer does not operate after the above-stated checks,
proceed to the following procedures:
[2] Checking the Main Unit
1. Turn off the power, and loosen the four screws on the
handlebar stem to remove the control unit. (Fig. 4)
2. Remove the cable connector which is connected to the back of
the control unit. (Fig. 4)
3.Remove the frame cover. (See the Section D1 & D2
"Removing the Frame Covers.")
4. Remove the CN-2 connector on the power supply board. (Fig.
5)
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)
tWhen there is no shortcircuit, the 5P cable is disconnected.
tWhen it is short-circuited, the power supply board is
defective.
No Printer Operation
In case the printer symbol is not indicated on the LCD
panel, press the printer button to have the symbol
indicated.
Replace the control unit with a brand new one.
Replace the 5P cable. (See the Section ES-2
"Replacing the 5P Cable.")
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board.")

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
16
T-5
No Loading (Check of mechanical systems)
[1] Checking the Mechanical Systems
See the Section D1 & D2 "Removing the Frame Covers" to remove
the frame cover, and check the inside of frame.
1. Check if the chain has not been broken. (Fig. 1)
2. Rotate the crank and check if the belt of the workload unit will
rotate. (Fig. 2)
3. Check if the free wheel set is not idling. (Fig. 2)
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 chain with a brand new one. (See the
Section MS-4 "Replacing the Chain.")
Replace the free wheel with a brand new one. (See
the Section MS-5 "Replacing the Free Wheel Set.")
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.")
Replace the workload unit. (See the Sections MS-1 &
MS-2 "Replacing the Workload Unit.")
Fig. 1
Chain
Free Wheel Derailleur Crank
Fig. 2
Gap
Timing Belt
Plastic Pulley Free Wheel
No Loading (Check of Mechanical Systems)
T-5

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
17
Connector Terminal 3
T-5
T-5
[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.
tWhen the pedal torque is loaded, the control unit is
defective.
When no torque loading is possible, proceed to the following
procedures.
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)
tWhen there is no shortcircuit, the 5P cable is disconnected.
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 9Ωand 14Ω,
the connector is all right. (Figs. 4 & 5)
tWhen the meter reading is exceedingly large, the solenoid
coil is defective.
tWhen the meter reading is in the acceptable range, the
power supply board may be defective.
Fig. 1
Power Supply Board
CN-2 Connector
Fig. 2
Fig. 3
Normal when zero (0)
Connector
Terminal 4
5P Cable Connector Terminal 4
Fig. 4
CN-1 Connector
Fig. 5
Connector
Terminal 2
To Solenoid Coil
CN-1 Connector
Normal for 14V thru 19V
No Loading (Check of Electrical Systems)
No Loading (Check of Electrical Systems)
Replace the control unit with a brand new one.
Replace the 5P cable with a brand new one. (See the
Section ES-2 " Replacing the 5P Cable.")
Replace the workload unit. (See the Sections MS-1 &
MS-2 "Replacing the Workload Unit.")
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board.")

Check Method of Causes Repair Method Explanation Figures
EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Cateye Ergociser Series 1000 Service Manual
18
T-6
T-6
No Pedal Rotation (Locked)
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)
tNo damage on the plain belt
tThe plain belt is damaged.
Apply the plain belt correctly. (See the Section MS-2
"Replacing the Workload Unit (w/ Flywheel).")
Replace the workload unit and free wheel with brand
new ones. (See the Section MS-2 "Replacing the
Workload Unit (w/ Flywheel).")
Fig. 1
No Pedal Rotation (Locked)
Plain Belt