Technical course Technical course
Programme 1
The EPS and its operation
2
Installation
3
Adjustments after installation
4
Maintenance
5
Diagnostics
6
Options, accessories and warranty
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The EPS system
The product
Section
Chapter
Information and agreements Important information Danger: if care is not taken injury to personnel and to those nearby may occur
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Definitions used in this presentation ascend
ascend
11th REV.10B
descend
descend
1st 4
1
The EPS and its operation
2 3 4 5
• • • •
The product Operation on the road System components Customer adjustments
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The EPS system
The product EPS, Electronic Power Shift, is the 11 speed electronic drivetrain system conceived, built and marketed by Campagnolo. 2 versions are available:
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The EPS system
Operation on the road
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. REV.10B
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The EPS system
Operation on the road The control levers of the EPS system are positioned and act with the same logic as mechanical Campagnolo system levers.
3
Lever 1 Lever 2 Lever 3
2
brake lever near the brake internal lever
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The EPS system
Operation on the road Right control Lever 2
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The EPS system
Operation on the road Right control Lever 3
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The EPS system
Operation on the road Right control
By holding down levers 2 or 3 we obtain a continuous movement of the rear derailleur in ascent or descent. REV.10B
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The EPS system
Operation on the road Left control Lever 2
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The EPS system
Operation on the road Left control Lever 3
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The EPS system
Operation on the road
Example of a correction
Automatic correction of the front derailleur 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. REV.10B
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The EPS system
Operation on the road The front derailleur over‐run In order to aid the front derailleur in ascent, in the event of a large chain crossover, the front derailleur carries out an over‐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. REV.10B
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The EPS system
Operation on the road Front derailleur in descent with high chain crossover 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 correction previously described.
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The EPS system
Operation on the road The rear derailleur over‐run The system also carries out a rear derailleur over‐run in case of descent and ascent on the first 5° sprockets
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Example of descent to the 4th sprocket
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The EPS system
Operation on the road 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 which precision is tied to the cable movement and the return spring in the derailleur. constant front and rear derailleur action speed, by eliminating cable friction soft action and limited run of the levers possibility of braking and changing gears simultaneously the design of the frame is no longer dictated by the need for simple cable runs REV.10B
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The EPS system
System components The EPS system, unlike traditional systems, is made up of 6 main components, 2 of which are completely new: right rear derailleur control left front derailleur control interface power unit front derailleur rear derailleur Each of these components has one or more cables for proper interconnection. A battery charger is also provided in order to recharge the batteries as well as a magnet to switch off the system. REV.10B
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The EPS system
System components
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The EPS system
System components
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The EPS system
System components Right control lever 1 brake lever 2 command to “ascend” to the largest sprocket lever 3 command to “descend” to the smallest sprocket MODE button: short‐ press this button to view the battery charge state
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MODE 22
The EPS system
System components Left control lever 1 brake lever 2 command to “ascend” to the largest chain ring lever 3 command to “descend” to the smallest chain ring MODE button: short‐press this button to view the battery charge state
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MODE 23
The EPS system
System components 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 REV.10B
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The EPS system
Verification of the battery charge state
The battery charge level can be verified by short pressing one of the two Mode buttons FIXED GREEN LED From 100 % to 60 % charge FLASHING GREEN LED From 60 % to 40 % charge FIXED YELLOW LED From 40 % to 20 % charge FIXED RED LED From 20 % to 6 % charge FLASHING RED LED + ACOUSTIC ALARM (BUZZER) From 6 % to 0 % charge (using EPS every 5 min, decreasing frequency from 1 to 20 min if not used since 30 min)
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The EPS system
System components Power system Its main functions are: Contains and manages the battery pack Activates and controls the rear derailleur and the front derailleur Indicates any faults with the LED Dialogues, thanks to a digital line, with the interface Activates the buzzer
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Il sistema EPS
System components 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.
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Il sistema EPS
System components
Example of electric circuit (electro‐mechanic system)
EPS: electronic system …11100101101..
I = VxR
…110101..
Interface
Power system
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The EPS system
System components Average duration of the battery for use on the road: •average of 500 km/month: 1500 km •average of 1000 km/month: 1800 km •average of 2000 km/month: 2000 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. The battery has no memory effect, so you can charge it for a short time too if requested. REV.10B
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The EPS system
System components The rear derailleur Is made up of: Mechanical structure Electric motor with resolver Mechanical limit switch adjustment screw Adjustment screw for the distance between the pulley and the sprocket cassette REV.10B
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The EPS system
System components The front derailleur Is made up of: Mechanical structure with cage Electric motor with resolver
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The EPS system
System components The shut‐off magnet 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.
