Cateye Ergociser EC-5000 User manual

CAT EYE ERGOCISER
STAIR CLIMBER TYPE
Applicable Model EC-5000
SERVICE MANUAL

Cateye Ergociser EC-5000 Service Manual
2
EC-5000
INDEX
INTRODUCTION
• How to Use This Service Manual --------------------------------------------------------------------------------------- 3
• Name of Parts ------------------------------------------------------------------------------------------------------------- 4~5
• Circuit Diagram -------------------------------------------------------------------------------------------------------------- 6
Part A
Symptoms of Problems & Causes
T-1: No Display on Control Unit after Power ON
1. Back light does not turn on--------------------------------------------------------------------------------- 7~8
2. Back light turns on----------------------------------------------------------------------------------------------- 9
T-2: No Display of Cadence when the Pedal is Rotated --------------------------------------------------10~13
T-3: No Display of Pulse Rate -----------------------------------------------------------------------------------------14
T-4: No Display of Heart Rate (The Case with Wireless Chestbelt Pulse Sensor Kit) ------------15~16
T-5: Improper Display on Control Unit-------------------------------------------------------------------------------17
T-6: No Cadence Control
1. Slower cadence control is not possible--------------------------------------------------------------18~19
2. Faster cadence control is not possible --------------------------------------------------------------20~23
T-7: Pedal will not be Restored to Original Position -------------------------------------------------------------24
T-8: Unusual Noise
1. Continuous and Increasing -----------------------------------------------------------------------------25~26
2. Unusual Noise Synchronized with Pedal Rotation ----------------------------------------------------27
INDEX
Part B
Removing / Mounting the Frame Covers
D-1: Removing the Frame Covers ----------------------------------------------------------------------------- 28
D-2: Mounting the Frame Covers------------------------------------------------------------------------------- 29
Repair Methods
ES-1: Replacing the Wiring within Frame (Inlet Metal Base Set) -------------------------------------------30
ES-2: Replacing the 5P Cable ----------------------------------------------------------------------------------------31
ES-3: Replacing the Power Supply Board-------------------------------------------------------------------------32
ES-4: Correcting the Postion of Solenoid Coil--------------------------------------------------------------------33
ES-5: Replacing the Slenoid Coil Set -------------------------------------------------------------------------------34
ES-6: Replacing the CDC Sensor set-------------------------------------------------------------------------------35
ES-7: Replacing the CDC Sensor Cable---------------------------------------------------------------------------36
ES-8: Correcting the Postion of CDC Sensor---------------------------------------------------------------------37
ES-9: Replacing the Control Unit ------------------------------------------------------------------------------------38
ES-10: Replacing the Button Panel -----------------------------------------------------------------------------------39
MS-1: Replacing the Workload Unit ---------------------------------------------------------------------------------40
MS-2: Replacing the Accelerating Chain ---------------------------------------------------------------------------41
MS-3: Replacing the Pedal Chain ------------------------------------------------------------------------------------42
MS-4: Replacing the V-Belt --------------------------------------------------------------------------------------------43
MS-5: Replacing the Idler Set -----------------------------------------------------------------------------------------44
MS-6: Replacing the Pulley A -----------------------------------------------------------------------------------------45
MS-7: Replacing the V-Belt tension Pulley ------------------------------------------------------------------------46
MS-8: Replacing the Sprocket (Gear for Chains) ----------------------------------------------------------------47
MS-9: Replacing the Shaft Set A -------------------------------------------------------------------------------------48
MS-10: Replacing the Spring--------------------------------------------------------------------------------------------49
MS-11: Replacing the Spring Pulley Set -----------------------------------------------------------------------------50
MS-12: Replacing the Linkstep Set-------------------------------------------------------------------------------51~52
MS-13: Replacing the Pedal Stopper ---------------------------------------------------------------------------------53
MS-14: Replacing the BB Set -------------------------------------------------------------------------------------------54
MS-15: Replacing the Front Reg Cover ------------------------------------------------------------------------------55
MS-16: Replacing the Caster--------------------------------------------------------------------------------------------56
MS-17: Replacing the Rubber Stopper -------------------------------------------------------------------------------57
MS-18: Replacing the Tray-----------------------------------------------------------------------------------------------58
Part C
List of Genuine Parts --------------------------------------------------------------------------------------------------- 59~62

Cateye Ergociser EC-5000 Service Manual
3
How to Use This Service Manual
How to Use This Service Manual
The manual consists of Part A, Part B and Part C. Part A refers to trouble-shooting which allows you to
identify the cause and areas to be fixed depending on typical symptoms. Part B shows how to repair and/
or adjust specific defects. This part contains sections; How to Repair Electrical Parts [ES] and How to
Repair Mechanical Parts [MS].
Part C lists up all genuine parts and corresponding parts numbers that will be necessary for replacement
or stock.
Whenever any problem has occurred on the main unit, take the following actions to repair or adjust it.
Before taking these actions,please always put on gloves and be sure to refer to and understand the
corresponding work procedures.
1. Check and identify the cause by referring to Part A.
2. Identify the part name by referring to Name of Parts.
3. Perform repair or adjustment in accordance with the instructions in Part B.
4. Replacement, if required, should be done by using genuine parts as specified in Part C.

