Technical course Technical course - Bikesportz Imports · Technical course Technical course ... possibilityof braking and changinggears ... a magnet to switch off the system. 19

1

Technical course

Technical course

Campagnolo Training Center

REV.06

Programme

2

1

2

5

4

3

The EPS and its operation

Installation

Diagnostics

Spare parts and warranty6

Maintenance

Adjustments after installation

2


REV.06

Important information

3

The EPS system

The product

Danger: if care is not taken injury to personnel and to those nearby may occur

Information and agreements

Section Chapter


REV.06

ascend

4

Definitions used in this presentation

ascend descend

descend

1st11th

3


REV.06 5

12

4

3

5

The EPS and its operation

• The product• Operation on the road• System components• Customer adjustments

6


REV.06

EPS, Electronic Power Shift, is the 11 speedelectronic rear derailleur system conceived, builtand marketed by Campagnolo.

2 versions are available:

6

The EPS system

The product

4


REV.06

The requests that the cyclist makes through the levers of the two controllers located on the handlebar are received by the electronic system. This system, with some optimisations, implements the requests, activating the rear and front derailleurs through electric motors.

Simultaneously the electronic system verifies that the rear and front derailleurs move correctly and reaches the required position.

The system also carries out other functions which we will discuss later.

7

The EPS system

Operation on the road


REV.06

The control levers of the EPS system are positioned and act with the same logic as mechanical Campagnolo system levers.Lever 1 brake

Lever 2 lever near the brake

Lever 3 internal lever

8

The EPS system


3

1

2

5


REV.06

Right control

Lever 2

9

The EPS system



REV.06

Right control

Lever 3

10

The EPS system


6


REV.06

Right control

By holding down levers 2 or 3 we obtain a continuous movement of the rear derailleur in ascent or descent.

11

The EPS system



REV.06

Left control

Lever 2

12

The EPS system


7


REV.06 13

The EPS system


Left control

Lever 3


REV.06

Depending on the sprocket selected, the EPS automatically repositions the front derailleur to optimise its position with respect to the chain and prevent rubbing.

This allows crossovers of the chain that are not ideal in traditional systems.

Both in ascent and descent, 2 corrections are carried out.

14

The EPS system


Automatic correction of the front derailleurExample of a correction

8


REV.06

In order to aid the front derailleur in ascent, in the event of a large chain crossover, the front derailleur carries out anover‐run with respect to the expected movement and, after a moment, assumes it’s correct position. The overrun is proportional to the sprocket used and cannot be adjusted by the user.

15

The EPS system


The front derailleur over‐run


REV.06

In case of large chain crossover, but with a front derailleur shifting to the small chainring, the front derailleur does NOT carry out an overrun as it may seem, but carries out the normal run and, immediately afterward, carries out a correctionpreviously described.

16

The EPS system

Operation on the road Front derailleur in descent with high chain crossover

9


REV.06

The system also carries out a rear derailleur over‐run in case of descent and ascent on the first 5° sprockets

17

The EPS system


Example of descent to the 4th sprocket

The rear derailleur over‐run


REV.06

Other advantages of the EPS system are:greater positioning precision (max error of 0.05 mm thanks to the electric motor’s position resolver) compared to a mechanical rear derailleur ‐ in whichprecision is tied to the cable movement and the returnspring in the derailleur.constant front and rear derailleur action speed, by eliminating cable frictionsoft action and limited run of the leverspossibility of braking and changing gearssimultaneouslythe design of the frame is no longer dictated by the need for simple cable runs

18

The EPS system


10


REV.06

The EPS system, unlike traditional systems, is made up of 6 main components, 2 of which are completely new:

right rear derailleur controlleft front derailleur controlinterfacepower unitfront derailleurrear derailleur

Each of these components has one or more cables for properinterconnection.

A battery charger is also provided in order to recharge the batteries as well asa magnet to switch off the system.

19

System components

The EPS system


REV.06 20

System components

The EPS system

11


REV.06 21

System components

The EPS system


REV.06

Right control lever 1 brakelever 2 command to “ascend” to the largest sprocketlever 3 command to “descend” to the smallest sprocketMODE button: short‐press this button to view the battery charge state

22

System components

The EPS system

MODE

12


REV.06

Left controllever 1 brakelever 2 command to “ascend” to the largest chain ringlever 3 command to “descend” to the smallest chain ringMODE button: short‐press this button to view the battery charge state

23

System components

The EPS system

MODE


REV.06

Interface

Its main functions are:

To activate the various coloured LEDs in order to communicate with the user

To receive the command actions

To dialogue, thanks to a digital line, with the power unit

24

System components

The EPS system

13


REV.06 25

FIXED GREEN LEDFrom 100 % to 60 % charge

FLASHING GREEN LEDFrom 60 % to 40 % charge

FIXED YELLOW LEDFrom 40 % to 20 % charge

FIXED RED LEDFrom 20 % to 6 % charge

FLASHING RED LED + ACOUSTIC ALARM (BUZZER)From 6 % to 0 % charge (with decreasing frequency of automatic indication)

The battery charge level can be verified by short pressing one of the two Mode buttons

Verification of the battery charge state

The EPS system


REV.06

Power system

Its main functions are:

Contains and manages the battery pack

Activates and controls the rearderailleur and the front derailleur

Indicates any faults with the LEDDialogues, thanks to a digitalline, with the interface

Activates the buzzer

26

System components

The EPS system

14


REV.06

So ‐ EPS is an electronic system, controlled by a number of electronic components, that communicate and manage the drive train to obtain the best performance.

27

System components

Il sistema EPS


REV.06 28

Il sistema EPS

Example of electric circuit(electro‐mechanic system)

EPS: electronic system

Interface

Powersystem

I = VxR

…11100101101..

