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True Fitness 500U User's Manual

1. Step 8 Remove Bearing amp Washer Page 74 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600U Remove Right Belt Poly V Wheel Tools Required Pliers Snap Ring Pliers Step 1 Use pliers or needle nose pliers to remove the belt tensioning spring Step 1 Belt Tensioning Spring Step 2 Remove the belt Step 2 Remove Belt Copyright 2001 True Fitness Technology Inc Page 75 Removal amp Replacement 600U Remove Right Belt Poly V Wheel continued Step 3 Use snap ring pliers to pry snap ring from center of small poly V pulley Step 3 Prying with snap ring pliers Step 4 Remove the snap ring and washers Step 5 Remove the small poly V pulley Step 5 Remove the small poly V pulley Page 76 Copyright 2001 True Fitness Technology Inc Removal Replacement 600U Remove Right Side Tensioner Assembly Tools Required Snap Ring Pliers Step 1 Remove snap ring Step 1 Remove Snap Ring Step 2 Slide tensioner assembly off pivot shaft Note Frame is slotted to allow brake bracket to slide when bolts are loose Step 2 Slide Tensioner Assembly Copyright 2001 True Fitness Technology Inc Page 77 Removal amp Replacement 600U Remove Belt amp Tensioner Assembly Tools Required 6 mm Hex Wrench 13 mm Open End Wrench Hammer Handle Step 1 Use 6 mm hex wrench to remove brake bracket locking screw
2. Step 2 Use 13 mm open end wrench to loosen the 4 bolts holding the brake bracket to the frame Note Frame is slotted to allow brake bracket to slide when bolts are loose Step 2 Loosen Bracket Bolts Page 78 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600U Remove Belt amp Tensioner Assembly continued Step 3 Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt Step 3 Pry on Brake to Loosen Belt Step 4 Remove brake belt from larger poly V wheel Step 4 Remove Belt Copyright 2001 True Fitness Technology Inc Page 79 Removal amp Replacement 600U amp 600R Remove Belt amp Tensioner Assembly continued Step 5 Disconnect wiring harness from brake Step 6 Remove the loosened bottom screws Step 7 Remove brake and belt assembly N Step 7 Remove Brake amp Belt Assembly Page 80 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600U Remove Left Side Belt From Assembly Tools Required Internal amp External Snap Ring Pliers Flat Blade Screwdriver Step 1 Remove snap ring Step 2 Carefully pry bearing out of housing Step 3 Remove inner snap ring P m Step 7 Remove Inner Snap Ring Copyright 2001 True Fitness Technology Inc Page 81 Removal amp Replacement 600U Remove Left Side Belt From Assembly
3. Step 2 Remove Small Poly V Pulley Page 88 Copyright 2001 True Fitness Technology Inc Removal Replacement 600R Remove Left Side Tensioner Assembly Tools Required Snap Ring Pliers Step 1 Remove snap ring Step 1 Remove Snap Ring Step 2 Slide tensioner assembly off pivot shaft Note Frame is slotted to allow brake bracket to slide when bolts are loose Step 2 Slide Tensioner Assembly Copyright 2001 True Fitness Technology Inc Page 89 Removal amp Replacement 600R Remove Belt amp Tensioner Assembly Tools Required 6 mm Hex Wrench 13 mm Open End Wrench Hammer Handle Step 1 Use 6 mm hex wrench to remove brake bracket locking screw Step 1 Remove Locking Screw Step 2 Use 13 mm open end wrench to loosen the 4 bolts holding the brake bracket to the frame Note Frame is slotted to allow brake bracket to slide when bolts are loose Step 2 Loosen Bracket Bolts Page 90 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600R Remove Belt amp Tensioner Assembly continued Step 3 Use hammer handle to pry the brake and bracket assembly toward the back of the bike to loosen the belt Step 3 Pry on Brake to Loosen Belt Step 4 Remove brake belt from larger poly V wheel Step 4 Remove Belt Copyright 2001 True Fitness Technology Inc Page 91 Removal amp Replacement 600U amp 600R Remove Belt amp
4. 1 SET 1SET TR 750 PARTS DIAGRAM After 08 05 01 and Prior to Serial 4 02 RE0283C After 8 5 01 and prior to Serial 02 RE0283C New Seat Assembly 3 Piece Crank True TR 750 Page 51 Page 52 114 117 001 003 039 043 118 083 084 085 086 087 031 045 088 116 050 051 089 052 053 090 028 091 093 094 092 097 024 098 031 030 099 035 102 100 002 054 060 055 056 057 058 026 027 750 AFTER 8 5 01 PRIOR 02 RE0283C REF PART AD5 AG2 1 51 26 27 B35 D76 D77 D78 D79 D80 D81 D82 G06 G06 G08 G09 G10 G11 G12 H01 H33 H37 H38 H39 H41 J07 J08 J09 J10 J11 J12 P01 P04 05 11 12 15 17 22 23 24 7TSZRB40SAS 7TSP0212003 7TSM0209004 7TMD0208006 7 0701001 7TME0107014 7TMJ3251001 7TMB1001005 7TMB1002002 7TME01 12013 7TME0112014 7TME0501006 7TME01 12024 7TME0501007 7TMB0401021 7TSP0206006 7TMJ1278001 7TMB06A7001 7TMB0609031 7TME0102069 7TME0201028 7TSZRB40RAL 1 7TMB0103001 7TMZE01 12042 7TMZE 0107015 7TMB0211008 7TMB0632007A 7TSZRB40RST 7TMB0304006 7TMEO112109 7TME01 12024 7TME0502108 7TME0902007 7TMC0501027 7TMC0550001 7TMC0549005 7TMC0203004 7TMC0736002 7TMB06B8001 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 Q06L 7TMB0609026 Q06R 7TMB0609028 NEW SEAT ASSY 3 PIECE CRANK DESCRIPTION SEAT SLIDE SET CONSOLE HANDLE BAR CONSOLE ASSY BRAKE ASSY CLAMP SI
5. Page 10 a Handle Bar Buttons Do Not Page 11 7500 750R No Resistance 12 a Heavy Page 13 a Irregular or No Display Page 14 a Contact Heart Rate Page 15 a No Polar Heart Rate Page 16 Page 3 Symptom ECB MALFUNCTION 500R 500U Probable Cause Control Panel Defective Cables Defective ECB Control Board Optical Sensor DC Motor ECB Limit Switch Loud Continuous Tone from lower board ECB board Corrective Action Power on unit Check for 5VDC between pins 1 and 2 Page 18 No 5VDC Replace control panel Check for 6VDC or more between pins 5 and 6 of 6PA while issuing a resistance command No 6VDC or more Replace control panel Perform continuity check on upper section and lower section cables Replace broken cables If cables test OK and voltage is correct on 5 amp 6 pins replace ECB board If ECB does not fix connect 6PA and 6PB Check DC volts between pins 2 and 3 Rotate blades of the motor shaft voltage should shift from 0 VDC and 5VDC If voltage does not shift replace EC B Board Check for 6 VDC or more between pins 5 amp 6 on 6 pin PBA ECB board connection If gt 6 VDC exists but motor doesn t rotate replace motor Check continuity between pins 2 and 4 of 6PB Press lower limit swi
6. Tools Required 4 mm Hex Wrench Flat blade Screwdriver Hammer Handle Step 1 Use hammer handle to prevent Rotation of large wheel when Removing pulley Step 1 Prevent Rotation of Fly Wheel Step 2 Use 4 mm wrench to loosen set screw in pulley Step 2 Loosen Set Screw Copyright 2001 True Fitness Technology Inc Page 61 Removal Replacement 500R Remove Small Poly V Pulley continued Step 3 Use 17 mm box wrench to loosen Nut from belt tension screw Step 3 Loosen Nut Step 4 Loosen rear hub bracket screws Step 4 Loosen Hub Bracket Screws Step 5 Remove belt from belt tensioner Assembly and wheels Step 5 Remove Belt Page 62 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 500R Remove Belt amp Tensioner Assembly Tools Required 17 mm Box Wrench 5mm Hex Wrench Snap Ring Pliers Step 1 Remove small poly V pulley Step 2 Remove keyway using flat blade Screwdriver as required Step 2 Remove Keyway Copyright 2001 True Fitness Technology Inc Page 63 Removal amp Replacement 500R Remove Belt amp Tensioner Assembly continued Step 3 Remove snap ring from belt Tensioner Step 2 Remove Snap Ring Step 4 Remove belt tensioner Step 3 Remove Belt Tensioner Page 64 Copyright 2001 True Fitness Technology Inc Removal Replacement 500R Remove Front Hub Assembly 1 Tools Required