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The EPS system
System components The battery charger 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.
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The EPS system
System components The battery charger The battery charger is compatible with: •110‐220V voltage and 50‐60 Hz frequency •12 V voltage for car recharging (optional cable) Do not use a battery charger other than the one provided with the EPS system REV.10B
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The EPS system
System components 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.
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The EPS system
Customer adjustments The MODE buttons, besides verifying the battery charge state, allow the user to carry out adjustments to the rear and front derailleur which correspond to the adjustments carried out with the cable adjusters in traditional systems cancel any temporary malfunctions detected by the system and indicated by the LED on the power unit (please see the Diagnostics Chapter) REV.10B
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The EPS system
Customer adjustments Adjustment of the rear and front derailleurs The 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 levers 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. 7 right and 7 left fixed movements are available. REV.10B
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The EPS system
Customer adjustments Adjustment of the rear and front derailleurs Once 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 mm after 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 … REV.10B
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The EPS system
Customer adjustments 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.
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The EPS system
Customer adjustments Adjustment of the rear and front derailleurs 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.
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The EPS system
Customer adjustments Adjustment of the rear derailleur press the right MODE button for about 6 seconds
A
adjust the position by pressing levers 2 and/or 3 short‐press the right MODE button to store the adjustment
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The EPS system
Customer adjustments Adjustment of the front derailleur press the left MODE button for about 6 seconds adjust the position by pressing levers 2 and/or 3 short‐press the left MODE button to store the adjustment REV.10B
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The EPS system
Customer adjustments Failure to conclude the adjustment If 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.
Contemporary adjustment of front and rear derailleur When you press one of the two MODE button, right or left, it’s possible to do the adjustment of the front or rear derailleur. The memorization can be done with one of the 2 MODE buttons.
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Installation Workshop tools Interface with the frame Compatibility Preparation of the frame and components • Cable run and installation
• • • •
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Installation
Workshop tools
The specific tools, available for the operators (S.C., OEM, Pro Shop), for installation of the EPS system are: •Cable run magnet kit
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Installation
Workshop tools • Connector disconnection tool
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Installation
Workshop tools
The generic tools for the EPS system are: Tool Chain tool Torque wrench BB cups tool (for torque wrench) Allen wrench Torque wrench Allen wrench (for torque wrench) Torx wrench (for torque wrench) Caliper Allen wrench Torx wrench Philips screwdriver Philips screwdriver Screwdriver Wrench Cutter Pliers flat tips Derailleur Hanger Alignment Gauge Bottom Bracket Tapping & Facing Set Thickness gauge REV.10B
code or size UT‐CN300 20‐100 Nm UT‐BB130 UT‐BB110 0 ‐ 20 Nm 5 T25 2‐3‐4‐5‐6 T25 1,5 medium medium 7
used for chain BB axle, BB cups BB cups BB ergopower, rear gear, f. deraill.clamp on ergopower, rear gear, f. deraill.clamp on rear derailler frame various rear derailler ergopower cover
front derailler housing various to check the drop out frame chain position
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Installation
Interface with the frame The EPS system is compatible with the following threaded bottom bracket shells and cups TYPE
X
Italian thread
From 69.2 to 70.8
English thread
From 67.2 to 68.8
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Installation
Interface with the frame In case of frames with bottom bracket cups Press Fit 86.5 x41 the following measurements have to be observed
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Installation
Interface with the frame In case of frames with Press Fit BB30 68 X 42 bottom bracket cups the following measurements have to be observed
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Installation
Interface with the frame In case of frames with Press Fit BB30 68 X 46 bottom bracket cups the following measurements have to be observed
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Installation
Interface with the frame Braze‐on version
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Installation
Interface with the frame Braze‐on version (other than mechanical front derailleur)
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QUOTA L
CENTRATURA ATTACCO A SALDARE
INGRANAGGI COMPATIBILI
138 140 142 144 146 148 150 152
48T 49T 50T 51T 52T 53T 54T 55T
45T,46T,47T,48T,49T,50T,51T 46T,47T,48T,49T,50T,51T,52T 47T,48T,49T,50T,51T,52T,53T 48T,49T,50T,51T,52T,53T,54T 49T,50T,51T,52T,53T,54T,55T 50T,51T,52T,53T,54T,55T,56T 51T,52T,53T,54T,55T,56T 52T,53T,54T,55T,56T
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Installation
Interface with the frame Clamp‐on version A 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.10B
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Installation
Interface with the frame Rear derailleur
L = 405 mm min
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Installation
Interface with the frame 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.10B
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Installation
Interface with the frame Rear derailleur
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Installation
Interface with the frame Rear derailleur
B = 30 mm
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Installation
Interface with the frame 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) REV.10B
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Installation
Interface with the frame
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Installation
Interface with the frame M4
M2,5 M5
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Installation
Interface with the frame
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Installation
Compatibility
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 REV.10B
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Installation
Compatibility For complete functionality of the EPS system the dimensions of the compatible chainrings or sprockets cannot be changed.