…110101..

System components

15


REV.06

Average duration of the battery for use on the road:

•average of 500 km/month: 1500 km



Range in km with 0‐6% charge is variable depending on the outdoor temperature and conditions of use

Battery charge times from a charge of 0‐6 % to 100%: about 4 hours

29

System components

The EPS system


REV.06

The rear derailleur

Is made up of:

Mechanical structure

Electric motor with resolver

Mechanical limit switchadjustment screw

Adjustment screw for the distance between the pulleyand the sprocket cassette

30

System components

The EPS system

16


REV.06 31

System components

The EPS system

The front derailleur

Is made up of:

Mechanical structure with cage

Electric motor with resolver


REV.06

In case of assembly/disassembly or maintenance of the components, the EPS must be switched off by inserting the magnet in its lodging on the lower part of the power unit.

32

System components

The EPS system

In case of transportation of the bicycle leaving the system in stand‐by is recommended (do NOT insert the magnet) because, in the event the rear or front derailleur should be accidentally moved, the system will not lose the reference point for its proper position.

The shut‐off magnet

17


REV.06

There are 2 LEDs on the power supply unit which perform the following functions:

•on in the presence of mains power

•on while the battery is being charged; once the battery is fully charged, this LED turns off.

33

System components

The EPS system

The battery charger


REV.06

The battery charger is compatible with:

•110‐220V voltage and 50‐60 Hz frequency

•12 V voltage for car recharging (optional cable)

34

System components

The EPS system

Do not use a battery charger other than the oneprovided with the EPS system

The battery charger

18


REV.06

The battery charger

While recharging the interface displays the battery charge state while the rear and front derailleur motors are deactivated.

In this state, even if the magnet is inserted to switch off the system, the battery charge procedure will not be interrupted.

35

System components

The EPS system


REV.06

The MODE buttons, besides verifying the batterycharge state, allow the user to

carry out adjustments to the rear and front derailleur which correspond to the adjustmentscarried out with the cable adjusters in traditional systems

cancel any temporary malfunctions detectedby the system and indicated by the LED on the power unit (please see the Diagnostics Chapter)

36

Customer adjustments

The EPS system

19


REV.06

Adjustment of the rear and front derailleursThe customer can adjust the reference position of the rear and/or front derailleur through the adjustment procedure. Adjustment of the rear derailleur is done mainly in the event of a wheel change. This might be required if the wheel that is fitted has the casette positioned differently relative to the rear drop‐out.In the case of adjustments of the rear and front derailleur, we can position the chain on whichever chainring we wish.With each pressing of buttons 2 or 3, the system carries out a fixed movement of about 0. 25 mm if we act on the rear derailleur, and about 0.1 mm if we act on the front derailleur.

37


The EPS system


REV.06

Adjustment of the rear and front derailleursOnce adjustment is completed, the system will implement a change to the positions established for all of the sprockets (or chainrings) with a correction equal to that reset with the adjustment.For example, if the distance of the first 3 index points from the drop‐out is: 12.40 ‐ 16.60 ‐ 20.4 mmafter a correction of about 0.25 mm with lever 3 toward the drop‐out, the new positions which the rear derailleur assumes will be about:12.15 – 16.35 – 20.15 mm …

38

The EPS system


20


REV.06

Adjustment of the rear and front derailleurs

Remember that the chain is perfectly centred, for the sprockets from the 3rd to the 10th, with about 3 movements in descent the chain approaches the lower sprocket and with 3 movements in ascent it approaches the upper sprocket.

39

The EPS system



REV.06

Adjustment of the rear and front derailleurs

40

The EPS system


Note that any adjustment carried out whilst in motion may cause a danger of injury to the cyclist or others: proceed with extreme caution if you decide to carry out the adjustment anyway.

21


REV.06

Adjustment of the rear derailleur

press the right MODE button for about 6 seconds

adjust the position by pressing buttons 2 and/or 3

short‐press the right MODE button to store the adjustment

41

A

The EPS system



REV.06

Adjustment of the front derailleur

press the left MODE button for about 6 seconds

adjust the position by pressing buttons 2 and/or 3

short‐press the left MODE button to store the adjustment

42

The EPS system


22


REV.06

Failure to conclude the adjustmentIf the MODE button is not short‐pressed to conclude the adjustment procedure, after a predetermined time of about 48sec, the system automatically exits the adjustment procedure and the new adjustment is stored.

43

The EPS system


Contemporary adjustment of front and rear derailleurWhen you press one of the two MODE button, right or left, it’spossible to do the adjustment of the front or rear derailleur.

The memorization can be done with one of the 2 MODE buttons.


REV.06

In some case of rear wheel replacement, if the cassette of the new wheel is very different from the previously installed one, it may be more adviseable to carry out a more precise adjustment by performing a full reset of the rear derailleur.

44

Rear derailleur reset procedure

The EPS system


23


REV.06

This procedure allows the system to learn the positions of the chain on the 2nd and 10th sprockets, from which it can then calculate the positions of the other sprockets.

During the reset procedure movements of the rear derailleur take place continuously, and not with fixed incriments as during adjustment, depending on the time that rear derailleur levers 2 and 3 are held in.

It is possible to very accurately modify the position, by just a few hundredths of a millimetre.

45

The EPS system




REV.06

1. Position the rear derailleur on the 11°sprocket and on the large chainring

46

The EPS system


24


REV.06

2. simultaneously press the two MODE buttons until the blue LED turns on (about 6 seconds)

47

The EPS system




REV.06

3. position the rear derailleur on the 2nd sprocket

4. adjust the position by pressing buttons 2 and/or 3

48

The EPS system



25


REV.06

5. press the right MODE button to store the position of the 2nd sprocket

6. position the rear derailleur on the 10th sprocket

49

The EPS system




REV.06


8. short‐press the right MODE button to store the position of the 10th sprocket and to conclude the procedure.