7. 0501007 405 7 0103001 407 7TSZCB24RST J08 7TMB0304006 409 7 0112024 J10 7TME0112044 J11 7TME0502108 J12 7TMB0705001 1 7TMC0501027 P08 7TMC0549002 P11 7TMC0203004 P12 P17 P22 P23 P24 P15 P19 P20 Q01 J14 J15 Q02 NEXT FIVE PIECES ASSEMBLY BUT NO ASSY NUMBER 0736002 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 06 8001 7TME0107043 7TME0107043 7TMN1101006 7TMB0304020A 7TMZE0112119 7TMB0604018 10750 02 TU 750 3 PIECE CRANK UP0161C DESCRIPTION QTY FRAME UPRIGHT HANDLE BAR SEAT POST FRONT GROUNDING BAR ASSEMBLY CONSOLE SET BRAKE ASSEMBLY C CLAMP SIDE COVER SCREW SIDE COVER SIDE COVER BRACKET HAND PULSE SENSOR SENSOR BRACKET PULSE SCREW PULSE BRACKET NUT PULSE BRACKET WATER BOTTLE CAGE SCREW BOTTLE CAGE SCREW HANDLEBAR MAST TRIM CAP END CAP OF HANDLEBAR SEAT CUSHION NYLON NUT SEAT CUSHION SPRING WASHER SEAT CUSHION MOVING WHEEL REAR GROUNDING BAR ASSEMBLY REAR FEET PAD BOLT MOVING WHEEL FT GROUNDING BAR BOLT REAR GROUNDING BAR ASSEMBLY WASHER MOVING WHEEL MOVING WHEEL COVER CONSO CONTA CONTROL BOARD POWER RESISTANCE COVER POWER RESISTENCE SCREW NUT WASHER CONTROL BOARD BRACKET SCREW CONTROL BOARD SCREW RESISTOR TO FRAME SEAT ADJUSTMENT KNOB BLUE FOOT PAD FRONT BOLT FRONT FOOT PAD SEAT POST SLEEVE N N N N NOV NH DN A O A aa N N AAA P
8. Tensioner Assembly Remove Crank Hub Assembly 600U Remove Right Belt Poly V Pulley Remove Right Side Tensioner Assembly Remove Belt amp Tensioner Assembly Remove Left Side Belt from Assembly Remove Left Side Poly V Wheel Remove Crank Hub Assembly 600R Remove Left Belt Poly V Pulley Remove Left Side Tensioner Assembly Remove Belt amp Tensioner Assembly Remove Right Side Belt from Assembly Remove Right Side Poly V Wheel Remove Crank Hub Assembly Page 58 Removal Replacement Remove Access Covers 500R 500U 600R amp 6000 Tools Required Pedal Wrench Phillips Screwdriver Step 1 Use pedal wrench to remove both pedals from pedal cranks Step 1 Remove Pedals Note Left pedal loosens clockwise Right pedal loosens counter clockwise Step 2 Remove front cover screws and nuts Copyright 2001 True Fitness Technology Inc Page 59 Removal amp Replacement Remove Access Covers 500R 500U 600R amp 600U continued Note Electrical connections are on 500 series bikes only Step 3 Disconnect electrical power adapter Step 1 Remove Electrical Connection 500 series only Step 4 Rotate crank handle forward to 2 o clock Position to allow removal of cover Step 2 Remove Cover Page 60 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 500R Remove Small Poly V Pulley Note Leave belt in place to help lock pulley
9. 7TR50400 7TR60100 71050200 71060700 CONSOLE MAST W BOLTS CABLE ASSY 12 PIN UPPER CABLE ASSY 52 PIN UPPER COMPUTER SET 660RIU LT FRT ROLLER SET SEAT LT RR IDLER ARM SHAFT KIT REAR SHROUD RT ROUND CROSS SCREW TAPPING SCREW REAR SHROUD LT BTTL HDLR W SCREWS REAR HNDLBR W SWITCHES BOLTS SEAT SHUTTLE THUMB SWITCH ASSY LT THUMB SWITCH ASSY RT MODEL DECAL LT WHITE MODEL DECAL RT WHITE DECAL A SILVER DECAL B SILVER DECAL C SILVER DECAL D SILVER MODEL DECAL PNEUMATIC CYLINDER SEAT BK FH RR STABILIZER HDW KIT HNDLBR HDW KIT HLDR HDW KIT ASSY HDW KIT CPANEL HDW KIT ASSY TOOL KIT A A m A gt gt A A o Page 37 Page 38 True Upright Bike 750 TU 750 Exploded Diagram Prior to serial 02 UP0161C 3 Piece Crank 750 Parts List Prior to serial 02 UP0161C 3 Piece Crank TU 750 Exploded Diagram After serial 02 UP0161C 1 Piece Crank 750 Parts List After serial 02 UP0161C 1 Piece Crank Pg 37 Pg 38 Pg 40 Pg 41 Page 39 TU 750 PARTS DIAGRAM 3 PIECE CRANK 8 B Page 40 REF PART 1 7 5 0101006 AC1 7TSZCB24CSM AD1 7TSW0150005 AJ1 7TSZCB24FST AN1 7TSM0209004 AS1 7TMD0208006 B22 7TME0701001 B24 7TME0107014 B31 7TMJ1208001 C07 7TMJ1278001 C08 7TMB06A7001 C10 7TME0102069 C11 71MB0201028 C12 7TMB0601005 C13 7TME0102043 C14 7TME0111014 C15 7 0605006 16 7TMJ1291001 003 7TMB1001018 D04 7TME0204019 D05 7
10. Assembly 6 Pin Lower Cable Assembly 5 Pin Lower Shroud Trim Cap Console Mast Set Cable Assy 6 Pin Upper Cable Assy 5 Pin Upper Computer Set Rear Shroud Right Screw Sidecover Rear Shroud Left Screw Rear Cover 500R Shroud Left Complete w Model Decal and Shroud Decals Screw Side Cover Screw 500R Shroud Right Complete w Model Decal and Shroud Decals Hex Nut Side Cover Model Decal for 500R Left Wht Shroud Decal Wht Shroud Decal Wht Model Decal for 500R Right Wht Shroud Decal B Wht Shroud Decal D Wht Pedal Set w Straps Poly v Belt TR500 Brake Assy Aluminum Idler Assembly ECB DC Motor w Screws ECB Limit Switch w Screws ECB Control Board w Screws Aluminum Rail Trim Aluminum Rail w Bolts Stopper Kit Fore and Aft Adjusting Rack w Bolts A do do A OUO m a QTY SET SET PCS SET SET SET PC 0 PCS PC PC SET PC PCS PC PCS PC PC PC PC SET PC SET SET SET SET SET SET SET 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 71002500 71002600 71002700 71002800 71002900 71003000 71003100 71003200 71003300 71003400 71003500 71003600 71003700 71003800 71003900 71013000 71012901 71012902 71012903 71012904 71012800 Transportat
11. If not 5 VDC replace Control Panel Disconnect 6PG from 6PH Pedal Check DC voltage between pins 2 and 3 for 5 VDC No 5 VDC Replace Control Board Perform continuity checks on all upper and lower cables Replace defective cables Check for AC Voltage between pins 1 and 2 of 3PB and pins 2 and 3 of 3PB Is there AC voltage output in both places If yes replace Control Board Check for AC Voltage between pins 1 and 2 of 3PD and pins 2 and 3 of 3PD Is there AC voltage output in both places If no replace Generator Perform a continuity check on the generator output cable If no continuity replace cable Symptom Probable Cause NO RPM Control Panel READING 600R 600U Defective Cables Defective RPM Sensor Set Corrective Action Recommended Tools Disconnect 5PA from 5PB Page 19 Multi meter 20 Set meter to check continuity between pins 2 and 5 of 5PB Turn crank and align the magnet with the sensor Is there continuity If Yes Replace Control Panel If No continue to next Check continuity of RPM Sensor when magnet is in alignment with the sensor there should be continuity when not aligned no continuity If it does not respond properly replace the sensor Check gap on RPM Sensor Perform a continuity check on all upper and lower cables No continuity Replace defective cable Continuity Replace RPM Sensor Set Symptom NO CONTACT HEART RATE 600R 6
12. Large Crescent Wrench Hammer amp Punch Step 1 Use crescent wrench to remove Large nut on crank Note The crank nut has left handed threads Turn clockwise to loosen Step 2 Remove keyed washer from under nut Step 3 Use crescent wrench to remove hex nut bearing Note The hex nut bearing has left handed threads Turn clockwise to loosen s a ma ak Step 3 Remove Hex Nut Bearing Copyright 2001 True Fitness Technology Inc Page 65 Removal amp Replacement 500R Remove Front Hub Assembly continued Step 4 Use crescent wrench to remove Large nut on crank Note Slide brake towards seat to allow pulley to clear frame Step 5 Use crescent wrench to remove hex nut bearing Step 5 Remove Large Pulley Assembly Page 66 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 500R Remove Front Hub Assembly continued Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Note Right hand thread Step 7 Use hammer 4 punch to loosen spanner nut on bearing Step 8 Remove bearing and washer by Slipping off crank Note Pulley and crank are a welded assembly cannot be separated Step 8 Remove Bearing amp Washer Copyright 2001 True Fitness Technology Inc Page 67 Removal amp Replacement 500U Remove Small Poly V Pulley Note Leave belt in place to help lock pulley Tool