Cateye Ergociser EC-5000 Service Manual
4
EC-5000
Name of Parts
Caster Pipe
Levelling Knob
Rubber Stopper
Chain Joint
Sprocket A
Shaft Set A
Pedal Chain
Power Suplly Board
Spring
Name of Parts
Caster
Leg Cover
Linkstep Set
Coad Clip
V-Belt Tension Pulley
Frame
V-Belt
5P Cable
Coad Clip
Spring Pully Set
2P Cable
(Inlet Metal Base Set)
Consolepost Fastening Bolt
(cap bolt M8 x 25)
CDC Sensor Cable
Pully A
3
Crank Nut
t
Hexagonal Nut M8-3
e
Spring Washer 6
Plain Washer 6-22-1.6
Hexagonal Nut M6-1
6
9
w
Bolt (+) M6 x 16
i
Bolt (+) M6 x 45 y
Hexagonal Nut 10-1 r
Tapping Screw(2) 4 x 12 5
Axle & Nut Set (R/L) o
EC-5000 Pully B Set

Cateye Ergociser EC-5000 Service Manual
5
Name of Parts
5P Cable
Frame
Pully A
Sprocket B
Spring
Spring Pully Set
Copper Plate
Caster
CDC Sensor Cable
CDC Sensor Set
Idler Set
Idler Spring
Link Step Set Accelerating
Chain
Rubber Stopper
Pedal Chain
Step
Step Stopper Shaft Set A
Sprocket A Chain Joint
Workload Unit
Solenoid Coil Fixing Metal Base
Solenoid Coil
Cap Bolt M6 x 22
1
Crank Nut
t
Plain Washer 6-13-1.0
E-Ring 4
8
q
Bolt (+) M6 x 12 u
Tapping Screw (B) 4 x 16 4
Cap Bot M8 x 20
Spring Washer 8
Plain Washer 8-17-1.6
2
7
0

Cateye Ergociser EC-5000 Service Manual
6
EC-5000
Circuit Diagram
ACAdapter
AC100V
ACPlug ※Fluctuatedependingontheelectricload
about16Vwhentheloadiszero.
DCPulg
DC12V※
InletMetalBaseSet（2PCable）
BlackCable(−)
ACAdapterInlet
Switch −
− − −
−
1
1
1
1
1
2
2
2
2
2
5
4
4
G

N
D
3
3
3
3
RedCable(＋) ＋
＋
＋
＋＋＋
DCPowerSupply
D3
Q4
R58
C15
R57
C14
R55
R56
R54
R53 VR2
C2
VI VO
JP1
（4PConnector）
JP4
（5PConnector）
JP6
（2PConnector）
JP6
U26A
C1
REG
R76
2.2K
PowerSupplyControlCircuit
SolenoidCoilCurrentControlCircuit PowerSupplyBoard
Coil
Electromagnet


12ＶPowerSupply
SpeedSensorSignal
SolenoidCoilCurrent
ControlSignal
CommonLine
5ＶPowerSupply
CDCSensor
WorkloadUnit-CopperDiskPlate
CDCSensor
※※
※※
CDCSensorTurnBoard
JP3
（3PConnector）
Circuit Diagram