50

The EPS system



26


REV.06 51

2

1

4

3

5

Installation • Workshop tools• Interface with the frame• Compatibility• Preparation of the frame and

components• Cable run and installation6


REV.06

The specific tools, available for the operators(S.C., OEM, Pro Shop), for installation of the EPS system are:

•Cable run magnet kit

52

Installation

Workshop tools

27


REV.06

• Connector disconnection tool

53

Installation

Workshop tools


REV.06

The generic tools for the EPS system are:

54

Installation

Workshop tools

Tool code or size used for

Chain tool UT‐CN300 chain

Torque wrench 20‐100 Nm BB axle, BB cups

BB cups tool (for torque wrench) UT‐BB130 BB cups

Allen wrench UT‐BB110 BB

Torque wrench 0 ‐ 20 Nm ergopower, rear gear, f. deraill.clamp on

Allen wrench (for torque wrench) 5 ergopower, rear gear, f. deraill.clamp on

Torx wrench (for torque wrench) T25 rear derailler

Caliper frame

Allen wrench 2‐3‐4‐5‐6 various

Torx wrench T25 rear derailler

Philips screwdriver 1,5 ergopower cover

Philips screwdriver medium

Screwdriver medium

Wrench 7 front derailler

Cutter housing

Pliers flat tips various

Derailleur Hanger Alignment Gauge to check the drop out

Bottom Bracket Tapping & Facing Set frame

Thickness gauge chain position

28


REV.06

The EPS system is compatible with the following threaded bottom bracket shells and cups

55

Installation

Interface with the frame

TYPE X

Italian thread From 69.2 to 70.8

English thread From 67.2 to 68.8


REV.06

In case of frames with bottom bracket cups Press Fit 86.5 x41 the following measurements have to be observed

56

Installation


29


REV.06

In case of frames with Press Fit BB30 68 X 42bottom bracket cups the following measurements have to be observed

57

Installation



REV.06 58

Installation

In case of frames with Press Fit BB30 68 X 46bottom bracket cups the following measurements have to be observed


30


REV.06 59

Installation

Braze‐on version



REV.06 60

Installation

QUOTA L

CENTRATURA

ATTACCO A

SALDARE

INGRANAGGI COMPATIBILI

138 48T 45T,46T,47T,48T,49T,50T,51T

140 49T 46T,47T,48T,49T,50T,51T,52T

142 50T 47T,48T,49T,50T,51T,52T,53T

144 51T 48T,49T,50T,51T,52T,53T,54T

146 52T 49T,50T,51T,52T,53T,54T,55T

148 53T 50T,51T,52T,53T,54T,55T,56T

150 54T 51T,52T,53T,54T,55T,56T

152 55T 52T,53T,54T,55T,56T

Braze‐on version (other than mechanical front derailleur)


31


REV.06 61

Installation

Clamp‐on versionA new clamp was created for frames with 35 mm tube diameter. The clamp also replaces the current clamp for non EPS units.For 32 mm frames use the current clamp.


Use Campagnolo clamp only (code R1134888 for 35 mm tube)


REV.06 62

Installation

Rear derailleur

L = 405 mm min


32


REV.06 63

Il montaggio

Rear derailler

|LA-LB| & |LC-LD|6 mm

The tool must be positioned on vertical position (LA & LB) and on horizontal position: if the measurements are out of tolerance, use the tool to set the rear derailler hanger



REV.06 64

Installation

Rear derailleur


33


REV.06 65

Installation

Rear derailleur

B = 30 mm



REV.06

The diameter of the holes and their positions have to conform to the measurements indicated here (note that the connector has a diameter of 7 mm)

66

Installation


34


REV.06 67

Il montaggio



REV.06 68

Il montaggio


M4

M5

M2,5

35


REV.06 69

Installation



REV.06

The compatible cranksets are:

53‐39, 52‐39 (Standard),

50‐34 (Compact EVO),

55‐42, 54‐42 (Individual Time Trial),

52‐36 (New 2013).

The 11 V compatible cassettes are:

11‐23, 11‐25, 12‐25, 12‐27, 12‐29

70

Installation

Compatibility

36


REV.06

For complete functionality of the EPS system the dimensions of the compatible chainrings or sprockets cannot be changed.

71

Installation

Compatibility


REV.06 72

Installation

Preparation of the frame and components

Because the presence of impurities, dirt or even worse, liquids, must be avoided during assembly of the electrical connectors, it is important that installation of the EPS system is carried out with clean hands, in a clean environment and not carried out whilst exposed to inclement weather in order to avoid the presence of dust, grease, water, etc. during installation.

37


REV.06

Before installation, where possible, remember to mill the bottom bracket shell with the bottom braket facing tool in order to have:

•the two surfaces faced

•the correct chain line: 43,5 mm

Verify that the frame is free of any possible obstructions internally (i.e. bags from the production of carbon frames...)

73

Installation



REV.06

It’s important to chase the thread of the rear derailler hanger to install correctly the rear derailler.

Verify that the frame is free of any possible obstructions internally (i.e. bags from the production of carbon frames ...)

74

Installation


38


REV.06

Power system: install bracket for water‐bottle fixing or for lower position on the frame and verify the presence of the magnet

75

Installation



REV.06 76

Il montaggio

70 cm

55 cm 55 cm

55 cm

50 cm85 cm

Component connectors

Each pair of connectors is marked by differently coloured cable ties near the connectors.