13. REF AD1 AD2 AG1 AG2 1 AS1 B37 B27 DO1 D02 D16 D28 D33 D34 G06 G07 G09 G10 G11 G12 H01 H02 H03 H09 H13 H16 H15 H14 J05 PART 7 5 0203003 7TSZRB40SLP 7TSP0206006 7TSP0212003 7TSZRB40FST 7TSM0209004 7TMD0208006 7TME0701001 7TME0107014 7TMJ3251001 7TME0102047 7TMJ1208001 7 1001005 7TMB1002002 7TMJ3228002 7TMJ3243001 7TMJ3244001 7TMJ3220006 7TME1111002 7TMJ3245001 7TSZRB40SER 7TSZRB40ESR 7 0104065 7TME0104004 7TME0112023 7TME0204004 7TME0112013 7TME0112039 7 0501006 7 0112014 7TMB0401021 7TMJ1278001 7TMB06A7001 7TMB0609031 7TME0102069 7 0201028 7TSZRB40RAL 7TMJ3230001 7TMJ1228019 7 0112042 7TME0502018 7TMB0632001 7 0107015 7TMB0211008 7TMB0634002 7 0102027 7TMB0103001 TR750 PRIOR 8 5 01 3 PIECE CRANK DESCRIPTION SEAT SLIDE WELDMENT SEAT SLIDE PLATE LOCK SEAT HANDLE BAR WELDMENT CONCOLE HANDLE BAR WELDMENT FRONT GROUNDING BAR ASSY CONSOLE ASSEMBLY BRAKE ASSY C CLAMP SIDECOVER SCREW SIDE COVER FIXTURE SHAFT SIDE COVER SCREW FOR SIDE COVER SHAFT SIDE COVER BOTTOM FIXTURE SEAT BOTTOM PAD SEAT BACK PAD ADJUSTMENT BAR FIXTURE PIN BULB CONNECTOR CLEVIS SPACER OPPOSITE SPRING ADJUSTMENT BAR WITH GRIP RECUMBANT SEAT ROLLER W HARDWARE ECCENTRIC SEAT ROLLER ASSY W HARDWARE SCREW SEAT LOCK PLATE BRACKET SCREW SEAT LEVER FIXTURE PIN SCREW BULB CONNECTOR SEAT LEVER NUT CLEVIS SCREW SEAT BOTTOM
14. SCREW DIP BAR MOUNT SPRING WASHER SEAT BACK BOTTOM SCREW SEAT BACK HANDLE FOAM GRIP HANDPULSE SENSOR HANDPULSE BRACKET END CAP HANDLE BAR SCREW PULSE BRACKET NUT PULSE BRACKET RECUMBANT SEAT ASSY TUBE FIXTURE PIN BRACKET PLATE FIXTURE BRACKET SHIM SCREW REAR TUBE MOUNT WASHER REAR TUBE MOUNT END CAP OF FRONT SLIDE TUBE SCREW SEAT TUBE END CAP END CAP OF REAR SLIDE TUBE WIRE CLAMP WIRE CLAMP TRANSPORT WHEEL QTY 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 16 PCS 1 PC 2 PCS PC PC PC PC PC PC PC 1SET 1SET 4 PCS 1 1 1 4 PCS 4 PCS 8 PCS 4 PCS 2 PCS 1 SET 1 SET 4 PCS 4 PCS 4 PCS 1 1 1 8 PCS 8 PCS 1 2 PCS 1 1 1 2 PCS Page 49 Page 50 407 408 409 J10 J11 J12 P11 P12 P13 P15 P17 P22 P23 P24 Q06R Q06L Q07 008 911 912 R06 T02 TOS 04 05 06 07 08 VO1 V02 7TSW2221005 0304006 7TME0112109 7TME0112024 7TME0502108 7TME0902007 0501027 0520002 0550001 0203004 0736002 7TMC0535006 7TMB06B8001 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMB0601005 7TMB0609028 7TMB0609026 7TMB0609035 7TME0104055 REAR GROUNDING BAR FOOT PAD REAR ADJUSTABLE BOLT GROUNDING BAR BOLT TRANSPORT WHEEL WASHER TRANSPORT WHEEL EXTERNAL C RING TRANSPORT WHEEL CABLE DISPLAY CO
15. Tensioner Assembly continued Step 5 Disconnect wiring harness from brake Step 6 Remove the loosened bottom screws Step 7 Remove brake and belt assembly Step 7 Remove Brake amp Belt Assembly Page 92 Copyright 2001 True Fitness Technology Inc Removal Replacement 600R Remove Right Side Belt From Assembly Tools Required Internal amp External Snap Ring Pliers Flat Blade Screwdriver Step 1 Remove snap ring Step 2 Carefully pry bearing out of housing Step 3 Remove inner snap ring Step 7 Remove Inner Snap Ring Copyright 2001 True Fitness Technology Inc Page 93 Removal amp Replacement 600R Remove Right Side Belt From Assembly continued Step 4 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket Step 5 Remove brake bracket until belt Can be removed Step 5 Remove Bracket to Check Belt Page 94 8 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600R Remove Right Side Poly V Wheel Tools Required External Snap Ring Pliers Step 1 Remove snap ring from shaft on Right side Step 1 Remove Shaft Snap Ring on Right Side Step 2 Slide shaft through bearing in Frame to remove pulley and shaft assembly Step 2 Slide Shaft Through Frame Note Crank not welded to pulley so 1 extra step showing separating these for 600U set Copyright 2001 True Fit
16. continued Step 4 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket Step 5 Remove brake bracket until belt Can be removed Step 5 Remove Bracket to Check Belt Page 82 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600U Remove Left Side Poly V Wheel Tools Required External Snap Ring Pliers Step 1 Remove snap ring from shaft on Right side Step 2 Slide shaft through bearing in Frame to remove pulley and shaft assembly Le kla Step 2 Slide Shaft Through Frame Note Crank not welded to pulley so 1 extra step showing separating these for 600U set Copyright 2001 True Fitness Technology Inc Page 83 Page 84 Removal Replacement 600U Remove Crank Hub Assembly Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1 Use crescent wrench to remove Large nut on crank Note The crank nut has left handed threads Turn clockwise to loosen Step 2 Remove keyed washer from under nut ee Step 2 Remove Keyed Washer Step 3 Use crescent wrench to remove hex nut bearing Use rubber mallet to knock out the shaft pulley assembly Note The Hex nut bearing has left handed threads Turn clockwise to loosen Step 3 Remove Hex Nut Bearing Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600U Remove Crank H
17. 00U Probable Cause Control Panel Defective Cables Defective Handles Corrective Action Recommended Tools Multi meter Disconnect 7P6A and 7P6B from control panel 600U Page 19 600R Page 20 Check continuity between 7P6B and handle mounted heart rate sensor plates of the following HRRR and pin 6 of 7P6B HRRL and pin 5 of 7P6B HRLR and 2 of 7P6B HRLL and pin 1 of 7P6B Is there continuity If yes replace computer If No continue to the next step Perform a contact and continuity check on cable 600 12P 600 12P coils upper cables and the handle cables Are cables OK If No Replace defective cables If Yes continue on to the next step Remove and carefully check all connections to the contact plates Reconnect loose connections If connections OK Replace handles Symptom Probable Cause HANDLEBAR Cruise Control BUTTONS DO NOT FUNCTION 600R Button Shift Button Button Select Button Button Corrective Action Recommended Tools Remove console mounting screws Multi meter Locate 10P7B Page 20 Check for continuity between pin 7 and pin 1 at 10P7B Press Cruise control button No continuity Perform a continuity check on the appropriate cable Replace cable or if cable good replace handlebar assembly Check for continuity between pin 7 and pin 2 at 10P7B Press Start button See A above Check for continuity between pin 7 an
18. 012901 71012902 71012903 71012904 7TU60100 7TU60200 7TU60300 MODEL DECAL LEFT WHITE MODEL DECAL RIGHT WHITE DECALA DECAL B DECAL DECAL D PARTS KIT FRONT STABILIZER SCREW KIT REAR STABILIZER SCREW KIT 600 PARTS DIAGRAM BRG 011A jm 3 0980011A01010 fi B E IE 1 re 2 21 d gt NNG i MENAN 4 2 3 2 24 21 eed X gt DZ MSZ 5 SA HIG BN 44 E lt lt 2v gt gt O ES 7 W 7 R FYN NW MENT 2 4 o N VANA a Ve gk 88 Lill Y MY EE Z sie NI f w e Z 43 NB DN Page 35 Page 36 REF 24 1 24 2 24 3 24 4 24 5 24 6 24 7 24 8 24 9 24 10 24 11 24 12 25 26 27 28 29 30 31 32 33 34 35 36 13 9 15 16 17 18 19 PART 71011600 71001202 71001303 71001302 71011700 71001306 71011800 71001308 71001309 71012300 71001311 71001312 71001400 71002100 71002200 71002300 71006500 71002400 71002500 71002600 71002700 71002800 71002900 71003000 71003100 71003300 71003200 71000100 71000200 71000300 71011400 71005000 71005100 71005200 71005300 71005400 71005500 71005600 71011500 71007300 71005800 71005900 71006000 71006100 71000900 TR600 BIKE DESCRIPTION 600R L SHROUD amp DECALS SIDE CVR SCREW SIDE CVR SCREW SIDE CVR SCREW 600R R SH