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
7
No Display on Control Unit after Power ON. (Back light does not turn on.) (1)
T-1-1
T-1-1
Fig.1
Control Unit
Tapping Screw
Cable Connector
No Display on Control Unit after Power ON. (Back light does not turn on.) (1)
Check the power is available at the wall socket before proceeding to
checking of causes.
[1] Checking the AC Adapter
1. Turn off the power of the main unit, and detach the DC plug
from the AC adapter.
2. Connect the AC plug of the AC adapter to the wall socket.
3. Using a tester, measure the voltage at the DC plug which will
be connected to the main unit. (Fig. 1)
The inner area of the DC plug is minus (-) and the outer area is
plus (+).
[Note]: Never short-circuit the plug of AC adapter. This will
damage the AC adapter.
[Judgment]
ⓦWhen the measured voltage is within the range of 14V to
19V, the AC adapter will be working fine.
ⓦWhen the measured voltage is 0V or less than 14V, the AC
adapter will be defective. In this case, you need to take
actions as specified in the repair method (a) described at
the right.
When the AC adapter is found to be correct, proceed to the following
checkings.
[2] Checking the Wiring of Control Unit
1. Loosen the seven screws on the control unit cover to remove
the control unit. (Fig. 2)
2. Remove the cable connector at the tip of the 5P cable from the
cable inlet which is located at the back of the control unit. (Fig.
2)
ⓦWhen the 5P cable has been already disconnected, this
will be the cause. In this case you need to take actions as
specified in the repair method (b) described at the right.
(a) Replace the AC adapter.
(b)Firmly connect the 5P cable connector to the cable
inlet at the back of the control unit before installing
the control unit.
(See [ES-9: Replacing the Control Unit].)
Normal for 14V thru 19V
Black Cable
Fig.2
Red Cable
DC Plug

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
8
Fig.4
No Display on Control Unit after Power ON. (Back light does not turn on.) (2)
T-1-1
No Display on Control Unit after Power ON. (Back light does not turn on.) (2)
T-1-1
Fig.3
(c) Firmly connect the 5P connector to the power sup-
ply board.
(d)Firmly connect the 2P connector to the power sup-
ply board.
(e)Replace the 5P cable. (See [ES-2: Replacing the
5P Cable].)
(f) Replace the inlet metal base set.
(See [ES-1: Replacing the Wiring within
Frame (Inlet Metal Base Set)].)
5P Cable
Normal for 14V thru 19V
Power Cable
Red Cable
(Terminal 2)
Black Cable
(Terminal 1)
2P Connector
[3] Checking the Wiring within the Main Unit
1. Remove the cover of the main unit set.
(See [D-1: Removing the Frame Covers].)
2. Check if the 5P connector and the 2P connector of the inlet
metal base set are connected to the power supply board. (Fig.
3)
[Judgment]
ⓦWhen the 5P connector has been already disconnected,
this will be the cause. In this case you need to take actions
as specified in the repair method (c) described at the right.
ⓦWhen the 2P connector has been already disconnected,
this will be the cause. In this case you need to take actions
as specified in the repair method (d) described at the right.
When both 5P and 2P connectors are connected, proceed to the
following checkings:
3. Remove the 5P connector at the power supply board. (Fig. 3)
4. Check the short-circuiting by using a tester across the two con-
nectors of the 5P cable (across two Terminal No. 2s). (Fig. 4)
If the two connectors are short-circuited, the tester reading will
be zero (0).
[Judgment]
ⓦWhen there is no short-circuiting, the 5P cable may be dis-
connected.
In this case, you need to take actions as specified in the repair
method (e) described at the right.
When short-circuiting is found, check the following:
5. Remove the 2P connector at the power supply board. (Fig. 3)
6. Connect the AC adapter to the main unit, and turn on the main
unit.
7. Measure the voltage by using a tester across the terminals of
the 2P connector. (Fig. 5)
The Terminal 1 is for minus (-) and Terminal 2 is for plus (+).
[Judgment]
ⓦWhen the voltage is not same as in the case of checking
procedure [1] (in the range of 14V to 19V), the inlet metal
base set might be defective, or the 2P cable might be dis-
connected. In this case, you need to take actions as speci-
fied in the repair method (f) described at the right.
Fig.5
Power Supply
Board
5P Connector
The case a short-circuiting is found:0/no short-circuiting:1.
Black Cable
(Terminal 2)
Red Cable
(Terminal 2)

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
9
Fig.3
No Display on Control Unit after Power ON. (Back light turns on.)
T-1-2
No Display on Control Unit after Power ON. (Back light turns on.)
T-1-2
Control Unit
Tapping Screw
Cable Connector 5P Connector
[1] Checking the Control Unit
1. Turn off the power of the main unit.
2. Remove seven tapping screws at the cover of control unit, and
detach the control unit. (Fig. 1)
3. Disconnect the cable connector, which is at the tip of the 5P
cable, from the cable inlet at the back of the control unit. (Fig.
1)
4. Connect the 5P cable to the new control unit, and install to the
control unit cover.
5. Turn on the power of the main unit, and check the display.
[Judgment]
ⓦWhen the display works in the above procedures, the previ-
ous control unit might be defective. In this case, you need
to take actions as specified in the repair method (a) de-
scribed at the right.
[2] Checking the 5P Cable
1. Remove the cover of the main unit set.
(See [D-1: Removing the Frame Covers].)
2. Remove the 5P connector at the power supply board. (Fig. 2)
3. Check the short-circuiting by using a tester across the two con-
nectors of the 5P cable (across two Terminal No. 3s). (Fig. 3)
If the two connectors are short-circuited, the tester reading will
be zero (0).
[Judgment]
ⓦWhen a short-circuiting is found, the power supply board
might be defective. In this case, you need to take actions
as specified in the repair method (b) described at the right.
ⓦWhen there is no short-circuiting, the 5P cable may be dis-
connected.
In this case, you need to take actions as specified in the
repair method (c) described at the right.
(a)Replace the control unit.
(See [ES-9: Replacing the Control Unit].)
(b)Replace the power supply board.
(See [ES-3: Replacing the Power Supply Board].)
(c) Replace the 5P cable.
(See [ES-2: Replacing the 5P Cable].)
Power Supply Board
The case a short-circuiting is found:0/no short-circuiting:1.
Black Cable
(Terminal 3)
Red Cable
(Terminal 3)
5P Cable
Fig.1 Fig.2