39


REV.06


Each pair has polarized slots in order to make incorrect installation impossible (Poka‐yoke).

77

Installation


Example of slots


REV.06


In order to facilitate installation, each connector has an arrow for alignment with the respective counterpart.

78

Installation


40


REV.06


In a well lit area, before installation on the frame, highlighting the arrow with a white marker is recommended.

79

Installation



REV.06 80

Installation

Cable run and installationCable connection diagram

41


REV.06 81

Installation

Cable run and installation

Control front derailleur

interface

Powersystem

Front derailleur

Rear derailleur

Control rear derailleur

yellow

green

red

blue violet

Cable connection diagram


REV.06 82

Installation


interface

Powersystem

Front derailleur

Rear derailleur


green

blue violet

Cable run and installationCable run for rear derailleur

42


REV.06

Temporarily install the power unit

83

Installation



REV.06

Running the rear derailleur connection cable

84

Installation


43


REV.06 85

Installation


interface

Powersystem

Front derailleur

Rear derailleur


green

red

blue violet

Cable run and connection to the interface Cable run and installation


REV.06

Cable run and connection to the interface

86

Installation


44


REV.06 87

Installation

Controlfront derailleur

interface

Powersystem

Front derailleur

Rear derailleur


yellow

green

red

blue violet

Running the rear derailleur connection cable Cable run and installation


REV.06

Running the rear derailleur connection cable

88

Installation


45


REV.06

Installation of the controls on the handlebar

89

Installation


Tightening torque 10 Nm


REV.06

Installation of the power unit

90

Installation


Installation of vibration damping rubber washer

46


REV.06

Installation of the rear derailleur

91

Installation


Tightening torque: 15 Nm (Torx wrench T25)


REV.06

Do not let the front derailleur cable slide back into the frame ‐anchor it with adhesive tape

92

Installation


47


REV.06

Installation of the crankset

93

Installation


Be careful with the rear derailleur cable run


REV.06 94

I ricambi e la garanzia

R 1137097: BB cable guide

Example of BB cable guide with Press Fit cups


48


REV.06

Insert the BB cable guide cover cylinder from the bevelled side to ease insertion despite the presence of the rear derailleur cable

95

Installation



REV.06 96

Installation

Cable run and installationInstallation of the cranksetBottom bracket cup tightening torque 35 Nm with tool UT‐BB130Crankset tightening torque: 42‐60 Nm

49


REV.06 97

Installation

Cable run and installationInstallation of the rear derailleurtightening torque: clamp on versione 5 Nm; brazed on version 7 Nm


REV.06 98

Installation

Cable run and installationInstallation of the front derailleur observing the distance from the largest chainring (1.5 – 3 mm) and the parallelism between the derailleur cage and the chainring itself

50


REV.06 99

Installation

Cable run and installationInstallation of the interface

Fit elastic ring and adhesive rubber


REV.06 100

Installation

Cable run and installationInstallation of the control connectors

51


REV.06 101

Installation

Cable run and installationFunctional test of the system after installation: remove the system shut‐off magnet, the green led on the power unit will blinck, and activate levers 2, 3 and the mode button of each command, whilst observing the interface LED.

The blincking of the green led happens only if the magnet was inserted for a certain time (about 30 s, it can be shorter if the handlebars levers are activated )


REV.06 102

Installation


The final phases of installation are:

•completion of installation of the controls

•power unit cable protection

•installation of rubber grommets

•chain installation

52


REV.06

Position the control connector as illustrated in the photo below, being careful that the cable runs in the channel shown and close the cover.

103

Installation



REV.06 104

Installation

Cable run and installationPower unit cable protection

53


REV.06 105

Installation

Cable run and installationInstallation of the 3 rubber grommets in the holes near the interface,…


REV.06 106

Installation

Cable run and installation…the rear and front derailleur

54


REV.06 107

Installation

Cable run and installationChain

Install the chain in accordance with the procedure required for the mechanical groups using the tool UT‐CN300


REV.06 108

Installation


After completing the installation of the EPS group, we are now ready to carry out the adjustments.

55


REV.06 109

3

2

4

5


1

6

• The phases• The rear derailleur reset procedure• The rear derailleur mechanical

travel limit• Jockey cage distance adjustment• The front derailleur reset procedure• Conclusion


REV.06

The EPS system, after installation, needs to know the position of 2 sprockets and of one chainring, in order to calculate the position of all the other sprockets and of the other chainring.

Additionally it’s necessary to make a mechanical setting of the rear derailleur for a perfect functionality and to avoid any possibility that the rear derailleur might touch the spokes.

In the following page are the phases of the adjustment after the installation.

110

The phases

Adjustment after installation

56


REV.06

A. Rear derailleur reset

B. Rear derailleur travel limit adjustment

C. Jockey cage distance adjustment

D. Front derailleur reset

E. Test on the road of the EPS system with evaluation of the behaviour of the transmission

F. Correction of the system behaviour with the front and/or rear derailleur adjustment or resetting of the front and/or rear derailleur.

111

The phases



REV.06

The rear and front derailleur reset procedures are fundamentalfor proper operation of the system.

These procedures allow the system to learn the reference positions of the chain on the sprockets and the chainrings from which it can then calculate the position to assume in all operating conditions.

During the reset phase movements of the rear and front derailleur take place continuously, and not with fixed movements as during adjustment, depending on the time that rear derailleur levers 2 and 3 are held in.

It is possible to modify the position by just a few hundredths of a millimetre.

112

The reset procedures


57


REV.06 113

Rear derailleur reset procedureThis procedure allows the system to learn the position of the 2nd

and 10th sprocket with respect to the rear derailleur drop‐out attachment.