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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.
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Installation
Preparation of the frame and components 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
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Installation
Preparation of the frame and components 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 ...)
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Installation
Preparation of the frame and components Power system: install bracket for water‐bottle fixing or for lower position on the frame and verify the presence of the magnet
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Installation
Preparation of the frame and components Component connectors Each pair of connectors is marked by differently coloured cable ties near the connectors.
55 cm 55 cm 85 cm
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55 cm
70 cm 50 cm
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Installation
Preparation of the frame and components Component connectors Each pair has polarized slots in order to make incorrect installation impossible (Poka‐ yoke).
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Example of slots
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Installation
Preparation of the frame and components Component connectors In order to facilitate installation, each connector has an arrow for alignment with the respective counterpart.
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Installation
Cable run and installation Cable connection diagram
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Installation
Cable run and installation Cable connection diagram Control front derailleur
blue
violet
interface
Control rear derailleur
red yellow Power system green
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Front derailleur
Rear derailleur
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Installation
Cable run and installation Cable run for rear derailleur Control front derailleur
blue
violet
interface
Front derailleur
Power system green
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Control rear derailleur
Rear derailleur
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Installation
Cable run and installation
Temporarily install the power unit
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Installation
Cable run and installation Running the rear derailleur connection cable
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Installation
Cable run and installation Cable run and connection to the interface Control front derailleur
blue
violet
interface
Control rear derailleur
red Front derailleur
Power system green
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Rear derailleur
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Installation
Cable run and installation Cable run and connection to the interface
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Installation
Cable run and installation Running the rear derailleur connection cable Control front derailleur
blue
violet
interface
Control rear derailleur
red yellow Power system green
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Front derailleur
Rear derailleur
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Installation
Cable run and installation Running the rear derailleur connection cable
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Installation
Cable run and installation
Installation of the controls on the handlebar Tightening torque 10 Nm
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Installation
Cable run and installation
Installation of the power unit
Installation of vibration damping rubber washer and of the 2 washers to avoid to damage the cables if pressed between the bracket and the frame. REV.10B
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Installation
Cable run and installation
Installation of the rear derailleur Tightening torque: 15 Nm (Torx wrench T25)
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Installation
Cable run and installation Do not let the front derailleur cable slide back into the frame ‐anchor it with adhesive tape
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Installation
Cable run and installation
Installation of the crankset Be careful with the rear derailleur cable run
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I ricambi e la garanzia
Cable run and installation R 1137097: BB cable guide Example of BB cable guide with Press Fit cups
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Installation
Cable run and installation Insert the BB cable guide cover cylinder from the bevelled side to ease insertion despite the presence of the rear derailleur cable
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Installation
Cable run and installation
Installation of the crankset
Bottom bracket cup tightening torque 35 Nm with tool UT‐BB130 Crankset tightening torque: 42‐60 Nm
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Installation
Cable run and installation Installation of the front derailleur tightening torque: clamp on versione 5 Nm; brazed on version 7 Nm
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Installation
Cable run and installation Installation 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
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Installation
Cable run and installation Installation of the interface Fit elastic ring and adhesive rubber
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Installation
Cable run and installation Installation of the control connectors
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Installation
Cable run and installation Functional 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.10B
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Installation
Cable run and installation The final phases of installation are: •completion of installation of the controls •power unit cable protection •installation of rubber grommets •chain installation
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Installation
Cable run and installation Position the control connector as illustrated in the photo below, being careful that the cable runs in the channel shown and close the cover.