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
10
No Display of Cadence when the Pedal is Rotated. (1)
T-2
No Display of Cadence when the Pedal is Rotated. (1)
T-2
Tapping Screw
Cable Connector Nomal condition: Frequently shifting
between 0V & 5V
Cable Connector
Red Cable
(Terminal 1) Black Cable (Terminal 4)
5P Cable
Red Cable
(Terminal 4)
Power Supply Board
Fig.1
5P Connector
[1] Checking the Control Unit
1. Turn off the power of the main unit.
2. Loosen the seven screws on the cover of the control unit to
remove the control unit. (Fig. 1)
3.Remove the cable connector, which is at the tip of the 5P
cable, from the cable inlet at back of the control unit. (Fig. 1)
4. Turn on the power of the main unit.
5. Slowly move the pedal while measuring the voltage across the
terminals 1 and 4 of the cable connector. (Fig. 2)
The Terminal 1 is for plus (+) and Terminal 4 is for minus (-).
[Judgment]
ⓦWhen the voltage frequently changes between approx. 5V
and 0V, this shows that the main unit set is working fine but
that the control unit might be defective. In this case, you
need to take actions as specified in the repair method (a)
as described at the right.
ⓦWhen the voltage does not change as stated above, check
and record the voltage readings. These numbers will be
necessary at later stages as conditions for checks and
[Judgment].
When the voltage changes are found to be abnormal, check the fol-
lowing items:
[2] Checking the 5P Cable
1. Turn off the power of the main unit.
2. Remove the cover of the main unit set.
(See [D-1: Removing the Frame Covers].)
3. Remove the 5P connector at the power supply board. (Fig. 3)
4. Check the short-circuiting by using a tester across the two con-
nectors (Terminals No. 4) across the 5P cable. (Fig. 4)
When there is a short-circuiting, the tester reading will be zero (0).
[Judgment]
ⓦWhen there is no short-circuiting, the 5P cable might be
disconnected.
In this case, you need to take actions as specified in the
repair method (b) as described at the right.
ⓦWhen there is a short-circuiting and the voltage having
been checked during the procedure [1] is approx. 2V to 3V,
the CDC sensor might be defective. In this case, you need
to take actions as specified in the repair method (c) as de-
scribed at the right.
When there is a short-circuiting and the voltage having been
checked during the procedure [1] is 0V or fixed at approx. 5V, pro-
ceed to check [3].
(a)Replace the control unit.
(See [ES-9: Replacing the Control Unit].)
(b)Replace the 5P cable.
(See [ES-2: Replacing the 5P Cable].)
(c) Replace the CDC sensor set.
(See [ES-6: Replacing the CDC Sensor Set].)
Control Unit
Black Cable
(Terminal 4)
Fig.3 Fig.4
Fig.2
The case a short-circuiting is found:0/no short-circuiting:1.

