C520R/C531R Repair Manual
(Electronic)
Table of Contents
1-1-1. Display Picture - C520R/C531R
1-2-1. Component Placement - C520R/C520U Display
1-2-2. Component Placement - C520R/C531R Lower Body
1-3-1. Block Diagram - C520R/C531R Display Electronics
1-4-1. Cable Connections - C520R/C531R Display
1-4-2. Cable Connections - C520R/C531R Drive Board
1-5-1. Indicator LEDs – C520R/C531R Display
1-5-2. Indicator LEDs – C520R/C531R Drive Board
1-6-1. C520R Electronics Specifications
2-1-1. Display Malfunction Troubleshooting Table - C520R/C531R
2-1-2. Display Malfunction Troubleshooting Table - C520R/C531R, continued
3-1-1. Malfunction: No start up (alternator)
3-2-1. Malfunction: No start up (battery)
3-3-1. Malfunction: No RPM value
3-4-1. Malfunction: No resistance
3-5-1. Malfunction: Excessive resistance
3-6-1. Malfunction: Telemetry heart rate malfunction
3-7-1. Malfunction: Contact heart rate (HTR) malfunction
3-8-1. Malfunction: Remote control malfunction
4-1-1. Mechanical Maintenance Schedule -C531R/C520R
4-2-1. Mechanical Troubleshooting - C520R/C531R
1-1-1. Display Picture - C520R/C531R
1-1-1
1-2-1. Component Placement - C520R/C520U Display
1-2-1
1-2-2. Component Placement - C520R/C531R Lower Body
Bridge board
Electro-magnet
Reed sensor
Battery
Drive
board
Flywheel with
built-in alternator
1-2-2
1-3-1. Block Diagram - C520R/C531R Display Electronics
Display
Board
Sensor – L
Sensor – R
Alternator
Battery Charger
Battery
HTR board
HR receiver
Remote
Bridge
control
board
Electro-magnet
Drive
board
Reed switch
1-3-1
1-4-1. Cable Connections - C520R/C531R Display
indicator
To bridge
board
LED1
Power supply
Main IC
1-4-1
1-4. Cable Connections - C520R/C531R Drive Board
Bridge board cable connections
To display
To drive
To HTR
To remote control
To electro-magnet
To battery charger
To alternator
To bridge board (to
display)
To reed switch
1-4-2
To battery
1-5. Indicator LEDs - C520R / C531R Display
supply.
Indicator Led1
Lit indicates that there
is incoming power
1-5-1
1-5. Indicator LEDs - C520R/C531R
battery is being charged.
Drive Board
Drive board power
indicator
Lit indicates incoming
power supply.
Battery charger indicator
Lit indicates the
Exterior battery
charger fuse F3
Alternator fuse F1
CLK optic sensor
LED
LED flashes when
pedals move.
Battery fuse F2
1-5-2
1-6. C520R Electronics Specifications
Battery automatically recharges or can be recharged via an exterior
Specification
Power supply
Backup power
supply
Resistance
Speed detection
Resistance LEVEL 1 - LEVEL 20
Display method Segment array and numerical LEDs
Main window Dot matrix
Character
window
Workout
programs
Heart rate
control programs
Heart rate Telemetry heart rate detection
User IDs
AC alternator
6.4 VA battery
charger.
Electro-magnet
Reed switch
65% HR TARGET, Heart rate, 80% HR TARGET
WORKOUT LEVEL / CALORIES / TIME / RPM
DISTANCE / CAL/HR / WATTS / SPEED
INTERVAL / RANDOM / HILL / TRACK /
ZONE TRAINER / CARDIO / WT LOSS
CARDIO, WT LOSS, ZONE TRAINER
Four user IDs（USER1- USER4）
Contents Notes
Motion Belt operated
1-6-1
2-1. Display Malfunction Troubleshooting Table - C520R/C531R
Malfunction
Cannot
start unit
Cannot
start unit
Display
won’t
operate
No
resistance
Circumstance Inspection and Test Points Suggested
Components
The display is not
lit; I pedal the
bike; but the
display still
doesn’t light.
When I don’t
pedal the bike, the
display does not
light.
I start pedaling
the bike, but the
display shows no
reaction, and
values don’t
change.
I pedal the bike
and press
resistance keys.
Resistance values
on the display
change. But there
is no resistance.