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Installation
Cable run and installation Power unit cable protection
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Installation
Cable run and installation
Installation of the 3 rubber grommets in the holes near the interface,…
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Installation
Cable run and installation …the rear and front derailleur
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Installation
Cable run and installation Chain Install the chain in accordance with the procedure required for the mechanical groups using the tool UT‐CN300
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Installation
Cable run and installation After completing the installation of the EPS group, we are now ready to carry out the adjustments.
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Adjustments after installation • The phases • The rear derailleur reset procedure • The rear derailleur mechanical travel limit • Jockey cage distance adjustment • The front derailleur reset procedure • Conclusion 101
Adjustment after installation
The phases 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.
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Adjustment after installation
The phases A. B. C. D. E.
Rear derailleur reset Rear derailleur travel limit adjustment Jockey cage distance adjustment Front derailleur reset 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.
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Adjustment after installation
The reset procedures The rear and front derailleur reset procedures are fundamental for 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. REV.10B
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Adjustments after installation
Rear derailleur reset procedure This 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.10B
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Adjustments after installation
Rear derailleur reset procedure 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). REV.10B
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Adjustments after installation
Rear derailleur reset procedure 2. simultaneously press the two MODE buttons until the blue LED lights (about 6 seconds)
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Adjustments after installation
Rear derailleur reset procedure 3. position the rear derailleur on the 2nd sprocket
4. adjust the position by pressing levers 2 and/or 3 REV.10B
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Adjustments after installation
Rear derailleur reset procedure 5. press the right MODE button to store the position of the 2nd sprocket 6. position the rear derailleur on the 10th sprocket
Pay attention when pressing Lever 2 ‐ the speed of movement of the rear derailleur is not constant and it’s possible for the rear derailleur to run into the spokes. REV.10B
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Adjustments after installation
Rear derailleur reset procedure 7. adjust the position by pressing levers 2 and/or 3 8. short‐press the right MODE button to store the position of the 10th sprocket and to conclude the procedure.
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Adjustments after installation
The rear derailleur mechanical travel limit After resetting the rear and front derailleurs it is essential to 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.
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11°
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Le regolazioni dopo il montaggio
Il fine corsa meccanico del cambio To adjust correctly: • move the rear derailleur onto the 11th sprocket • tighten the grub screw until it touches the surface of the travel limit • loosen the grub screw by approximately ½ turn to prevent it from touching the contact surface of the travel limit when the rear derailleur is on the 11th sprocket • REV.10B
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Adjustments after installation
Rocker distance adjustment 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.
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Adjustments after installation
Top jockey wheel distance adjustment
The front derailleur has to be on the smallest chainring. The distance must be set at about 5 – 7 mm.
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Adjustments after installation
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.
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Adjustments after installation
Front derailleur reset procedure Position the front derailleur on the smallest chainring and the rear derailleur on the 11th sprocket (the largest)
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Adjustments after installation
Front derailleur reset procedure 1. simultaneously press the two MODE buttons until the blue LED lights (about 6 seconds)
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Adjustments after installation
Front derailleur reset procedure 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
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Adjustments after installation
Failure to finish reset 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 REV.10B
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Adjustments after installation
Conclusion 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.
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Maintenance • Routine maintenance • Special maintenance 121
Maintenance
Routine maintenance Cleaning Although the system meets the IP67 standards of water infiltration resistance, we would not recommend washing the bicycle with pressurised water and aggressive detergents. Periodically clean and lubricate the pivots of the derailleurs with a suitable oil for thermo‐plastic components Never use denatured alcohol to clean the power unit. REV.10B
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Maintenance
Routine maintenance Cleaning If the cover of the battery charger connector is not correctly positioned, water or dirty can go inside the connector. This is not a problem while you are riding, but if you charge the battery you can create electrical short cuts damaging the power unit or the battery could not be charged for anormal contacts. So before charging the battery, be sure the connector is dry and clean. REV.10B
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Maintenance
Routine maintenance 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
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Maintenance
Routine maintenance Without use on the road (magnet inserted)
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Maintenance
Routine maintenance 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. REV.10B
126
Maintenance
Special maintenance Ergopower controls Lever 1 can be replaced as with mechanical systems. Before replacing lever 1, we recommend immobilising lever 2 with a clamp as shown in order to avoid: REV.10B
127
La manutenzione
Special maintenance Ergopower controls • that the ends of the spring permitting rotation of the pivot of lever 2 do not come out of their respective seats,and in particular, take care that the end A does not come out of its seat B as shown • the spring 1 with the pusher head 2 does not come out of the seat on the underside of the hammer‐head 3 .