Starting from these two reference positions, the system will calculate the position of all the other sprockets.

In the 11 speed units the distance between the two adjacent sprockets is 3.8 mm except:

•between the 1st and 2nd it is 4.3 mm for 11 t smallest sprocket and 4.2 mm for 12 t smallest sprocket

•between the 2nd and 3rd it is 3.94 mm for 11 t smallest sprocket

Overall tolerance for each sprocket position with respect to the first: +/‐0.1 mm.



REV.06

1. Position the front derailleur on the large chainring and the rear derailleur on the 11°sprocket (or on the 10° if the system doesn’t reach the 11°sprocket).

114



58


REV.06

2. simultaneously press the two MODE buttons until the blue LED lights (about 6 seconds)

115




REV.06

3. position the rear derailleur on the 2nd sprocket


116



59


REV.06

5. press the right MODE button to store the position of the 2nd sprocket

6. position the rear derailleur on the 10th sprocket

117



Pay attention when pressing Lever 2 ‐ the speed of movement of the rear derailleur isnot constant and it’s possible for the rear derailleur to run into the spokes.


REV.06


8. short‐press the right MODE button to store the position of the 10th sprocket and to conclude the procedure.

118



60


REV.06

After resetting the rear and front derailleurs it is essentialto adjust the mechanical travel limit screw which ensures that the rear derailleur does not move inward to the point of interfering with the spokes of the rear wheel.

119

The rear derailleur mechanical travel limit



REV.06

In order to obtain a more rapid and accurate shift, the distance of the top jockey wheel from the largest sprocket (11th) must be adjusted.

The adjustment screw is in the same position as the mechanical rear derailleurs.

120

Rocker distance adjustment


61


REV.06

The distance must be about 5 – 7 mm.

121

Top jockey wheel distance adjustment



REV.06 122

Front derailleur reset procedure

In this procedure we position the front derailleur on the smallest chainring and the rear derailleur on the 11th sprocket (the largest).

Adjust the distance of the inside plate of the front derailleur cage from the inside surface of the chain to 0.5 mm.

Starting from this position, the system calculates the position of the largest chainring and all of the proportional travel based on the position requested by the user.


62


REV.06 123

Front derailleur reset procedure Position the front derailleur on the smallest chainring and the rear derailleur on the 11th

sprocket (the largest)



REV.06

1. simultaneously press the two MODE buttons until the blue LED lights (about 6 seconds)

124



63


REV.06

2. adjust the position by pressing lever 2 and/or 3 until the distance between the chain and the drop‐out is about 0.5 mm (use a feeler gauge if necessary)

3. press the left MODE button to store the position and finish the procedure

125




REV.06

In the event that, after entering the rear or front derailleur reset phase, the MODE button is not short‐pressed to finish the procedure, the procedure will not end and will remain active.

The system operates but movement of the rear or front derailleur is continuous and not in steps, as in normal operation.

It is ABSOLUTELY necessary to exit the procedure and carry out the reset again if required

126

Failure to finish reset


64


REV.06

The next phase is to check that the transmission works correctly on the road.

If the shifting isn’t perfect on the road, it may be necessary to make the adjustment of the rear or/and front derailleur as seen in the first chapter.

If the system still doesn’t work perfectly, repeat the resetting of the rear or/and front derailleur.

127

Conclusion



REV.06 128

4

2

3

5

Maintenance

1

6

• Routine maintenance• Special maintenance

65


REV.06

Although the system meets the IP67 standards of water infiltration resistance, we would notrecommend washing the bicycle with pressurisedwater and aggressive detergents.

Periodically clean and lubricate the pivots of the derailleurs with a suitable oil for thermo‐plasticcomponents

Never use denatured alcohol to clean the power unit.

129

Cleaning

Maintenance

Routine maintenance


REV.06

Power system

In order to prevent damage to the system battery pack, the system automatically switches off when it reaches 9 Volts to prevent dropping under this voltage.

If 7.2 Volts are reached, the system also shuts down other electronic components to prevent further energy absorption, protecting the battery from damage

130

Routine maintenance

Maintenance

66


REV.06

Without use on the road

131

Routine maintenance

Maintenance


REV.06

We therefore strongly recommend recharging the battery once the interface LED turns off.

The times indicated in the previous outline relate to temperatures up to 35°C and can drop significantly with an increase in temperature. Therefore storage of the power unit or the complete bicycle at a higher temperature for several months is not recommended.

132

Routine maintenance

Maintenance

67


REV.06

Ergopower controls

Lever 1 can be replaced as with mechanical systems.

133

Special maintenance

Maintenance


REV.06

Front derailleur

134

Special maintenance

Maintenance

The cage and the plate on the cage can be replaced as with mechanical systems.

Be careful not damage the component because the 3 pivots are inserted with a press since they have a knurled area for an interference fit. Use Molikote 40 grease on the pivots.

68


REV.06 135

5

2

3

4

Diagnostics

• Diagnostics by the end customer

• Diagnostics by technical support service

• Malfunctions without the LEDs turning on

1

6


REV.06

The EPS system can automatically detect various malfunctions.

In the event that a malfunction is detected, the EPS system turns on a LEDon the power unit.

Depending on the area in which the malfunction was detected, the LED takes on different colours based on the following table:

136

Diagnostics by the end customer

Diagnostics

69


REV.06

WHITE Power system

YELLOW Front derailleur

GREEN Rear derailleur

BLUE Front derailleur control

VIOLET Rear derailleur control

RED Interface system

137

LEDs on the power unit

Diagnostics



REV.06

Since, in some situations, the LED on the power unit may light because of a temporarymalfunction, the operations in the following pages are suggested for the end customer.