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
11
No Display of Cadence when the Pedal is Rotated. (2)
T-2
No Display of Cadence when the Pedal is Rotated. (2)
T-2
CDC Sensor Set
CDC Sensor Cable
4P Connector
Nomal condition: Frequently shifting
between 0V & 5V
Cable Connector
Power Supply Board
Power Supply Board
Fig.5
5P Connector
When the voltage having been checked during the procedure [1] on
the previous page is 0V or fixed at approx. 5V, proceed to the follow-
ing procedures.
[3] Checking the CDC Sensor
1. Replace the CDC sensor cable with a new one.
A.Remove the CDC sensor cable from the CDC sensor set.
(Fig. 5)
B.Remove the 4P connector at the power supply board, and
then remove the CDC sensor cable. (Fig. 6)
C.Connect the 4P connector, which is at the tip of the new
CDC sensor cable, to both the CDC sensor set and the
connector at the power supply board. (Figs. 5 and 6)
2. Connect the 5P cable to the power supply board, and check
the voltage. (Fig. 7)
A.Turn on the power of the main unit.
B.Slowly move the pedal while measuring the voltage across
the terminals 1 and 4 at the cable connector of the 5P cable
(5P connector at the side of the control unit connection).
(Fig. 8)
Terminal 1 is for plus (+) and Terminal 4 is for minus (-).
C.The CDC sensor is working fine when the voltage frequently
changes between approx. 5V and 0V.
[Judgment]
ⓦWhen the voltage check is found to be alright, the CDC
sensor cable might be disconnected. In this case, you
need to take actions as specified in the repair method (d)
as described at the right.
When the voltage check is found to be incorrect, proceed to the
checking procedures on the next page.
(d)Replace the CDC sensor cable.
(See [ES-7: Replacing the CDC Sensor
Cable].)
Black Cable
(Terminal 4)
Red Cable
(Terminal 1)
Fig.6
Fig.7 Fig.8

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
12
No Display of Cadence when the Pedal is Rotated. (3)
T-2
No Display of Cadence when the Pedal is Rotated. (3)
T-2
CDC Sensor Set
CDC Sensor Cable
Turn Board
CDC Sensor Set Turn Board
Cable Connector
Red Cable
(Terminal 1) Black Cable (Terminal 4)
Fig.9
Nomal condition: Frequently shifting
between 0V & 5V
5P Cable
Power Supply Board
[3] Checking the CDC Sensor (Continued)
3. Remove the CDC sensor set.
A.Remove the CDC sensor set by loosening screws. (Fig. 9)
B.Disconnect the CDC sensor cable from the CDC sensor set.
4. Rotate the CDC magnet to check if it is damaged or clogged.
(Fig. 10)
[Judgment]
ⓦDamaged CDC magnet will be the cause of the problem. In
this case, you need to take actions as specified in the re-
pair method (e) as described at the right.
5. When the CDC magnet is clogged, remove dust from the mag-
net.
6. Install the CDC sensor set.
A.First, connect the CDC sensor set and the CDC sensor
cable, and then mount it to the CDC sensor metal base.
(Fig. 9)
B.Rotate the CDC sensor around the screw, and adjust the
sensor so that it can be positioned to parallel with the CDC
magnet with the condition that the sensor does not touch the
magnet. (Fig. 11)
7. Connect the 5P cable to the power supply board, and check
the voltage. (Fig. 12)
A.Turn on the power of the main unit.
B.Slowly move the pedal while measuring the voltage across
the terminals 1 and 4 at the cable connector of the 5P cable
(5P connector at the side of the control unit connection).
(Fig. 13) Terminal 1 is for plus (+) and Terminal 4 is for
minus (-).
C.The CDC sensor is working fine when the voltage frequently
changes between approx. 5V and 0V.
[Judgment]
ⓦWhen the voltage check is found to be all right, the possible
cause is the clogging of the CDC magnet or incorrect posi-
tioning of the CDC sensor. In this case, you need to take
actions as specified in the repair method (f) as described at
the right.
When the voltage is not correct, proceed to the checking procedures
described on the next page.
Parallel
CDC Sensor Metal
Base
Fig.10
Fig.11 Fig.12
Fig.13
(e) Replace the workload unit. (See [MS-1: Re-
placing the Workload Unit].)
(f) Present status is correct. Go ahead to as-
semble Ergociser.

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
13
No Display of Cadence when the Pedal is Rotated. (4)
T-2
No Display of Cadence when the Pedal is Rotated. (4)
T-2
CDC Sensor Set
CDC Sensor Cable
CDC Sensor Set Turn Board
Cable Connector
Red Cable
(Terminal 1) Black Cable (Terminal 4)
[3] Checking the CDC Sensor (Continued)
8. Replace the CDC sensor set with a new one.
A.Remove the CDC sensor set by loosening screws. (Fig. 14)
B.Detach the CDC sensor cable from the CDC sensor set.
C.First, connect the CDC sensor set and the CDC sensor
cable, and then mount it to the CDC sensor metal base.
(Fig. 14)
D.Rotate the CDC sensor around the screw, and adjust the
sensor so that it can be positioned to parallel with the CDC
magnet with the condition that the sensor does not touch the
magnet. (Fig. 15)
9. Connect the 5P cable to the power supply board, and check
the voltage. (Fig. 16)
A.Turn on the power of the main unit.
B.Slowly move the pedal while measuring the voltage across
the terminals 1 and 4 at the cable connector of the 5P cable
(5P connector at the side of the control unit connection).
(Fig. 17)
Terminal 1 is for plus (+) and Terminal 4 is for minus (-).
C.The CDC sensor is working fine when the voltage frequently
changes between approx. 5V and 0V.
[Judgment]
ⓦWhen the voltage check is found to be all right, the possible
cause is the breakage of the CDC sensor. In this case, you
need to take actions as specified in the repair method (g)
as described at the right.
ⓦWhen the voltage is incorrect, the possible cause is the
breakage of the power supply board. In this case, you
need to take actions as specified in the repair method (h)
as described at the right.
(g)Replace the CDC sensor set.
(See [ES-6: Replacing the CDC Sensor Set].)
(h)Replace the power supply board.
(See [ES-3: Replacing the Power Supply
Board].)
Fig.14
Fig.16
Fig.15
Parallel
Nomal condition: Frequently shifting
between 0V & 5V
CDC Sensor Metal
Base