19. 1 PC 1 PC 1 SET 1 SET 1 PC 2 PCS 2 PCS 1 SET 1 SET 1 PC 1 SET 1 PC 1 SET 6 PCS 6 PCS 2 PCS 2 PCS 2 PCS 1 PC 1 PC 1 PC 1 PC 2 PCS 1 SET 2 PCS 1 SET 4 PCS 2 PCS 3 PCS Page 53 quel 30811 cO Penes OG 31 SMIL gt 55 DS 55 e gt lt 3 S A 5 lt lt I lt O o 9 Page 54 TR 750 AFTER SERIAL 02 RE0283C REF PART AD5 AG1 AG2 AN1 AS1 AS1 B26 B27 D76 D77 D78 D79 D80 D81 D82 G06 G08 G09 G10 G11 G12 H01 H37 H41 H40 H39 P01 05 04 12 15 7TSZRB40SAS 7TSZRB40SER 1 7TSP0206006 7TSP0212003 7TSM0209004 7TMD0208006 7TSM0206008D 7TME0701001 7TME0107014 7TMJ3251001 7TME0102047 7TMJ1208001 7TMB1001005 7 1002002 7TME0112013 7TME0112014 7TME0501006 7TME01 12024 7TME0501007 7 0401021 7TMJ1278001 7TMB06A7001 7TMB0609031 7TME0102069 7TME0201028 7TSZRB40RAL 1 7TMZE0112042 7TMB0632007A 7TMZE0107015 7TMB021 1008 7TMJ1215008C 7TMZE0103007 7TMB0103001 7TSZRB40RST 7TMB0304006 7TME0112109 7TME01 12024 7TME0502108 7TME0902007 7TMC0501027 7TMC0549005 7TMC0520002 7TMC0550001 7TMC0203004 7TMC0736002 7TMC0535006 7TMB06B8001 NEW SEAT ASSEMBLY 1 PIECE CRANK DESCRIPTION SEAT SLIDE SET SEAT ROLLER ASSY SEAT HANDLE BAR CONSOLE HANDLE BAR FRONT GROUNDING BAR ASSY CONSOLE ASSY BRAKE ASSY BRAK
20. 1005800 71000900 71004300 71004400 71004500 71004600 71006900 71006202 71004100 71006300 71004200 71007000 71012600 71002600 71002700 71002800 71005100 71013100 TU 600 BIKE DESCRIPTION FRONT STABILIZER WITH BOLTS TRANSPORTATION WHEEL KIT FRONT STABILIZER END CAP DRIVE BELT KIT DO NOT ORDER POLY V PULLEY SET KIT SECONDARY LEFT COMPLETE W MODEL SHROUD DECALS SIDE COVER SCREW SIDE COVER SCREW SIDE COVER SCREW RIGHT SHROUD W MODEL DECALS HEX NUT MODEL DECAL LEFT WHITE SHROUD DECAL BLUE SHROUD DECAL BLUE MODEL DECAL RIGHT WHITE SHROUD DECAL BLUE SHROUD DECAL BLUE PEDAL SET W STRAPS LFT amp RT CRANK AND CUPS PULLEY SET W BEARINGS J8 POLY V BELT PRIMARY ALUMINUM IDLER AND IDLER ARM C RING IDLER ARM SPRING IDLER ARM BRAKE KIT BRAKE CABLE GENERATOR BRACKET SET CONTROL BOARD W SCREWS RESISTOR W SCREWS RPM SENSOR W WIRE AND NUT SHROUD TRIM CAP SEAT ADJUSTING KNOB SEAT POST SLEAVE SEAT POST SET SADDLE W CLAMP HANDLEBAR W CONTACT HR AND BOLTS CABLE ASSY BOTTLE CAGE W SCREWS COMPUTER W SCREWS CD PLAYER HOLDER W SCREWS CABLE ASSEMBLY 5 PIN LOWER IDLER ARM AXLE KIT REAR STABILIZER W SCREWS LEVELERS x2 WITH LOCKS REAR STABILIZER END CAP POLY V PULLEY SET KIT CLUTCH HANDLEBAR END CAPS QTY po 002 Aa N N Page 33 Page 34 71011800 71011900 71
21. 104055 END CAP REAR GROUNDING BAR SCREW DISPLAY 7TSZRB40SCV L SIDE COVER LEFT 7TSZRB40SCV R SIDE COVER RIGHT 7TSZRB40PAX 7TMD0602018 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7 0113012 7TMG0214008 7TMG0214014 7TMG0222006 7TSZRB40DAX 7TMB0705001 7TMZE0112119 7TMB0304020A 7TMJ1208001 7TME0103022 7TME0514002 7TME0107043 7TME0104014 7TME0502092 7TMJ1245003 7TME0204010 7TME0201012 7TMJ1215008C 7tszrb40sld 7 0520002 7 0535006 7TMB0601005 7TMJ3247001 7TME1103002 7TMG0102054 7TME0602016 7TSZRB40SER 1 7TME0107015 7TME0502018 7TME0102047 7TMZE0103007 FLYWHEEL SHAFT ASSY SECONDARY POLY V BELT LEFT CRANK RIGHT CRANK PEDAL SET 9 16 PEDAL STRAP SET RT amp LT POLY V BELT PRIMARY CRANK BOLT CAP CRANK BOLT SIDE COVER DECAL LEFT BLUE SIDE COVER DECAL RIGHT BLUE SEAT RAIL DECAL BOTTOM BRACKET WHEEL ASSY MOVING WHEEL COVER BOLT FOOT PAD FRONT FOOT PAD FRONT FIXTURE SIDE COVER BOTTOM FLATHEAD SCREW WASHER FRONT GROUNDING BAR ASSY SCREWS CONTROL BOARD SCREW FLYWHEEL WASHER FLYWHEEL HOOK COVER BELT ADJ NYLON NUT BELT ADJ NUT BRAKE AXEL SEAT LOCK seat install kit HR WIRE SENSOR PLATE WIRE BREAK WATER BOTTLE CAGE EYE BOLT BELT ADJUSTER SPRING BELT TENSIONER MODEL DECAL WHITE ASSY HARDWARE KIT SEAT ROLLER ASSY SCREWS RAIL CAP END WASHER REAR TUBE MOUNT SCREW SIDE COVER SCREW SEAT LOCK 2 PCS 4 PCS 1 SET 1 SET 1 SET 1 PC
22. 202 71001303 71011100 71001306 71011200 71001311 71001312 71011300 71001308 71001309 71001400 71004000 71004001 71004002 71004100 71001100 71003800 71003900 71004200 71004300 71000900 71004400 71004500 71004600 TU 500 EXERCISE BIKE DESCRIPTION FRONT STABILIZER WITH BOLTS TRANSPORTATION WHEEL HIT FTONT STABILIZER END CAP CRANK PULLEY WITH CAPS AND BEARINGS BOLT BELT TENSION BRAKE ASSY ALUMINUM IDLER ASSY ECB DC MOTOR WITN SCREWS ECB CONTROL BOARD WITH SCREWS ECB LIMIT SWITCH WTH SCREWS LEFT SHROUD WITH DECALS SCREW SCREW SCREW RIGHT SHROUD WITH DECAL HEX NUT SIDE COVER DECAL WHITE RIGHT SHROUD DECAL B WHITE SHROUD DECAL D WHITE DECAL WHITE LEFT SHROUD DECAL A WHITE SHROUD DECAL C WHITE PEDALSET WITH STRAPS HANDLE BAR 6 PIN WITH BOLTS CABLE ASSY 6 PIN UPPER CABEL ASSY 5 PIN UPPPER BOTTLE CAGE WITH SCREWS COMPUTER WITH SCREWS DC JACK ADAPTER 9VDC 1 2A CD PLAYER HOLDER WITH SCREWS SEAT ADJUSTING KNOB SHROUD TRIM CAP SEAT POST SLEAVE SEAT POST SADDDLE WITH CLAMP QTY 1 SET 1 SET 2PCS 1 SET 1 PC 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 1 PC 6 PCS 3 PCS 1 SET 3 PCS 1 PC 1 PC PC PC PC PC SET SET PC 0 m 4 do 0 m Page 25 Page 26 25 26 27 28 29 30 31 71002600 71002700 71002800 71012700 71005800
23. 71004700 71004800 71013000 71012901 71012902 71012903 71012904 71450100 71450200 77060200 71060500 71060600 7TU60700 7 060300 REAR STABILIZER WITH BOLTS ADJUSTING STAND KIT REAR STABILIZER END CAP POLY V BELT RPM SENSOR WITH WIRE AND NUT CABLE ASSY 5 PIN LOWER SPEED SENSE CABLE ASSY 6 PIN LOWER SECTION MODEL DECAL SILVER DECAL A SILVER DECAL B SILVER DECAL C SILVER DECAL D SILVER ASSY HDW KIT COMPUTER SCREW KIT FRONT STABILIZER HDW KIT HANDLE BAR HDW KIT CD HOLDER HDW KIT TOOL KIT REAR STABILIZER HDW KIT 1 SET 1 SET 2PCS 1PC 1 SET 1 PC 1 PC 1 SET 1 PC 1 PC 1 PC 1 PC 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET TRUE TR500 Decal Detail Page 27 Page 28 REF PART 02 71000100 03 71000200 04 71000300 05 71000400 06 71005800 07 71000600 08 71000700 09 71000800 10 71000900 11 71001000 11 1 1 77001001 11 1 2 77004700 12 71001100 13 1 71001201 13 2 71001202 13 3 71001203 13 4 71001204 14 1 77001301 14 2 77001302 14 3 71001303 14 5 71001305 14 6 71001306 14 7 71001307 14 8 71001308 14 9 71001309 14 10 71001310 14 11 71001311 14 12 77001312 15 71001400 16 71001500 17 71010700 18 71001700 19 71001800 20 71001900 21 71002000 22 71002100 23 71002200 24 71002300 71002400 TR 500 DESCRIPTION Front Stabilizer w Bolts Transportation Wheel Kit Front Stabilizer End Cap Crank Pulley w E Caps amp Bearings RPM Sensor w Wire amp Nut Bolt Belt Tension Cable