If the LED turns back on after these procedures have been followed, the customer should contact an Authorised Service Centre

138


Diagnostics

70


REV.06

Power system: contact an Authorised Service Centre

Front derailleur: give a command and short‐press the MODE button

Activate the front derailleur: if it operates correctly, turn the LED off by short pressing the MODE button. If it does not operate properly and the LED remains on, contact an Authorised Service Centre

139

Diagnostics



REV.06

Rear derailleur: give a command and short‐press a MODE button

If it does not operate properly and the LED remains on, contact an Authorised Service Centre.

140

Diagnostics


71


REV.06

Rear derailleur control: If lever 2 or 3 was pressed for more than 9 seconds, this LED will light.

SOLUTION: short‐press a MODE button

If the rear derailleur does not operate properly and the LED remains on after this has been done, contact an Authorised Service Centre

141

Diagnostics



REV.06 142

Diagnostics

Front derailleur control: If lever 2 or 3 was pressed for more than 9 seconds, this LED will light. SOLUTION: short‐press a MODE button. If the front derailleur then operates correctly, turn the LED off by short‐pressing the MODE button. If it does not operate properly and the LED remains on, contact an Authorised Service Centre


72


REV.06 143

Diagnostics

Interface system: SOLUTION: short‐press a MODE button. If the system still does not operate properly and the LED remains on, contact an Authorised Service Centre



REV.06

In case of a fall or accidental impact on the rear derailleur, it may «disengage» (to avoid damage).You will notice this because the rearderailleur will not shift into the smallersprockets.We recommend to take the rear derailleur to the smallest reachable sprocket, stop pedalling and act repeatedly on lever 2.

144

Diagnostics

Rear derailleur disengaged due to impact


In order to verify whether the rear derailleur is hooked again, drop down to the 1st sprocket: If this has not occurred "manually force"the rear derailleur. After successful re‐engagement, check the alignment of the drop‐out/rear derailleur mount and proper operation of the rear derailleur.

73


REV.06

In normal operation, the rear derailleur works by the motor driving the yellow female screw. The female screw is locked by a trasvere screw that pushes a ballbearing into a depression.When the rear derailleur is disengaged, the sphere runs into the external channel on the female screw and so, independently from the motor activation, permits the user to change the position of the rear gear.

145

Diagnostics




REV.06

Position of the rear derailleur disengaged

146

Diagnostics



depressionchannel

74


REV.06

If the battery goes flat on the road, it is possible to ‘disengage’ the rear derailleur manually so that the user can move the rear derailleur position onto any of the lower sprockets.Once ‘back home’ remember to re‐engage the rear derailleur and to re‐charge the battery.

147

Diagnostics

‘Ride back home’ function



REV.06

Since in some cases the EPS system is not able to detect a malfunction or the malfunction does not cause the LED on the power unit to light, please follow the EPS fault troubleshooting flow chart. In some cases the chart refers to diagnostics based on the colour of the power unit LED or it indicates the diagnostics to follow where no LED lights.

148

Diagnostics

Diagnostics by technical support service

75


REV.06 149

Diagnostics



REV.06

The procedures which should be followed in the event that a LED on the power unit lights are listed below.

150

Diagnostics


76


REV.06

Power systemCAUSE: malfunction of power electronics.

SOLUTION: the component must be replaced.

Once the new component is installed, since the memory of the rear and front derailleur positions were stored in the original unit, the rear and front derailleur reset procedure must be carried out again.

151

Diagnostics



REV.06

Front derailleurCAUSES: connector disconnected, damaged cabling (cable or terminal) and / or malfunctioning electric motor.

SOLUTION: visually check that the connector is properly connected, disconnect it, check to see whether there are traces of water, dirt, oxidation or abnormalities in the pins and reconnect the connector, after eliminating any abnormalities found. If necessary, use antioxidizing products. If this does not work and the LED remains on, check the entire cable that goes from the front derailleur to the power unit to ensure that there are no cuts, crushed sections or other abnormalities.

152

Diagnostics


77


REV.06

Front derailleurIf an abnormality has been detected with the power system cable, replace the power unit. If an abnormality has been detected with the front derailleur cable or if no abnormality is detected, replace the front derailleur.

Once the new component is installed, the front derailleur reset procedure must be carried out again.

153

Diagnostics



REV.06

Rear derailleurCAUSES: connector disconnected, damaged cabling (cable or terminal) or / and malfunctioning electric motor.

SOLUTION: visually check that the connector is properly connected, disconnect it, check to see whether there are traces of water, dirt, oxidation or abnormalities in the pins and reconnect the connector, after eliminating any abnormalities found. If necessary use antioxidizing products.

If an abnormality has been detected with the power system cable, replace the power unit. If an abnormality has been detected with the rear derailleur cable or if no abnormality is detected, replace the rear derailleur.

Once the new component is installed, the rear derailleur reset procedure must be carried out again.

154

Diagnostics


78


REV.06

Rear derailleur controlCAUSE: one or more of the 3 circuits remain constantly closed (pressed buttons mechanically ‘stuck’, dome deformed, short circuit in cabling, water causing a short circuit).

SOLUTION: check that the control hoods do not press on the lever

in an abnormal way or foul levers 2 and 3.Visually check that the connector is properly connected, disconnect it, check to see whether there are traces of water, dirt, oxidation or abnormalities in the pins and reconnect the connector, after eliminating any abnormalities found. If necessary use antioxidizing products.

155

Diagnostics



REV.06

Rear derailleur control

If it operates correctly, turn the LED off by short‐pressing the MODE button.

If an abnormality with the interface system cable has been detected replace the interface system. If an abnormality has been detected to the control cable or if no abnormality was detected replace the control.