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
14
No Display of Pulse Rate
T-3
No Display of Pulse Rate
T-3
1. Turn on the power of the main unit to display the in-training
screen (any exercise program).
2. Install a brand new pulse sensor, and check if pulse rate will be
displayed.
[Judgment]
ⓦIf the pulse rate can be displayed, the old pulse sensor is
defective. In this case, you need to take actions as speci-
fied in the repair method (a) described at the right.
ⓦIf the pulse rate cannot be displayed, the control unit is de-
fective. In this case, you need to take actions as specified
in the repair method (b) described at the right.
(a)Replace the pulse sensor.
(b)Replace the control unit.
(See [ES-9: Replacing the Control Unit].)

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
15
No Display of Heart Rate (The case with Wireless Chestbelt Pulse Sensor Kit) (1)
T-4
No Display of Heart Rate (The case with Wireless Chestbelt Pulse Sensor Kit) (1)
18 27
Fig.1
Control Unit
Tapping Screw
Cable Connector
Control Unit
Control Unit
Receiver Board
Connector Cable
First, check the items as described in the section [Trouble-Shooting
and Handling Care] of the Operating Instructions which comes with
the Wireless Chestbelt Pulse Sensor Kit.
When the symptom does not go with those items, proceed to the
following checks.
[1] Checking the Wireless Chestbelt Pulse Sensor
1. Turn on the power to display the in-training screen (any exer-
cise program).
2. Install a new transmitter on the chestbelt as described in the
operating Instructions for the Wireless Chestbelt Pulse Sensor
Kit.
Check if your pulse rate will be displayed.
[Judgment]
ⓦWhen the heart rate can be displayed, the previous trans-
mitter might be defective. In this case, you need to take
actions as specified in the repair method (a) described at
the right.
When the heart rate cannot be displayed, proceed to the following
checks.
[2] Checking the Receiver Board
1. Turn off the power of the main unit.
2. Remove seven tapping screws on the control unit cover and
detach the control unit. (Fig. 1)
3. Disconnect the cable connector, which is at the tip of the 5P
cable, from the cable inlet at the back of the control unit. (Fig.
1)
4. Remove ten screws at the back of the control unit and remove
the rear panel of the control unit. (Fig. 2)
5. Check that connectors at both ends of the connector cable
which connects the receiver board and the board within the
control panel are not disconnected from respective boards.
(Fig. 3)
[Judgment]
ⓦThe disconnected connectors are the possible cause of the
problem.
In this case, you need to take actions as specified in the
repair method (b) described at the right.
When the connector cable is correctly connected, proceed to the
procedures as described in the next page.
(a)Replace the transmitter.
(b)Firmly connect the connector cable to the connec-
tors of both the receiver board and the control unit.
Fig.2
Fig.3

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
16
No Display of Heart Rate (The case with Wireless Chestbelt Pulse Sensor Kit) (2)
T-4
No Display of Heart Rate (The case with Wireless Chestbelt Pulse Sensor Kit) (2)
T-4
Fig.4
Connector Cable
Receiver Board
Control Unit
Control Unit
Control Unit Control Unit
Receiver Board
Control Unit Under Cover
[2] Checking the Receiver Board (Continued)
6. Replace the connector cable with a new one. (Fig. 4)
7. Connect the 5P cable to the control unit. Note that the rear
cover has been detached from the control unit. (Fig. 5)
8. Turn on the power to display the in-training screen (any exer-
cise program).
9. Check if the heart rate will be displayed.
[Judgment]
ⓦWhen the heart rate can be displayed, the previous con-
nector cable might be defective. In this case, you need to
take actions as specified in the repair method (c) described
at the right.
When the heart rate cannot be displayed, proceed to the following
checks.
10. Turn off the power of the main unit.
11. Replace the receiver board with a brandnew one. (Fig. 6)
12. Turn on the power to display the in-training screen (any exer-
cise program.)
13. Check if the heart rate will be displayed.
[Judgment]
ⓦWhen the heart rate can be displayed, the previous re-
ceiver board might be defective. In this case, you need to
take actions as specified in the repair method (d) described
at the right.
ⓦWhen the heart rate cannot be displayed, the control unit
might be defective. In this case, you need to take actions
as specified in the repair method (e) described at the right.
(c) Replace the connector cable.
(d)Replace the receiver board.
(e)Replace the control unit.
(See [ES-9: Replacing the Control Unit].)
5P Cable
Fig.5
Fig.7
Fig.6