1. Inspect cable connections.
2. Inspect drive board fuse.
3. Inspect drive board power LED.
4. Inspect the alternator.
1. Inspect battery fuse on the drive board.
2. Measure battery voltage. Battery voltage should be 5.5V
or more.
3. If battery voltage is under 5.5V, pedal the unit at over 50
RPM to recharge the battery.
4. Replace the battery if voltage is under 2.0 and it won’t
recharge.
RPM signal didn’t enter the display IC. Inspect RPM signal.
1. Inspect cable connections and the bridge board.
2. Inspect the reed switch and magnet.
3. Inspect the drive board CLK LED.
4. Inspect the reed switch and its wire.
1. Inspect cable connections.
2. Inspect alternator startup. If alternator will not start unit,
there will be no resistance.
3. Inspect the electro-magnet and its wires.
4. Test whether the drive board emits voltage to the
electro-magnet.
1. drive board
fuse
2. drive board
3. alternator
1. battery fuse
on the drive
board
2. battery
1. magnet
2. reed switch
1. drive board
Notes
2-1-1
Telemetry heart
rate detection
malfunction
Telemetry heart
rate malfunction
1. Inspect heart rate transmitter and its batteries. Replace
batteries if batteries haven’t been replaced for a long time.
2. Inspect heart rate receiver board cable connections.
3. Test or replace the heart rate receiver board.
4. Inspect environment for sources of interference, such as
speakers and lights.
Contact heart
rate
malfunction
Key
malfunction
(display)
Remote
malfunction
Contact heart
rate malfunction
No key function,
or continual key
function
Press remote
keys; display
1. Inspect bridge board HTR cable.
2. Inspect HTR indicator LED on the drive board.
3. Replace the HTR board.
1. Replace the display key switches. 1. display
1. Inspect the remote and bridge board wire connections.
2. Replace the remote controller.
shows no
reaction.
Excessive
resistance
Pedal on the
unit; resistance
is too heavy.
1. Inspect all wire connections and whether screws have
created an electrical short.
2. Move the flywheel with your hand to see whether the
electro-magnet is stuck on the flywheel.
3. Inspect whether drive board components have an
electrical short, sending maximum power to the
electro-magnet, causing excessive resistance.
Total distance 1. Press workout level<▲>+<▼>+<stop> to see total
distance.
2. telemetry
heart rate
transmitter
3. telemetry
heart rate
receiver
board
1. HTR board C531R
keys
1. remote
C531R
control
1. drive board
2-1-2
Troubleshooting
Model: C520R/C531R
Malfunction: No start up (alternator)
Circumstance: Pedal on the bike; the display does not light.
Possible causes: 1. Cables are not connected.
2. Drive board malfunction
Troubleshooting: 1. Inspect all cable and bridge board connections.
2. Inspect alternator wire connections.
3. Inspect cable connections, fuse F1, and PWR
LED at the drive board.
4. Replace the drive board.
5. Inspect the display IC pin connections.
Display
Inspect the
program IC
board
Bridge board
Alternator
Speed sensor
Drive
Board
3-1-1
Inspect bridge
board wire
connections
F1 fuse
Power indicator
EAC 驅動器組
Inspect alternator
wires
Troubleshooting
Model: C520R/C531R
Malfunction: No start up (battery)
Circumstance: Display shuts off if you don’t pedal.
Possible causes: 1. Cables are not connected.
2. Battery voltage is too low.
Troubleshooting: 1. Inspect all cable connections.
Inspect connections at the bridge board.
2. Test battery voltage. Normal is 5.5V or more.
3. Inspect drive board F2 fuse.
4. If battery voltage is less than 5.5V, pedal at 50 RMP or faster to replenish the battery.
Inspect the
program IC.
Display
board
Test battery voltage. The
Bridge board
display requires more than
5.3V to power up.
EAC 驅動器組
Drive
Battery
Board
3-2-1
Power indicator LED
F3 fuse
Troubleshooting
Model: C520R/C531R
Malfunction: No RPM value
Circumstance: 1. No RPM value appears.
2. Pedal the bike; the display shows no reaction.
Possible causes: 1. Reed switch and magnet
2. Wire connections
Troubleshooting: 1. Inspect the reed switch and magnet.
2. Inspect all cable connections.
3. Inspect the drive board CLK signal
indicator LED.