24. AFT ASSEMBLY POLY V BELT 520 J8 FLAT HEAD SCREW DO NOT ENTER WASHER DO NOT ENTER SCREW FLYWHEEL ATTACH WASHER FLYWHEEL ATTACH EYE BOLT BRAKE BLT TENSION HOOK CVR BRAKE BELT TENSION NYLON NUT BRAKE BELT TENSION NUT BRAKE AXLE WASHER BRAKE TENSION BOLT WASHER BRK AXLE BTTM BRKT WHEEL LEFT CRANK RIGHT CRANK 1 2 PEDALS W STRAP PEDAL STRAP SET 2 POLY V BELT 400 J08 CRANK CVR CAP SCREW CRANK ARM SCREW BELT TENSIONER STRETCH ADJUSTER STRETCH SPRING WASHER SCREW BELT TENSIONER NUT BELT TENSIONER SIDE CVR DECAL BLUE MODEL DECAL SILVER N N N N Page 45 Page 46 03 908 7TMG0102036 7TMG0214009C 7TMG0214016C 7TMH0205023 7TME0601017 71MB0237002 MODEL DECAL WHITE SIDE CVR DECAL SILVR SIDE CVR DECAL SILVR OWNERS MANUAL ASSEMBLY KIT UPPER FRAME CVR True Recumbent Bike 750 TR 750 Exploded Diagram Prior to 08 05 2001 3 Piece Crank TR 750 Parts List Prior to 08 05 2001 3 Piece Crank 750 Exploded Diagram After 08 05 2001 amp Prior to Serial 02 RE0283C 3 Piece Crank TR 750 Parts List After 08 05 2001 amp Prior to Serial 02 RE0283C 3 Piece Crank 750 Exploded Diagram After Serial 02 RE0283C 1 Piece Crank 750 Parts List After Serial 02 RE0283C 1 Piece Crank Pg 46 Pg 47 Pg 49 Pg 50 Pg 52 Pg 53 Page 47 Page 48 TR750 Prior to 8 5 01 3 piece crank
25. DE COVER SCREW SIDE COVER FIXTURE SHAFT SIDE COVER SEAT BOTTOM SEAT BACK SCREW SEAT BOTTOM SCREW SEAT BACK WASHER SEAT BACK AND BOTTOM SCREW SEAT HANDLE BAR WASHER SEAT HANDLE BAR HANDLE BAR FOAM GRIP SEAT HANDLE BAR HANDPULSE SENSOR HANDPULSE BRACKET HAND PULSE END CAP SCREW HAND PULSE NUT HAND PULSE SEAT RAIL ASSY TRANSPORT WHEEL BOLT SEAT RAIL SCREW RAIL AND CAP END CAP OF REAR SLIDE TUBE RAIL CAP END REAR STABILIZER LEVELER BOLT REAR STAILIZER BOLT TRANSPORT WHEEL WASHER TRANSPORT WHEEL EXTERNAL C RING TRANSPORT WHEEL CABLE DISPLAY CONTROL BOARD WIRE HRC RAIL TO CONSOLE HR SENSOR WIRE CONTROL BOARD RESISTOR BRACKET CONTROL BOARD RESISTOR COVER SCREW RESISTOR NYLON NUT RESISTOR WASHER RESISTOR END CAP FRONT GROUNDING BAR LEFT QTY 1 SET 1 SET 1 SET 1 SET 16 PCS 16 PCS 1 PC 1 PC 1 PC 4 PCS 4 PCS 8 PCS 4 PCS 4 PCS 2 PCS 1 SET 2 SETS 2 SETS 4 PCS 4 PCS 4 PCS 1 PC 2 PCS 8 PCS 2 PCS 1 PC 1 PC 1 PC 4 PCS 4 PCS 2 PCS 2 PCS 2 PCS 1 PC 1 PC 2 PCS 1 PC 1 PC 1 PC 1 PC 4 PCS 4 PCS 4 PCS 1 PC END CAP FRONT GROUNDING BAR RIGHT 1 PC 023 105 081 082 005 018 010 011 006 107 019 049 048 109 110 112 004 029 032 033 038 046 047 059 061 062 063 065 066 067 095 095 101 103 104 106 108 111 113 115 120 143 Q07 008 Q11 Q12 ROS R06 T02 TOS 04 05 06 08 TO9 V02 V03 V08 7TMB0609035 7TME0
26. E ASSY AFTER SERIAL 02 RE1237K C CLAMP SIDE COVER SCREW SIDE COVER FIXTURE SHAFT SIDE COVER SCREW SIDE COVER FIXTURE SIDE COVER BOTTOM SEAT BOTTOM SEAT BACK SCREW SEAT BOTTOM SCREW SEAT BACK WASHER SEAT BACK AND BOTTOM SCREW SEAT HANDLE BAR WASHER SEAT HANDLE BAR HANDLE BAR FOAM GRIP HANDPULSE SENSOR HANDPULSE BRACKET HAND PULSE END CAP SCREW HAND PULSE NUT HAND PULSE SEAT RAIL ASSY BOLT SEAT RAIL RAIL CAP END SCREW RAIL AND CAP END CAP OF REAR SLIDE TUBE SEAT LOCK SCREW SEAT LOCK TRANSPORT WHEEL REAR STABILIZER LEVELER BOLT REAR STAILIZER BOLT TRANSPORT WHEEL WASHER TRANSPORT WHEEL EXTERNAL C RING TRANSPORT WHEEL CABLE DISPLAY CONTROL BOARD HR WIRE SENSOR HR WIRE SENSOR PLATE WIRE HRC RAIL TO CONSOLE CONTROL BOARD RESISTOR WIRE BREAK BRACKET CONTROL BOARD 1 SET 4 PCS 1 SET 1 SET 1 SET 1 SET 1 SET 1 SET 16 PCS 16 PCS 1 PC 2 PCS 1 PC 1 PC 1 PC 4 PCS 4 PCS 8 PCS 4 PCS 4 PCS 2 PCS 2 SETS 2 SETS 4 PCS 4 PCS 4 PCS 1 PC 8 PCS 1 PC 2 PCS 1 PC 1 PC 3 PCS 2 PCS 1 PC 4 PCS 4 PCS 2 PCS 2 PCS 2 PCS 1 PC 2 PCS 1 PC 1 PC 1 PC 1 PC 1 PC 1 PC Page 55 Page 56 17 Q06R Q06L 007 008 Q11 Q12 ROS R06 R17 R20 501 502 503 504 04 05 06 V02 V03 V08 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMB0601005 7TMB0609028 7TMB0609026 7TMB0609035 7TME0104055 RESISTOR COVER SCREW RESISTOR NY
27. EL DECAL WHITE OWNERS MANUAL ASSEMBLY KIT UPPER FRAME COVER 2 SET N N N N N N O O N N gt po DP TU 750 PARTS DIAGRAM 1 PIECE CRANK After Serial 02 UP0161C 1 Piece Crank True TU 750 Page 43 Page 44 REF 1 AC1 AD1 AJ1 AN1 AS1 B22 B24 B31 C07 C08 C10 C11 C12 C13 C14 C15 C16 DO3 004 005 405 407 408 409 J10 J11 J12 1 P08 P11 P12 P17 P22 P23 P24 P15 P19 P20 PART 7TSP001006 7TSZCB24CSM 7TSW0150005 7TSZCB24FST 7TSM0209004 7TMD0208006 7TME0701001 7TME0107014 7TMJ1208001 7TMJ1278001 6 7001 7TME0102069 71MB0201028 7 0601006 7TME0102043 7TMEO111014 7TMB0605006 7TMJ1291001 7TMB1001018 7TME0204019 7 0501007 7TMB0103001 7TSZCB24RST 7TMB0304006 7TMEO112024 7 0112044 7TME0502108 7TMB0705001 7TMC0501027 7TMC0549002 7TMC0203004 7TMC0736002 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMBO6B8001 7TME0107043 7TME0107043 TU 750 1PC CRANK DESCRIPTION QTY FRAME HANDLE BAR W HR SEAT POST FRONT GROUND BAR ASSEMBLY CONSOLE ASSEMBLY BRAKE ASSEMBLY C CLAMP SIDE CVR SCREW SIDE CVR SIDE CVR BRACKET HAND PULSE SENSOR SENSOR BRACKET PULSE SCREW PULSE BRKT NUT PULSE BRKT WATER BTL CAGE SCREW BTL CAGE SCREW HANDLEBAR MAST TRIM CAP END CAP OF HDLBR SEAT CUSHION NYLON NUT SC SPRING WASHER
28. G DIAGRAM TRUE600R WIRING DIAGRAM computer T_REC 5P UPPER SECTION 5 SPA 600R 12P 7 PE UPPER SECTION BODAJZE COLE SPC 5PD z ez GENERATOR E CONTROL BOARD SPB 2 5 5 25 gt rua 5 00 e 6PG RESISTOR CABLE 16008 2 RPM B RESISTOR CABLE T6OOR 1 5 RPM A RPM SENSOR RESISTOR CABLE T600R_1P M x n n U 2 Page 20 TR TU 750 WIRING DIAGRAM NOMONnd WUY ONIMS LHORI cx MMM NN SYOLSISIY la aoNvao 5 L ONO motsa P val Z IANYdASS BLIHM _____ u0109 TBNVd GHS SMT SSBNHVH 3YIM ayog TOYLNOD HSIION3 X OL S3HOLIMS H1O8 OL SJHOLIMS H108 N avus pH 9 L S woo t Lewis 2 t 3 ONIMS 1331 Hove 3108NOO Buin 052327 Page 21 Page 22 True Upright Bike 500 True Recumbent Bike 500 TU 500 Exploded Diagram TU 500 Parts List TR 500 Exploded Diagram TR 500 Parts List Pe 22 Pg 23 Pg 25 Pg 26 Page 23 Page 24 TRUE TU500 O RO DT o PART 71010800 71000200 71000300 71000400 71000600 71010900 71001700 71001800 71002000 71001900 71011000 71001302 71001
29. LON NUT RESISTOR WASHER RESISTOR WATER BOTTLE CAGE END CAP FRONT GROUNDING BAR RIGHT END CAP FRONT GROUNDING BAR LEFT END CAP REAR GROUNDING BAR SCREW DISPLAY 7TSZRB40SCV L1 SIDE COVER LEFT 7TSZRB40SCV R1 SIDE COVER RIGHT 7TSZRB40PAX 7TMD0602018 7TME0104014 7TME0502092 7TMJ3247001 7TMJ1245003 7TME0204010 7TME0201012 7TSZRB40PAX 1 7TSZRBAOKIT 7TSM0915027A 7TMD0403002 7TMD0602013 7TME1103002 7TMG0214008 7TMG0214014 7TMG0102054 7TMG0222006 7TME0602016 FLYWHEEL SHAFT ASSY SECONDARY POLY V BELT SCREW FLYWHEEL WASHER FLYWHEEL EYE BOLT BELT ADJUSTER HOOK COVER BELT ADJ NYLON NUT BELT ADJ NUT BRAKE AXEL BOTTOM BRACKET WHEEL ASSY 1 PC 4 PCS 4 PCS 4 PCS 1 PC 1 PC 1 PC 2 PCS 4 PCS 1 SET 1 SET 1 SET 1 PC 6 PCS 6 PCS 2 PCS 2 PCS 2 PCS 2 PCS 1 SET BEARING KIT BOTTOM BRACKET WHEEL ASSY 1 SET PEDAL SET 1 2 02 XXXXXL PEDAL STRAP SET RT amp LT POLY V BELT PRIMARY SPRING BELT TENSIONER SIDE COVER DECAL LEFT BLUE SIDE COVER DECAL RIGHT BLUE MODEL DECAL WHITE SEAT RAIL DECAL ASSY HARDWARE KIT 1 SET 1 SET 1 PC 1 SET 1 SET 1 SET 2 PCS 1 PC 1 SET True Fitness Removal Replacement 500R 500U 600U 600R Page 57 TABLE CONTENTS Removal and Replacement Remove Access Covers Bikes 500R Remove Small Poly V Pulley Remove Belt amp Tensioner Assembly Remove Crank Hub Assembly 500U Remove Small Poly V Pulley Remove Belt amp
30. NTROL BOARD CABLE SEAT RAIL WIRE HEART RATE SEAT RAIL CONSOLE CONTROL BOARD POWER RESISTANCE CABLE GENERATOR CONTROL BOARD BRACKET POWER RESISTANCE COVER SCREW RESISTOR NYLON NUT RESISTOR WASHER RESISTOR WATER BOTTLE HOLDER END CAP FOR FRONT GROUNDING BAR RH END CAP FOR FRONT GROUNDING BAR LH END CAP OF REAR GROUNDING BAR R ORL SCREW CONTROL PANEL 7TSZRB40SCV L SIDE COVER LEFT WITH DECALS 7TSZRB40SCV R SIDE COVER RIGHT WITH DECALS 7TSZRB40PAX 7TMD0602018 7TME0104014 7TME0502092 7TMJ3247001 7TMJ1245003 7TME0204010 7TME0201012 7TSZRB40DAX 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7 0113012 7TME1103002 7TMG0214008 7TMG0214014 FLYWHEEL SHAFT ASSY WITH TENSIONER POLY V BELT SECONDARY SCREW FLYWHEEL WASHER FLYWHEEL BELT ADJUSTOR BRAKE HOOK COVERBELT ADJUSTOR BRAKE NYLON NUT BELT ADJUSTOR BRAKE NUT BRAKE AXEL BOTTOM BRACKET WHEEL ASSY LEFT CRANK RIGHT CRANK PEDALS 9 16 WITH STRAPS PEDAL STRAP PR POLY V BELT PRIMARY CRANK ARM BOLT CRANK ARM BOLT SPRING BELT TENSIONER SIDE COVER DECAL LEFT BLUE SIDE COVER DECAL RIGHT BLUE 1 4 PCS 4 PCS 2 PCS 2 PCS 2 PCS 4 PCS 4 PCS 4 PCS 1 PC 1 PC 1 PC 2 PCS 4 PCS 1 SET 1SET 1SET 1 PC 6 PCS 6 PCS 2 PCS 2 PCS 2 PCS 2 PCS 1SET 1 PC 1 PC 1 SET 1SET 1 PC 2 PCS 2 PCS 1 PC