REV.10B
128
Il montaggio
Il passaggio cavi ed il montaggio …del cambio e del deragliatore
REV.10B
129
Maintenance
Special maintenance Front derailleur 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. REV.10B
130
1 2 3 4
5 6 REV.10B
Diagnostics • Diagnostics by the end customer • Diagnostics by technical support service • Malfunctions without the LEDs turning on 131
Diagnostics
Diagnostics by the end customer The EPS system can automatically detect various malfunctions. In the event that a malfunction is detected, the EPS system turns on a LED on the power unit and activates the buzzer. Depending on the area in which the malfunction was detected, the LED takes on different colours based on the following table: REV.10B
132
Diagnostics
Diagnostics by the end customer LEDs on the power unit WHITE YELLOW GREEN BLUE VIOLET RED REV.10B
Power system Front derailleur Rear derailleur Front derailleur control Rear derailleur control Interface system 133
Diagnostics
Diagnostics by the end customer Since, in some situations, the LED on the power unit may light because of a temporary malfunction, 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 REV.10B
134
Diagnostics
Diagnostics by the end customer 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 REV.10B
135
Diagnostics
Diagnostics by the end customer 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.
REV.10B
136
Diagnostics
Diagnostics by the end customer 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 REV.10B
137
Diagnostics
Diagnostics by the end customer 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
REV.10B
138
Diagnostics
Diagnostics by the end customer 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.10B
139
Diagnostics
Diagnostics by the end customer Rear derailleur disengaged due to impact In case of a fall or accidental impact on the rear derailleur, it may «disengage» (to avoid damage). You will notice this because the rear derailleur will not shift into the smaller sprockets. We recommend to take the rear derailleur to the smallest reachable sprocket, stop pedalling and act repeatedly on lever 2. 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. REV.10B
140
Diagnostics
Diagnostics by the end customer Rear derailleur disengaged due to impact 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.
REV.10B
141
Diagnostics
Diagnostics by the end customer Rear derailleur disengaged due to impact Position of the rear derailleur disengaged
channel
REV.10B
depression
142
Diagnostics
Diagnostics by the end customer ‘Ride back home’ function 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. REV.10B
143
Diagnostics
Diagnostics by technical support service 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. REV.10B
144
Diagnostics
Diagnostics by technical support service
REV.10B
145
Diagnostics
Diagnostics by technical support service
The procedures which should be followed in the event that a LED on the power unit lights are listed below.
REV.10B
146
Diagnostics
Diagnostics by technical support service Power system CAUSE: 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.
REV.10B
147
Diagnostics
Diagnostics by technical support service Front derailleur CAUSES: 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. REV.10B
148
Diagnostics
Diagnostics by technical support service Front derailleur If 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.
REV.10B
149
Diagnostics
Diagnostics by technical support service Rear derailleur CAUSES: 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.
REV.10B
150
Diagnostics
Diagnostics by technical support service Rear derailleur control CAUSE: 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.
REV.10B
151
Diagnostics
Diagnostics by technical support service 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.
REV.10B
152
Diagnostics
Diagnostics by technical support service Front derailleur command CAUSES: 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. REV.10B
153
Diagnostics
Diagnostics by technical support service Front 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.
REV.10B
154
Diagnostics
Diagnostics by technical support service 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 more than 30 seconds and remove the magnet: if the LED turns back on, check the entire cable which goes ... (ctd) REV.10B
155
Diagnostics
Diagnostics by technical support service 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.
REV.10B
156
Diagnostics
Malfunctions without the LEDs turning on 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 REV.10B
157
Diagnostics
Malfunctions without the LEDs turning on 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. REV.10B
158
Diagnostics
Malfunctions without the LEDs turning on
Battery is completely flat: The system does not have sufficient energy to indicate the excessively low charge level of the battery.