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
17
Improper Display on Control Unit
T-5
Improper Display on Control Unit
T-5
In case of the problems stated below, check should be made by re-
ferring to corresponding “Symptoms of Problems & Causes.”
· No display of cadence is possible even when the pedal is ro-
tated. (See T-2.)
· No display of pulse rate is possible. (See T-3.)
· No display of heart rate is possible. (In the case of the Wire-
less Chestbelt Pulse Sensor Kit is used.) (See T-4.)
[1] The displayed language is different from the one described in the
Operating Instructions.
ⓦYou need to take actions as specified in the repair method
(a) described at the right.
[2] Pulse rate, etc. can be displayed, but corresponding graphs can-
not be displayed.
ⓦYou need to take actions as specified in the repair method
(b) described at the right.
[3] Other problems (including breakage of display unit, and unclear
display quality)
ⓦYou need to take actions as specified in the repair method
(c) described at the right.
(a)Operate the select switch on the back of the con-
trol unit.
(See [ES-9: Replacing the Control Unit]: 
ASSEMBLE: 2.)
(b)Replace the control unit.
(See [ES-9: Replacing the Control Unit].)
(c) Replace the control unit.
(See [ES-9: Replacing the Control Unit].).

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
18
Fig.3
Fig.2
No Cadence Control (Slower cadence control is not possible.) (1)
T-6-1
No Cadence Control (Slower cadence control is not possible.) (1)
T-6-1
Fig.1
V-belt
Pedal Chain Accelerating Chain
Timing Belt Plastic Pulley
<1> Checking the Mechanical System
Remove the cover of the main unit set, and observe the inner area of
the main unit.
(See [D-1: Removing the Frame Covers].)
1. Check if the pedal chain has not been broken. (Fig. 1)
[Judgment]
ⓦIf it has been broken, you need to take actions as specified
in the repair method (a) described at the right.
2. Check if the accelerating chain has not been broken. (Fig. 2)
[Judgment]
ⓦIf it has been broken, you need to take actions as specified
in the repair method (b) described at the right.
3. Check if the V-belt has not been broken. (Fig. 1)
[Judgment]
ⓦIf it has been broken, you need to take actions as specified
in the repair method (c) described at the right.
4. Check if the belt (timing belt) at the workload unit has not been
broken. (Fig. 3)
[Judgment]
ⓦIf it has been broken, you need to take actions as specified
in the repair method (d) described at the right.
5. Check if the plastic pulley at the workload unit has not been
broken. (Fig. 3)
[Judgment]
ⓦIf it has been broken, you need to take actions as specified
in the repair method (e) described at the right.
(a)Replace the pedal chain.
(See [MS-3: Replacing the Pedal Chain].)
(b)Replace the accelerating chain.
(See [MS-2: Replacing the Accelerating Chain].)
(c) Replace the V-belt.
(See [MS-4: Replacing the V-Belt].)
(d)Replace the Workload Unit.
(See [MS-1: Replacing the Workload Unit].)
(e)Replace the Workload Unit.
(See [MS-1: Replacing the Workload Unit].)
In order to view the timing belt, CDC sensor is omitted in
this figure.