Once the new component is installed the error must be cancelled by short‐pressing the MODE button.

156

Diagnostics


79


REV.06

Front derailleur commandCAUSES: one or more of the 3 circuits remain constantly closed (pressed buttons mechanically ‘stuck’, dome deformed, short circuit in cables, water which causes a short circuit).

SOLUTION: check that the control hoods do not press on the lever in an abnormal way or foul levers 2 and 3.

Visually check that the connector is properly connected, disconnect it, check to see whether there are traces of water, dirt, oxidation or abnormalities in the pins and reconnect the connector, eliminating any abnormalities found. If necessary use antioxidizing products.

157

Diagnostics



REV.06

Front derailleur controlIf it operates correctly, turn the LED off by short‐pressing the MODE button.

If an abnormality with the interface system cable has been detected replace the interface system. If an abnormality has been detected to the control cable or if no abnormality was detected replace the control.

Once the new component is installed the error must be cancelled by short‐pressing the MODE button.

158

Diagnostics


80


REV.06

Interface system:

The LED turns on or a fault is detected only when the magnet is initially removed and the system turns on.

CAUSE: cable or connector or internal electronics.

SOLUTION: Visually check that the connector is properly connected, disconnect it, check to see whether there are traces of water, dirt, oxidation or abnormalities in the pins and reconnect the connector once any abnormality is corrected. Position the magnet in the housing on the power unit, wait about 10 seconds and remove the magnet: if the LED turns back on, check the entire cable which goes ... (ctd)

159

Diagnostics



REV.06

Interface system

... from the interface to the power unit, ensuring that there are no cuts, crushed sections or other abnormalities.

If an abnormality is found with the power unit cable replace the power unit. If an abnormality has been detected with the interface system cable, or if no abnormality is detected, replace the power unit.

Once the new component is installed the error must be cancelled.

160

Diagnostics


81


REV.06

In some cases, as indicated in the troubleshooting chart, electrical malfunctions occur without the LEDs on the power unit turning on:

•one or more circuits of the rear and front derailleur are interrupted

•battery is completely flat

161

Diagnostics

Malfunctions without the LEDs turning on


REV.06

One or more circuits of the rear and front derailleur are interrupted:This is the normal situation when the rear or front derailleur control is not being activated by the user, because the switch the control operates is open. Therefore the system does not ‘see’ this as a malfunction. When the defective circuit's lever is activated the system does not activate the requested command because there is an additional break in the circuit. Check the entire cable that goes from the interface to the rear or front derailleur control, ensuring that there are no cuts, crushed sections or other abnormalities.Visually check that the connector is properly connected, disconnect it, check to see whether there are traces of dirt, oxidation or abnormalities in the pins and reconnect the connector after correcting any abnormality.If no abnormality is detected, replace the control.

162

Diagnostics


82


REV.06

Battery is completely flat: The system does not have sufficient energy to indicate the excessively low charge level of the battery.

163

Diagnostics



REV.06 164

6

2

3

4

Spare parts and warranty

1

5

• Product options• Accessories• Spare parts• Warranty: terms and

conditions/what is covered• Warranty: management

83


REV.06 165


Some components of the EPS system must be chosen based on kind of installation on the frame required and depending on the geographical area where the system will be used:•power system bracket•BB cups•power cable for battery charger

Product options


REV.06 166


Product options

POWER SYSTEM AC12‐HOSTDEPS POWER SYST. BRACKET + VIBRATION DAMP. AB

POWER SYSTEM AC12‐HOOPTEPS POWER SYST.BRACKET FIXED HT.

BATTERY CHARGER AC12‐CACEEEPS EEC POWER CABLE

BATTERY CHARGER AC12‐CAUSEPS AMERICAN TYPE POWER CABLE

BATTERY CHARGER AC12‐CAUKEPS BRITISH TYPE POWER CABLE

BATTERY CHARGER AC12‐CAAUSEPS OCEANIA TYPE POWER CABLE

84


REV.06 167


We are producing new cups, to fit the BB cable guide, that are also compatible with mechanical series.

The new cups will be marked: EPS COMPATIBLE.

We’ll also produce new BBright cups (Cervelo)

Product options

Seriesthread /

press fitCode Name

Mechanical

series

compatibility

SUPER RECORD italian OC12‐SRI outboard cups SUPER RECORD™ ULTRA‐TORQUE™ ‐ IT yes

SUPER RECORD english OC12‐SRG outboard cups SUPER RECORD™ ULTRA‐TORQUE™ ‐ BSC yes

‐ press fit IC12‐SR41 Ultra Torque™ OS‐Fit™ integrated cups 86,5x41 yes

‐ press fit IC12‐SR42 Ultra Torque™ OS‐Fit™ integrated cups BB30 68x42 yes

‐ press fit IC12‐RE46 Ultra Torque™ OS‐Fit™ integrated cups BB30 68x46 yes

RECORD italian OC12‐REI outboard cups RECORD™ ULTRA‐TORQUE™ EPS ‐ IT yes

RECORD english OC11‐REG outboard cups RECORD™ ULTRA‐TORQUE™ ‐ BSC yes


REV.06 168


Accessories

PART CODE DESCRIPTION

COMMANDS R1137084 LARGE HANDS INSERT KIT FOR EPS

FRONT DER FD‐SR001EPS FRONT DER. STIFFNESS INCREASER

FRONT DER R7204008 CHAIN SAVER SYSTEM

FRONT DER DC12‐SR2B SR Ø 32 mm BLACK clamp front derailleur

FRONT DER DC12‐SR5B SR Ø 35 mm BLACK clamp front derailleur

EPS AC12‐CAADBBEPS CABLE EXTENTION KIT

EPS AC12‐CAADSPEPS UNDER SADDLE CABLE EXTENTION KIT

85


REV.06 169

Front derailleur mount stiffness increaser

It guarantiees a perfect working of the front derailleur even with ‘brazed on’ type mountings with low stiffness.In particular it’s necessary with carbon frames with carbon ‘brazed on’ mountings, where one can sometimes reach up to 10 mm of movement by forcing the derailleur cage with the hands.