REV.10B
159
1 2
Spare parts and warranty
3 4 5
6 REV.10B
• Product options • Accessories • Warranty: terms and conditions/what is covered • Warranty: management 160
Access., spare parts and warranty
Product options 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 REV.10B
161
Access., spare parts and warranty
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
REV.10B
162
Access., spare parts and warranty
Product options 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)
Series SUPER RECORD SUPER RECORD ‐ ‐ ‐ RECORD RECORD REV.10B
thread / press fit italian english press fit press fit press fit italian english
Code OC12‐SRI OC12‐SRG IC12‐SR41 IC12‐SR42 IC12‐RE46 OC12‐REI OC11‐REG
Mechanical Name series compatibility outboard cups SUPER RECORD™ ULTRA‐TORQUE™ ‐ IT yes outboard cups SUPER RECORD™ ULTRA‐TORQUE™ ‐ BSC yes Ultra Torque™ OS‐Fit™ integrated cups 86,5x41 yes Ultra Torque™ OS‐Fit™ integrated cups BB30 68x42 yes Ultra Torque™ OS‐Fit™ integrated cups BB30 68x46 yes outboard cups RECORD™ ULTRA‐TORQUE™ EPS ‐ IT yes outboard cups RECORD™ ULTRA‐TORQUE™ ‐ BSC yes 163
Access., spare parts and warranty
Accessories PART COMMANDS FRONT DER FRONT DER FRONT DER FRONT DER EPS EPS
REV.10B
CODE
DESCRIPTION
R1137084
LARGE HANDS INSERT KIT FOR EPS
FD‐SR001EPS R7204008
FRONT DER. STIFFNESS INCREASER CHAIN SAVER SYSTEM
DC12‐SR2B
SR Ø 32 mm BLACK clamp front derailleur
DC12‐SR5B
SR Ø 35 mm BLACK clamp front derailleur
AC12‐CAADBBEPS CABLE EXTENTION KIT AC12‐CAADSPEPS UNDER SADDLE CABLE EXTENTION KIT
164
Access., spare parts and warranty
Accessories 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.
REV.10B
165
Access., spare parts and warranty
Accessories Front derailleur stiffness increaser 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.
REV.10B
166
Access., spare parts and warranty
Accessories Front derailleur stiffness increaser 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.10B
167
Access., spare parts and warranty
Accessories Front derailleur stiffness increaser 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.
REV.10B
168
Access., spare parts and warranty
Accessories CHAINÂ GUARD
REV.10B
169
Access., spare parts and warranty
Accessories 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 REV.10B
170
Access., spare parts and warranty
Accessories Chain guard It’s compulsary for: •use of the bike on particularly badly surface roads, pavè as in Paris-Roubaix, etc or other cobblestone paving.
REV.10B
171
Access., spare parts and warranty
Accessories CABLE EXTENTION KIT UNDER BB CABLE EXTENSION KIT
UNDER SADDLE CABLE EXTEN. KIT This kit is composed by the following extension cords: green yellow red REV.10B
rear derailleur front derailleur interface
55 55 135
cm cm cm 172
Access., spare parts and warranty
Accessories CABLE EXTENTION KIT You need it if the distance between A-B or C(D) – B is more than 67 cm
REV.10B
173
Access., spare parts and warranty
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.10B
174
Access., spare parts and warranty
Warranty Procedure 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. REV.10B
175
Access., spare parts and warranty
Warranty 3 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 replaced with Campagnolo components. REV.10B
176
Super Record Vs Record DIFFERENZE Biella Frontale Carbonio con foro di alleggerimento
SUPER RECORD x
Biella frontale Carbonio Viti parallelogramma in Acciaio con trattamento TIN rear derailleur
x x
Viti Parallelogramma in Acciaio Involucro attuatore in Alluminio
x x
Involucro attuatore in Acciaio Inox Rotellina inferiore con sfere in ceramica
x x
Rotellina inferiore standard front derialleur
Forcella Carbonio/Alluminio
commands
x x x x
leva 1 in carbonio leva 2 in tecnopolimero con foro di alleggerimento leva 2 in tecnopolimero
REV.10B
x
Forcella Alluminio/Alluminio leva 1 in carbonio con 3 fori di alleggerimento
RECORD
x x
177
I pesi Super Record (Titanio)
Record
R Command
131
133
L Command
131
133
Rear derailleur
198
203
Fornt derailleur (brazed on)
129
133
Power Unit
167
167
24
24
Brakes
272
278
Crank set (53/39)
630
673
Chain
239
239
Srpocket casset
177
201
Total
2098
2184
Wheights (gr.)
Interface
REV.10B
178
Thank you for your attention
REV.10B
179