Check Method of Causes Explanation Figures
Repair Method
Cateye Ergociser EC-5000 Service Manual
19
No Cadence Control (Slower cadence control is not possible.) (2)
T-6-1
No Cadence Control (Slower cadence control is not possible.) (2)
T-6-1
Fig.4
3P Connector
Normal for 9V thru 14V
<2> Checking the Electrical System
[1] Checking the Control Unit
1. Replace the control unit with a new one.
(See [ES-9: Replacing the Control Unit].)
2. Check if the cadence will change (to slower rate) under the
manual training mode.
The check should be made by using a training mode which
provides frequent change in cadence.
[Judgment]
ⓦWhen the cadence changes correctly, the previous control
unit might be defective. In this case, you need to take ac-
tions as specified in the repair method (f) described at the
right.
When no cadence change is noted, proceed to the following proce-
dures.
[2] Checking the 5P Cable
1. Turn off the power of the main unit and remove the cover of the
main unit set.
(See [D-1: Removing the Frame Covers].)
2. Remove the 5P connector at the power supply board. (Fig. 4)
3. Check any short-circuiting across the two connectors (Termi-
nal 5s) at both ends of the 5P cable. (Fig. 5)
When there is a short-circuiting, the tester reading will be zero (0).
[Judgment]
ⓦWhen there is no short-circuiting, the 5P cable might be
disconnected.
In this case, you need to take actions as specified in the
repair method (g) described at the right.
When there is short-circuiting, proceed to the following procedures.
[3] Checking the 3P Connector
1. Remove the 3P connector at the power supply board. (Fig. 6)
2. Measure the resistance by using a tester across Terminals 1
and 2 on the 3P connector. (Fig. 7)
[Judgment]
ⓦWhen the measured resistance is in the range of 9- to 14-
ohms, the 3P connector is normal but the power supply
board might be defective. In this case, you need to take
actions as specified in the repair method (h) described at
the right.
ⓦIn case the measured resistance is excessively large, the
solenoid coil might be defective. In this case, you need to
take actions as specified in the repair method (i) described
at the right.
(f) Replace the control unit.
(See [ES-9: Replacing the Control Unit].)
(g)Replace the 5P cable.
(See [ES-2: Replacing the 5P Cable].)
(h)Replace the power supply board.
(See [ES-3: Replacing the Power Supply Board].)
(i) Replace the solenoid coil set.
(See [ES-5: Replacing the Solenoid Coil Set].)
Power Supply Board
Power Supply
Board
3P Connector
Black Cable
(Terminal 1)
Red Cable
(Terminal 2)
The case a short-circuiting is found:0/no short-circuiting:1.
Black Cable
(Terminal 5)
Red Cable
(Terminal 5)
5P Cable
Fig.5
Fig.6 Fig.7
5P Connector

Check Method of Causes Repair Method Explanation Figures
Cateye Ergociser EC-5000 Service Manual
20
No Cadence Control (Faster cadence control is not possible.) (1)
T-6-2
No Cadence Control (Faster cadence control is not possible.) (1)
T-6-2
Fig.1
5P Connector
3P Connector
Normal for 14V thru 19V
(a)Replace the control unit with a new one.
(See [ES-9: Replacing the Control Unit].)
Power Supply Board
[1] Checking the Control Unit
1. Replace the control unit with a new one.
(See [ES-9: Replacing the Control Unit].)
2. Check if the cadence can be changed (to faster rate) under the
manual training mode.
The check should be made by using a training mode which
provides frequent change in cadence.
[Judgment]
ⓦWhen the cadence changes correctly, the previous control
unit might be defective. In this case, you need to take ac-
tions as specified in the repair method (a) described at the
right.
When no cadence change is noted, proceed to the following proce-
dures.
[2] Checking the 5P Cable
1. Turn off the power of the main unit, and remove the cover of
the main unit set.
(See [D-1: Removing the Frame Covers].)
2. Remove the 5P connector at the power supply board. (Fig. 1)
3. Check any short-circuiting across the two connectors (Termi-
nal 1s) at both ends of the 5P cable. (Fig. 2)
When there is a short-circuiting, the tester reading will be zero (0).
[Judgment]
ⓦWhen there is no short-circuiting, the 5P cable might be
disconnected.
In this case, you need to take actions as specified in the
repair method (b) described at the right.
When there is short-circuiting, proceed to the following procedures.
[3] Checking the 3P Connector
1. Remove the 3P connector at the power supply board. (Fig. 3)
2. Measure the resistance by using a tester across Terminals 1
and 2 on the 3P connector. (Fig. 4)
[Judgment]
ⓦWhen the measured resistance is in the range of 9- to 14-
ohms, the 3P connector is normal but the power supply
board might be defective. In this case, you need to take
actions as specified in the repair method (c) described at
the right.
ⓦIn case the measured resistance is excessively large, the
solenoid coil might be defective. In this case, you need to
take actions as specified in the repair method (d) described
at the right.
(b)Replace the 5P cable.
(See [ES-2: Replacing the 5P Cable].)
(c) Replace the power supply board.
(See [ES-3: Replacing the Power Supply Board].)
(d)Replace the solenoid coil set.
(See [ES-5: Replacing the Solenoid Coil Set].)
Power Supply
Board
3P Connector
Black Cable
(Terminal 1)
Red Cable
(Terminal 2)
The case a short-circuiting is found:0/no short-circuiting:1.
Black Cable
(Terminal 1)
Red Cable
(Terminal 1)
5P Cable
Fig.2
Fig.3 Fig.4