31. ROUD 8 DECALS HEX NUT SIDE CVR SCREW MODEL DECAL 66R L WHITE SHROUD DECAL A BLUE SHROUD DECAL C BLUE MODEL DECAL 600R RT WHITE SHROUD DECAL B BLUE SHROUD DECAL D BLUE PEDAL W STRAPS LT amp RT ALUM RAIL TRIM CAP ALUM RAIL W HDRW SEAT STOP KIT LT amp RT CABLE ASSY 12 PIN LWR SEAT RAIL SEAT ADJ RACK TRANSPORT HNDL KIT REAR STABILIZER W BOLTS LEVELS W LOCKS REAR STABILIZER END CAP ROLLER SET A RT amp LT FRT ROLLER SET B RT amp LT CTR SEAT BOTTOM W SCREWS SEATBACK W SCREWS SEAT ADJ LEVER W BOLTS FRT STABILIZER W BOLTS TRANSPORTS WHEEL KIT FRT STABILIZER END CAP TR TU600 DR BELT REPLACE KIT POLY V SEONDARY KIT CLUTCH POLY V CLUTCH PULLEY KIT ALUM IDLER amp IDLER ARM C RING IDLER ARM SPRING IDLER ARM CRANK amp PULLEY W BEARINGS J 8 POLY V BELT PRIM TU TR600 BRAKE KIT CABLE BRAKE RPM SENSOR amp KNOT CBL RESISTOR W SCREWS CNTRL BOARD W SCREWS CABLE ASSY SPIN LWR MAST TRIM CAP QTY USED A NN NN DP H HSH 0 O A A 20 20 121 20 1 2 21 22 23 40 1 24 2 40 3 40 4 41 42 43 44 45 24 08 24 11 24 9 24 12 43 1 2 1 20 1 41 1 71006200 71006201 71006202 71006300 71003700 71006400 71001201 71001202 71001204 71001203 71003500 71006600 71003400 71006700 71006800 71011800 71011900 71012901 71012902 71012903 71012904 71013000 71012800 7TR50200 7TR50300
32. ST CUSHION MOVING WHEEL 2 REAR GROUNDING BAR 1 ASSEMBLY REAR FEET PAD 4 BOLT MOVING WHEEL 2 FT GROUND BAR BOLT REAR GROUND 2 BAR ASSEMBLY WASHER MVG WHFFI 2 MOVING WI 2 DO NOT OF CONSOLE DA IA UBL 1 CONTACT HEART RATE 2 CABLE CONTROL BOARD 1 A RA ADD A O O R a m m POWER RESISTANCE 1 GOVER POWER 1 RESISTANCE SCREW 4 NUT 4 WASHER 4 CONTROL BRD BRKT 1 SCREW CNTRL BRD 8 SCREW RESISTER TO 8 Q01 J14 J15 Q02 Q06R Q06L Q07 Q11 Q12 R03 R06 R09 R14 R17 R20 S01 S02 S03 S04 S05 506 01 TO2 TOS 04 05 06 08 09 006 007 009 010 012 U13 VO1 7TMN1101006 7TMB030402A 7TMZE0112119 7TMB0604018 71MB0609028 7TMB0609026 7TMB0609035 7TSZCB24SCV L 7TSZCB24SCV R 7TSZRB40PAX 7TMD0602018 7TME0103022 7TME0514002 7TME0104014 7TME0502092 71MJ3247002 7TMJ1245003 7TME0204010 7TME0201012 7TME0502127 7TME0502115 7TSZRB40PAX 1 7TMD0405001 7TMD0406001 7TSM0915027A 7TMD0403002 7TMD0602013 7TMB0622001 7TME0113012 7TME01 12088 7TMJ1914002 7TME1104002 7TME0502084 7TME0104014 7TME0201003 7TMG021 4009 7TMG0102053D FRAME SEAT ADJ KNOB BLUE FOOT PAD FRONT BOLT FRONT FT PAD SEAT POST SLEEVE END CAP FOR FRONT GRNDG BAR FOR RIGHT END CAP FOR FRONT GRNDG BAR FOR LEFT END CAP FOR REAR GROUNDING BAR SIDE CVR ASSY LEFT 1 PIECE CRANK SIDE CVR ASSY RT 1 PIECE CRANK FLYWHEEL SH
33. True Fitness Service Manual Exercise Bicycles 500R 500U 600R 600U 750R 750U True fitness technology Inc makes no representations or warranties regarding the contents of this manual We reserve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes 2004 True Fitness Inc All rights reserved Printed in the United States of America 865 Hoff Road O Fallon MO 63366 1 800 426 6570 Fax 636 272 3026 www truefitness com Revision 9 2004 Recommended Tool List Technicians will need at minimum the tools listed below to work on the True Fitness equipment covered by these procedures Electrical Tools A multi meter capable of testing voltage amperage resistance and continuity Outlet tester with a grounding indicator Wire stripper cutter and crimper Flashlight Mechanical Tools Screwdrivers 1 Phillips 2 Phillips large flat blade small flat blade short handled flat blade Metric hex key Allen wrench set Metric socket set and ratchet with 6mm to 19mm sizes and 21mm and 34mm sizes Metric combination wrenches with 4mm to 21mm sizes and a 27mm El crank Snap ring pliers both internal and external Rubber mallet Channel lock pliers or standard pliers with a jaw opening of 2 9 16 for use in removing and tightening sleeve nuts Needle nose pliers Crescent wrench Specia
34. VAV lacada Varaoa Pp d onid od a dd lt Qu VOS TOHLNOD 823 sov lt 4240149 ff 3 5 js gt DA 25293 zi p ni RR om 249 49 Vd Od NY A 10812 aja S Wda gt gt m RR sosnas NOLLOAS 4979005 rze DJA un 32022 Wda 949 LE n i V VdT Wda i EEE soot eeoee gd NOILOHS 440 4552441 045 ads NOLLOSS 4 40145 4005 Page 18 TU 600 WIRING DIAGRAM T UP 5P UPPER SECTION 598 7P6A p SPA 10P7A I a 1 m m 1 SHIFT SE H START 528 CRUISE CONTROL u SELECT n m 90 CONTACT HR CABL vcc m zs GND HRLR T 600U CONTACT HR CABLE t u z HRRR m HRRL 6PA 7P6A GENERATOR CONTROL BOARD lt 0 ST CZ uN 2 6PG 2 2 cz RPM B 4 RESISTER CABLE 6PH T600U_1P L m 12V m GND M 5V m zc m cc m RPM Page 19 600 WIRIN
35. age 41 Page 42 Q06R Q06L Q07 Q11 Q12 R03 R06 R09 R14 R17 R20 501 502 503 504 505 506 01 TO2 TO3 TO4 TOS 06 08 T09 U06 007 009 010 012 013 V01 V03 Q08 71MB0609028 7TMB0609026 7TMB0609035 END CAP FOR FRONT GROUNDING BAR RT END CAP FOR FRONT GROUNDING BAR LT END CAP FOR REAR GROUNDING BAR 7TSZCB24SCV L SIDE COVER ASSY LEFT 3 CRANK 7TSZCB24SCV R SIDE COVER ASSY RIGHT 3 PC CRANK 7TSZRB40PAX 7TMD0602018 7TME0103022 7TME0514002 7TME0104014 7TME0502092 71MJ3247002 7TMJ1245003 7TME0204010 7TME0201012 7TME0502127 7TME0502115 7TSZRB40DAX 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7TME01132012 7 0112088 7TMJ1914002 7TME1 104002 7TME0502084 7TME0104014 7TMEO201003 7TMG021 4009 7TMG0102036 7TMH0205023 7 0601017 7 0237002 FLYWHEEL SHAFT ASSEMBLY POLY V BELT 520 J8 FLAT HEAD SCREW WASHER SCREW FLYWHEEL ATTACH WASHER FLYWHEEL ATTACH EYE BOLT BRAKE BELT TENSION HOOK COVER BRAKE BELT TENSION NYLON NUT BRAKE BELT TENSION NUT BRAKE AXLE WASHER BRAKE TENSION BOLT WASHER BRAKE AXLE BOTTOM BRACKET WHEEL ASSY 3 PC CRANK LEFT CRANK RIGHT CRANK PEDALS WITH STRAP PEDAL STRAP SET OF 2 POLY V BELT 400 J08 CRANK COVER CAP SCREW CRANK ARM ATTACH SCREW BELT TENSIONER STRETCH ADJUSTER BELT TESIONER STRETCH SPRING BELT TENSIONER WASHER BELT TENSIONER SCREW BELT TENSIONER NUT BELT TENSIONER SIDE COVER DECAL BLUE MOD
36. d pin 3 at 10P7B Press Shift button See A above Check for continuity between pin 7 and pin 4 at 10P7B Press _ button See A Check for continuity between pin 7 and pin 5 at 10P7B Press Select button See A above Check for continuity between pin 7 and pin 6 at 10P7B Press button See A If all have continuity and problem persists replace Console Symptom Probable Cause Console Set NO RESISTANCE 750U 750R Defective Cables Power Resistance Brake Harness Lower Board Corrective Action Recommended Tools Remove console bolts to access 7 pin connector Do not disconnect console set You must pedal at least Enter DA resistance test mode 30 RPM when Page 2 performing any voltage Press key to force 7 VDC out of A assistance of another panel person when performing Set meter for DC Volts Measure voltage checks between 2 pin and 4 pin at 7 pin connector Is 7 VDC present No replace console Multi meter set If present continue on Remove right mast cover and handlebar Measure between the 2and 4 wires at the 7 pin connector on the lower board Is 7 VDC present No replace cable for console If present continue on DO NOT PEDAL Set meter for resistance Disconnect 3 pin connector at the lower control board Measure resistance between 1 pin and 3 pin Resistance should be 10 ohms 1 ohm If less than 10 Ohms replace power resistance If resi
