True Fitness 600U, 750U, 500U, 600R, 500R User Manual

...
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
Special 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
Page 2
D
I
A
G
N
O
S
T
I
C
S
To Enter Diagnostic Mode
Console / Display Output
RPM
Console Key Input
Contact Heart Rate
Press and hold the “Start” key as you
Continue pedaling throughout the test.
Press “Enter” key – initiates the second
Press “Enter” key again –all LED’s
Press “Enter” key – RPM’s displayed in
Press “Enter” key –A beep should sound
Press “Enter” key. Hold both handle
DA (Resistance)
Exit Diagnostics
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Press “Enter” key – Press + to increase
To quit diagnostics press “Enter” key or
begin pedaling.
-------
LED function test.
should be on.
--------
the far right window.
--------
when each key is pressed.
--------
pick-ups. Heart symbol will flash and readout will display.
-------
resistance and – to decrease resistance.
stop pedaling and the unit will reset.
SYMPTOM GUIDE
500U, 500R
ECB Malfunction . . . . . . . . . . . . . . . . . . . . . . . Page 4
Irregular or No Display . . . . . . . . . . . . . . . . . . Page 5
No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 6
No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 7
600U, 600R
Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 8
No RPM Reading . . . . . . . . . . . . . . . . . . . . . . . . Page 9
No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 10
Handle Bar Buttons
Do Not Function . . . . . . . . . . . . . . . . . . . . . . . . .
Page 11
750U, 750R
No Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
Heavy Resistance . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
Irregular or No Display . . . . . . . . . . . . . . . . . . . Page 14
No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 15
No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 16
Page 3
g
Symptom Probable Cause Corrective Action
ECB MALFUNCTION 500R, 500U
Control Panel
Defective Cables
Defective ECB Control Board
Optical Sensor
DC Motor
ECB Limit Switch
Loud Continuous Tone from lower board (ECB board)
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 &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&6 on 6 pin PBA @ ECB
board connection. If >6 VDC exists but motor doesn’t rotate, replace motor.
Check continuity between pins 2 and 4 of 6PB. Press lower limit
switch.
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
bolt to allow for the motor to freely move the magnet bar.
Note: If motor has been bound and then freed the motor may have been weakened. If components now move freely but the motor is laborin
replace the motor.
Page 4
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
--------
--------
--------
--------
---------
for the magnet bar and loosen the
Symptom Probable Cause Corrective Action Recommended Tools
IRREGULAR OR
NO DISPLAY 500R, 500U
DC Adaptor
Adapter Plug or Jack
Control Panel
Cables
Connect DC Adapter to 110 VAC power
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
Panel.
--------
Perform continuity checks on all upper
and lower cables.
Replace defective cables.
If cables OK- replace DC Jack.
Multi-meter
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Page 5
Symptom Probable Cause Corrective Action Recommended Tools
NO RPM READING 500R, 500U
Control Panel/ RPM Sensor
Defective Cables
Defective RPM Sensor Set
Disconnect 5PA from 5PB. Set meter to
check continuity between 2 and 5 of 5PB. (See Page 18)
Turn pedals slowly, check continuity
between 2 and 5 of 5PB.
Does continuity 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.
--------
Perform continuity checks on all upper
and lower cables.
Replace defective cables.
--------
If cables OK- Replace RPM sensor set.
Multi-meter
Page 6
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Symptom Probable Cause Corrective Action Recommended Tools
NO POLAR HEART RATE 500R, 500U
Control Panel
Heart Rate Chest Strap
External Interference
Attach a known good heart rate
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.
Heart Rate Simulator
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Page 7
Symptom Probable Cause Corrective Action Recommended Tools
IRREGULAR OR NO DISPLAY 600R, 600U
Control Panel
Control Board
Cables
AC Voltage Output
Generator Output
Cable
Probe leads between pin 1 and 2 of 5PB.
(Page 19-20)
Pedal unit up to at least 30 RPM.