Accessories


REV.06 170

Front derailleur stiffness increaser


Accessories

It’s composed of two hinged pieces kept open by a spring. The position can be locked by a screw that can be tightened or loosened with an Allen wrench.

Installation procedure

1.Unscrew the screw, close the 2 sides and lock it with an Allen wrench.

86


REV.06 171



Accessories

2. Install the stiffness increaser on the ‘frame’ side of the front derailleur, screwing the mounting screw in the threaded hole provided in the derailleur body.


REV.06 172



Accessories

3. Install the front derailleur on the frame.

4. Put the rubber piece provided on the frame where the stiffness increaser touches it.

5. Unscrew the screw, and when the stiffness increaser opens, re-tighten the screw in order that the stiffness increaser touches both the frame and the front derailleur.

87


REV.06 173


Accessories

CHAIN GUARD


REV.06 174

Chain guard

The chain saver system guarantees that, when the chain descends to the smallest chain ring, it doesn’t drop onto the bottom bracket shell, even if external forces push on it.It’s suggested for:•racing use if under pressure the mechanic doesn’t set the front gear correctly•racing use where it may be necessary to shift to the smallest chainring on bends•use of the bike on poor road surfaces or pavè


Accessories

88


REV.06 175

Chain guard

It’s compulsary for:•use of the bike on particularly badly surface roads, pavè as in Paris-Roubaix, etc or other cobblestonepaving.•Cyclo-cross races


Accessories


REV.06 176


Accessories

CABLE EXTENTION KIT

89


REV.06 177


Spare partsPART CODE DESCRIPTION

REAR DERAILER R1119250 REAR DERAILER AXLE ROCKER S.REC‐REC

REAR DERAILER R1119253 EPS REC REAR DERAILER AXLE ROCKER

REAR DERAILER R7350671 MECHANICAL TRAVEL LIMIT SCREW

REAR DERAILER R1102380 REAR DERAILER BODY WITHOUT ROCKER ASSEMBLY

REAR DERAILER R1102370 S.REC REAR DERAILER BODY WITHOUT ROCKER ASSEMBLY

COMMANDS HANDLEBAR FIXING CLAMP BRACKET

COMMANDS R118128‐129 EP REC COMMAND without lever 1

COMMANDS R118126‐127 EP S.REC COMMAND without lever 1

COMMANDS R1241208‐209 EP S.RECORD EPS LEVER 1

COMMANDS R1241210‐211 EP RECORD EPS LEVER 1

COMMANDS R1137098/099 COVER + 2 SCREWS

COMMANDS R1137100 8 SCREWS

COMMANDS R1137083 EPS BRACKET COVER PKG


REV.06 178


Spare parts

PART CODE DESCRIPTION

FRONT DERAILER R1137085 EPS NUT+WASHER KIT FOR FRONT DERAILLEUR

FRONT DERAILER R1137090 EPS 5pcs FRONT DERAILLEUR CAGE INSERT KIT

FRONT DERAILER R7136211 EPS COVER FOR FRONT DERAILER ROCKER ASSEMBLY

FRONT DERAILER CAGE RECORD

FRONT DERAILER CAGE S.RECORD

INTERFACE R1137101 3 (O‐RING + PLASTIC + ADHESIVE PLUG) INTERFACE SYSTEM

POWER R1134886 MAGNET PKG 5 PCS

SPECIAL TOOL R1318001 MAGNETS KIT

SPECIAL TOOL ELECTRICAL CONNECTOR OPENER TOOL

90


REV.06 179


Warranty

Procedure for the end customer

In case of malfunction, after having conducted any checks suggested on the instruction sheet, the end customer must contact an Authorised Service Centre for the additional, necessary checks to be carried out, which the ASC is equipped to perform.


REV.06 180


WarrantyProcedure for the dealer/Pro Shop

In the event that malfunctions are found after having conducted the prescribed checks, the dealer or Pro Shop sends the defective component, after reporting, to the Authorised Service Center in their country.

Together with the component, the dealer or Pro Shop also sends the EPS Check Control document, filled in as far as the customer and dealer / Pro Shop are concerned.

91


REV.06 181


WarrantyProcedure for the Service Center The Service Center, based on the indications from the dealer / Pro Shop, conducts:1.a visual/mechanical check2.a functional check connecting the component to the EPS group in its possessionImmediately sends a new component to the dealer / Pro Shop, completes the EPS Check control document and sends it, together with the defective component, to the Vicenza headquarters.


REV.06 182


Warranty

Procedure for the Service Center

In order to provide optimum service for the end customer, the Authorised Service Centre will keep a stock of components to be sent to the dealers / Pro Shops in case of malfunctions covered under warranty.

This is because during the 1st year all defective components must be immediately returned to the Vicenza headquarters.

92


REV.06 183


Warranty3 year warranty

The Record EPS and Super Record EPS groups, in addition to the 2 year warranty (or 3 for chainset, chain and sprocket), have a warranty extention of 1 year, power unit excluded, if:

•they are used on the same bicycle

•they are registered on the Campagnolo web site

•the components subject to wear are replacedwith Campagnolo components.


REV.06 184

Thank you for your attention

Documents

Technical course Technical course - Bikesportz Imports · Technical course Technical course ... possibilityof braking and changinggears ... a magnet to switch off the system. 19