37. emove bearing amp washer by slipping off crank Note Pulley and crank are a welded assembly cannot be separated Step 9 Pull crank thru pulley to remove Step 9 Pull Crank Thru Pulley to Remove Page 98 Copyright 2001 True Fitness Technology Inc
38. en the console set and hand pulse sensor plates If continuity is OK Replace Console set If no continue on Multi meter Double sided tape Check wire connections handlebar console mast joint Check connections of wires to hand pulse sensor by removing hand pulse sensor plates To remove hand pulse sensor plates carefully pry under one end to free them from the plastic handgrips Bad connections Reconnect Replace bad wires Recheck continuity Symptom Probable Cause NO POLAR HEART RATE Control Panel 750U 750R Defective Cables Defective ECB Control Board Corrective Action Recommended Tools Attach known good heart rate transmitter around chest or use Polar WNN You must pedal at least simulator 30 RPM when Do not touch the hand pulse sensors performing any voltage test You may require the Start edaling assistance of another Check display for heart rate person when performing voltage checks Polar Heart Rate Does console display heart rate with Simulator chest strap Does console display heart rate with HR simulator If unit responds with simulator and not chest strap then replace chest strap If unit does not respond with strap or simulator then replace Console set WIRING DIAGRAMS TR TU 500 Page 18 600 U Page 19 00 Page 20 TR TU 750 Page 21 Page 17 148 HOLIMS LINI 828 Rm YOLOW DA gd 804 ddyaoa O m ma JOLA
39. ion Handle Set w Screws Rear Stabilizer w Bolts Adjusting Stand Kit Rear Stabilizer End Cap Roller Set A Rt Ft amp RR Roller Set B Center Seat Bottom w Bolts Fore and Aft Adjusting Lever w Bolts Seatback w Bolts Seat Shuttle Bottle Holder w Screws Rear Handlebar w Bolts Roller Set C LH Ft amp RR DC Jack Adapter 9vdc1 2a Model Decal Decal A Decal B Decal C Decal D Pneumatic Cylinder Seat Back 7TR50100 Assy Kit 7TR50200 Ft RR Stabilizer Hdw Kit 7TR50300 H Bar Hdw Kit 7TR50400 Bottle Holder Hdw Kit 7TU60700 Tool Kit gt ND NW SET SET SET PCS SET SET SET SET SET SET SET SET SET PC Page 29 Page 30 True Upright Bike 600 True Recumbent Bike 600 TU 600 Exploded Diagram Pg 29 TU 600 Parts List 30 600 Exploded Diagram 32 TR 600 Parts List Pg 33 Page 31 TU 600 PARTS DIAGRAM 009f L 12334 294 32 REF 02 03 04 05 7 8 7 9 7 10 7 11 7 12 08 09 10 11 12 13 14 14 9 15 16 17 18 19 20 21 22 23 24 24 1 1 25 26 27 28 29 30 31 32 33 24 2 PART NUMBER 71010800 71000200 71000300 71011400 71004900 71005000 71012000 71001302 71001202 71001303 71012100 71001306 71012200 71001311 71001312 71012300 71001308 771001309 71001400 71005500 71005600 71005200 71012400 71012500 71011500 71007200 71005700 71006000 71005900 7
40. l Tool Bicycle crank puller Park Tool USA CCP 2 True Fitness Bicycle Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1 Test Mode 750 ONLY Procedure To Enter Diagnostic Press and hold the Start key as you Mode begin pedaling Continue pedaling throughout the test Console Display Press Enter key initiates the second Output LED function test Press Enter key again all LED s should be on Press Enter key RPM s displayed in the far right window le Key Input Console Press Enter key A beep should sound when each key is pressed Contact Heart Rate Press Enter key Hold both handle pick ups Heart symbol will flash and readout will display DA Resistance Press Enter key Press to increase resistance and to decrease resistance Exit Diagnostics To quit diagnostics press Enter key or stop pedaling and the unit will reset D I A G N 5 5 SYMPTOM GUIDE 5000 500R u ECB Malfunction Page 4 a Irregular or No Display Page 5 a RPM Page 6 a No Polar Heart Page 7 600U 600R a Irregular or No Display Page 8 a No RPM Page 9 a No Contact Heart Rate
41. ness Technology Inc Page 95 Page 96 Removal Replacement 600R Remove Crank Hub Assembly Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1 Use crescent wrench to remove Large nut on crank Step 1 Remove Crank Nut Note The crank nut has left handed threads Turn clockwise to loosen Step 2 Remove keyed washer from under nut Dina Step 2 Remove Keyed Washer Step 3 Use crescent wrench to remove hex nut bearing Use rubber mallet to knock out the shaft pulley assembly Note The Hex nut bearing has left handed threads Turn clockwise to loosen Step 3 Remove Hex Nut Bearing Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600R Remove Crank Hub Assembly continued Note A flat blade screwdriver may be used to pry hub from frame Step 4 Pull hex nut bearing clear of frame Hub Step 5 Pull large pulley until bearing clears Frame Step 5 Remove Large Pulley Assembly Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Step 6 Twist Unit Thru Hub Frame Page 97 Copyright 2001 True Fitness Technology Inc Removal Replacement 600R Remove Crank Hub Assembly continued Step 7 Use hammer and punch to loosen spanner nut on bearing Note The spanner nut has right handed threads Turn counter clockwise to loosen Step 8 R
42. ntinuity change from off to on If yes cables and sensor are good Replace Control Panel If no Go to Defective RPM Set When the sensor is over the pickup continuity will exist When sensor is not over pickup cicuit will be open Defective Cables Perform continuity checks on all upper and lower cables Replace defective cables If cables OK Replace RPM sensor set Defective RPM Sensor Set Symptom Probable Cause NO POLAR HEART RATE Control Panel 500R 500U Heart Rate Chest Strap External Interference Corrective Action Recommended Tools Attach a known good heart rate Heart Rate Simulator transmitter around chest or use polar simulator If control panel does not display a heart rate replace Control Panel If heart rate registers with use of HR simulator but not chest strap replace chest strap If erroneous readings continue check for and eliminate external interference Locate RF sources and use process of elimination Common sources of RF interference are Invisible fences for pets wireless networks cordless phones Cell phones radios home security sensors etc Symptom Probable Cause IRREGULAR OR NO DISPLAY Control Panel 600R 600U Control Board Cables AC Voltage Output Generator Output Cable Corrective Action Recommended Tools Probe leads between pin 1 and 2 of 5PB Multi meter Page 19 20 Pedal unit up to at least 30 RPM Is voltage 5 VDC