Display
board
Bridge
Reed switch and magnet
board
Inspect the CLK
indicator on the drive
board
Drive board
When the reed
switch and magnet
come into contact, the
LED lights.
Reed switch
3-3-1
Troubleshooting
Model: C520R/C531R
Malfunction: No resistance
Circumstance: Pedal on the bike; there is no resistance.
Possible causes: 1. Cables are not connected.
2. Drive board is defective.
Troubleshooting: 1. Inspect all cable connections.
2. Inspect whether an RPM value appears when you pedal the bike. If not, inspect the reed switch
and magnet.
3. Inspect whether unit starts via the alternator.
4. Inspect the drive board fuse. Measure voltage from the drive board to the magnet.
5. Inspect the electro-magnet wires
and whether the electro-magnet has
attracts metal.
Inspect drive board
CON2 voltage:
LEV 5 6.3V
LEV 15 10V
Display board
Reed switch
Alternator
Reed switch
Drive board
Electro-
F1 fuse
magnet
3-4-1
Troubleshooting
Model: C520R/C531R
Malfunction: Excessive resistance
Circumstance: Pedal the bike; resistance is excessively heavy.
Possible causes: 1. There is an electrical short in the cables.
2. Drive board components have an electrical short.
Troubleshooting: 1. Inspect all cable connections. Inspect cables for damage.
2. Inspect drive board power components for a short.
3. Replace the drive board.
Display board
Inspect IGBTs for a short
Electro-
Drive
magnet
board
3-5-1
Troubleshooting
Model: C520R/C531R
Malfunction: Telemetry heart rate malfunction
Circumstance: Heart rate value does not appear.
Possible causes: 1. Telemetry transmitter batteries.
2. Heart rate receiver board malfunction.
3. Environmental interference, possibly from
lights or speakers.
Troubleshooting: 1. Replace the heart rate transmit ter strap or its batteries.
2. Inspect heart rate receiver board connections.
3. Inspect the HTR board LEDs.
Display
board
Heart rate board container
Telemetry heart rate receiver board
Bridge
board
Heart rate transmitter strap
(battery location)
HTR board
HR receiver
3-6-1
Troubleshooting
Model: C531R
Malfunction: Contact heart rate (HTR) malfunction
Circumstance: Hold HTR contact plates; heart rate value is
incorrect.
Possible causes: 1. HTR wires are disconnected.
2. HTR board is defective.
Troubleshooting: 1. Inspect display wire connections.
2. Inspect the HTR wire on the drive board.
3. Inspect the HTR bridge board and HTR board
indicator LEDs.
4. Inspect the HTR contacts and their wire
connections.
Display
board
HTR board indicator LEDs
LED Name Explanation
LED1 Telemetry Flashes to indicate incoming telemetry signal.
LED2 HTR contact Lights to indicate hands on contact plates.
LED3 HTR output Flashes to indicate incoming HTR (contact)
signal.
LED4 Heart rate
signal output
Flashes to indicate heart rate signal output to
the display
Drive board
HTR board placement
Bridge board
HTR board
Sensor
Sensor
3-7-1
Troubleshooting
Model: C531R
Malfunction: Remote control malfunction
Circumstance: Press remote control keys; there is no response.
Possible causes: 1. Wire from the remote control to the display is defective.
2. Remote control keys are defective.
Troubleshooting: 1. Inspect remote control wire connections.
2. Inspect bridge board wire connections.
3. Replace the remote control.
Display
board
Inspect the remote
control wire
Bridge
board
Remote
control
3-8-1
4-1. Mechanical Maintenance Schedule -C531R/C520R
Item Inspect and maintain Daily Weekly Monthly
1 Wipe exterior clean
2 Level unit
3 Inspect screws
4 Inspect pedals for
noise
5 Inspect seat back
angle adjustment
6 Inspect seat fore/aft
adjustment
7 Inspect seat bottom
angle adjustment
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4-1-1
4-2. Mechanical Troubleshooting - C520R/C531R
Item Malfunction Inspect
1 Unit wobbles or rocks. Adjust levelers.
2 Seat back angle won’t
adjust.
Replace seat back
angle shock.
3 Pedals make noise. Replace pedals.
4 Seat position won’t change. Replace the shock
under the seat.
5 Pedals free spin with no
resistance.
6 Movement seems to catch
while you pedal.
Inspect drive pulley,
flywheel, and belt.
Inspect drive pulley,
flywheel, and belt.
4-2-1
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