43. of another 21 for 5 5 7 5 VDC person when performing Is required voltage present voltage checks If yes replace console set If not continue on Remove pedal and if 3 piece crank remove crank arm Remove right side cover Multi meter Disconnect 3 wire connector at brake Set meter for AC volts Pedal The voltage should increase as pedaling increases Is minimum voltage 9 VAC 30 RPM If No replace Brake If yes continue on Remove pedal and if 3 piece crank remove crank arm Remove right side cover Disconnect 3 wire cable from brake and lower control board Set meter for continuity Check all 3 wires in cable for continuity No continuity Replace cable Set meter for DC volts Reconnect cable to brake and lower control board Pedal Measure for 5 5 7 5 VDC between 1 and 4 wires on 7 pin cable for the console at the lower control board Voltage is present Replace cable for console Voltage not present Replace lower control board Symptom Probable Cause NO CONTACT HEART RATE Dirty Sensors 750U 750R Console Set Wiring Wire Connections Corrective Action Recommended Tools Verify hand pulse sensors are clean You must pedal at least 30 RPM when performing any voltage test You may require the a 72 assistance of another Set meter for continuity person when performing Remove Console set voltage checks Check for continuity in both sets of hand pulse sensors betwe
44. s Required 4 mm Hex Wrench Flat blade Screwdriver Hammer Handle Step 1 Use hammer handle to prevent Rotation of large wheel when Removing pulley Caution Take care not damage outer Step 1 Prevent Rotation of Fly Wheel surface of flywheel on brake assembly Step 2 Use 4 mm wrench to loosen set screw in pulley Step 2 Loosen Set Screw Page 68 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 5000 Remove Belt amp Tensioner Assembly Tools Required 17 mm Box Wrench 5 mm Hex Wrench Snap Ring Pliers Step 1 Remove small poly v pulley Step 1 Remove Small Poly v Wheel Step 2 Remove keyway using flat blade Screwdriver as required Step 2 Remove keyway Copyright 2001 True Fitness Technology Inc Page 69 Removal amp Replacement 500U Remove Belt amp Tensioner Assembly continued Step 3 Use 17 mm box wrench to loosen Nut from belt tensioning screw Step 4 Use 5 mm hex wrench to loosen Rear hub bracket screws Step 4 Loosen setscrew Page 70 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 500U Remove Belt amp Tensioner Assembly continued Step 5 Remove belt from belt tensioner Assembly and wheels Step 6 Remove snap ring from belt tensioner Step 6 Remove Snap Ring Step 7 Remove belt tensioner Step 7 Remove belt tensioner Copyright 2001 True Fitnes
45. s Technology Inc Page 71 Removal Replacement 500U Remove Crank Hub Assembly Tools Required Large Crescent Wrench Rubber Mallet Flat Blade Screwdriver Step 1 Use crescent wrench to remove Large nut on crank Note The crank nut has left handed threads Turn clockwise to loosen Step 2 Remove keyed washer from under nut Step 3 Use crescent wrench to remove hex nut bearing Use rubber mallet to knock out the shaft pulley assembly Note The Hex nut bearing has left handed threads Turn clockwise to loosen Step 3 Remove Hex Nut Bearing Page 72 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 500U Remove Crank Hub Assembly continued Note A flat blade screwdriver may be used to pry hub from frame Step 4 Pull hex nut bearing clear of frame Hub Step 5 Pull large pulley until bearing clears Frame Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Step 5 Twist Unit Thru Hub Frame Copyright 2001 True Fitness Technology Inc Page 73 Removal Replacement 500U Remove Crank Hub Assembly continued Step 7 Use hammer and punch to loosen spanner nut on bearing Note The spanner nut has right handed threads Turn counter clockwise to loosen Step 8 Remove bearing amp washer by slipping off crank Note Pulley and crank are a welded assembly cannot be separated
46. stance checks OK continue on DO NOT PEDAL Remove main body cover set meter for continuity Disconnect brake cable from brake and lower board Check continuity of all wires in cable Check for cross continuity this would indicate multiple shorts in the cable No continuity Replace Brake cable Yes continuity Replace lower board Symptom Probable Cause HEAVY RESISTANCE 750U 750R Console Set Defective Cables Lower control Board Brake Corrective Action Recommended Tools Multi meter Remove the console set Disconnect the 7 pin connector from the back of the console set Pedal Resistance normal Replace console set Remove pedal and if 3 piece crank remove crank arm Remove right side cover assembly Disconnect 7 pin connector from the lower control board Pedal If resistance is normal replace cable for console Disconnect 3 pin connector from the brake Resistance still heavy Replace brake Resistance normal Check brake cables for cross continuity Replace lower control board Symptom No Display 750U 750R Probable Cause Console Set Defective Cable Console Cable Lower Control Board Corrective Action Recommended Tools Remove console set bolts Verify good connection at the back of the console WNN You must pedal at least set Set meter for DC volts 30 RPM when Pedal performing any voltage Measure between 1 and 4 wires Page test You nay UE assistance
47. tch If no continuity shift replace ECB limit switch assembly The loud continuous tone is a safety feature designed to protect the ECB motor If the motor binds and cannot move the ECB board will divert the power from the motor to a speaker that emits this tone If you have the continuous tone check to see if the motor is bound Check the front pivot point for the magnet bar and loosen the bolt to allow for the motor to freely move the magnet bar Symptom Probable Cause IRREGULAR OR NO DISPLAY DC Adaptor 500R 500U Adapter Plug or Jack Control Panel Cables Corrective Action Recommended Tools Connect DC Adapter to 110 VAC power Multi meter supply Look for printed output on adapters label If greater than 9 VDC computer board may be damaged Test for 9VDC output If not 9 VDC then replace adaptor Connect DC plug to Bike Does it seat into the socket properly If not replace adapter or jack Check DC voltage between pins 2 and 4 for 9 VDC on 5PB Page 18 If 9 VDC is found replace the Control Perform continuity checks on all upper and lower cables Replace defective cables If cables OK replace DC Jack Symptom Probable Cause Corrective Action Recommended Tools NO RPM READING Control Panel RPM Disconnect 5PA from 5 Set meterto Multi meter 500R 500U Sensor check continuity between 2 and 5 of 5PB See Page 18 Turn pedals slowly check continuity between 2 and 5 of 5PB Does co
48. ub Assembly continued Note A flat blade screwdriver may be used to pry hub from frame Step 4 Pull hex nut bearing clear of frame Hub Step 5 Pull large pulley until bearing clears Frame Step 6 Twist assembly thru frame hub Pull assembly until clear of frame Step 6 Twist Unit Thru Hub Frame Copyright 2001 True Fitness Technology Inc Page 85 Removal Replacement 600U Remove Crank Hub Assembly continued Step 7 Use hammer and punch to loosen spanner nut on bearing Note The spanner nut has right handed threads Turn counter clockwise to loosen Step 8 Remove bearing amp washer by slipping off crank Note Pulley and crank are a welded assembly cannot be separated Step 9 Pull crank thru pulley to remove Step 9 Pull Crank Thru Pulley to Remove Page 86 Copyright 2001 True Fitness Technology Inc Removal amp Replacement 600R Remove Left Belt Poly V Pulley Tools Required Pliers Snap Ring Pliers Step 1 Use pliers or needle nose pliers to remove the belt tensioning spring Step 2 Remove the belt Step 2 Remove Belt Copyright 2001 True Fitness Technology Inc Page 87 Removal amp Replacement 600 Remove Poly V Wheel Pulley continued Step 3 Use snap ring pliers to snap Ring from center of small poly V pulley Step 1 Prying with Snap Ring Pliers Step 4 Remove the small poly V pulley

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