Is voltage 5 VDC?
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
Multi-meter
Page 8
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Symptom Probable Cause Corrective Action Recommended Tools
NO RPM READING 600R, 600U
Control Panel
Defective Cables Defective RPM Sensor Set
Disconnect 5PA from 5PB. (Page 19-
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 step.
--------
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.
Multi-meter
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Page 9
Symptom Probable Cause Corrective Action Recommended Tools
NO CONTACT HEART RATE 600R, 600U
Page 10
Control Panel
Defective Cables
Defective Handles
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
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 pin 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.
Multi-meter
Symptom Probable Cause Corrective Action Recommended Tools
HANDLEBAR
BUTTONS DO
NOT FUNCTION 600R
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“Cruise Control”
“Start” Button
“Shift” Button
“_“ Button
“Select” Button
“+” Button
Remove console-mounting screws.
Locate 10P7B (Page 20).
Check for continuity between pin 7 and
pin 1 at 10P7B. Press Cruise control button.
(A)
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 and
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) above.
--------
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) above.
--------
If all have continuity and problem
persists – replace Console
Multi-meter
Page 11
Symptom Probable Cause Corrective Action Recommended Tools
p
p
g
NO RESISTANCE 750U, 750R
Console Set
Defective Cables
Power Resistance
Brake Harness/
Lower Board
Remove console bolts to access 7-pin
connector. Do not disconnect console set.
Enter DA (resistance) test mode.
(Page 2).
Press + key to force .7 VDC out of
panel.
Set meter for DC Volts. Measure
between #2 pin and #4 pin at 7- pin connector.
Is .7 VDC present? No- replace console
set. If present, continue on.
--------
Remove right mast cover and handlebar.
Measure between the #2and #4 wires at
the 7 –pin connector on
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 resistance 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.
the lower board.
Note:
You mus t pedal at least 30 RPM when
erforming any voltage test. You may require the assist ance of another
erson when performing volta
e checks.
Multi-meter
Page 12
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Symptom Probable Cause Corrective Action Recommended Tools
HEAVY
RESISTANCE
750U, 750R
Console Set
Defective Cables
Lower control
Board/Brake
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.
Multi-meter
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Page 13
Symptom Probable Cause Corrective Action Recommended Tools
p
p
g
No Display
750U, 750R
Console Set
Brake
Defective Cable
Console Cable/
Lower Control
Board
Remove console set bolts. Verify good
connection at the back of the console set. Set meter for DC volts
Pedal.
Measure between #1 and #4 wires (Page
21) for 5.5 – 7.5 VDC.
Is required voltage present?
If yes- replace console set. If not,
continue on.
--------
Remove pedal and if 3 piece crank
remove crank arm.
Remove right side cover.
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.
Note:
You must pedal at le ast 30 RPM when
erforming any voltage test. You may require the assistan ce of another
erson when performing
e checks.
volta
Multi-meter
Page 14
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Symptom Probable Cause Corrective Action Recommended Tools
p
p
g
NO CONTACT
HEART RATE
750U, 750R
Dirty Sensors
Console Set/ Wiring
Wire Connections
Verify hand pulse sensors are clean.
--------
Set meter for continuity.
Remove Console set.
Check for continuity in both sets of
hand pulse sensors between the console set and hand pulse sensor plates.
If continuity is OK – Replace Console
set. If no- continue on.
--------
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.
Note:
You must pedal at le ast 30 RPM when
erforming any voltage test. You may require the assistan ce of another
erson when performing
e checks.
volta
Multi-meter
Double sided tape
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Page 15
Symptom Probable Cause Corrective Action Recommended Tools
p
p
g
NO POLAR
HEART RATE
750U, 750R
Control Panel
Defective Cables
Defective ECB Control Board
Attach known good heart rate
transmitter around chest or use Polar simulator.
Do not touch the hand pulse sensors.
Start pedaling
Check display for heart rate.
--------
Does console display heart rate with
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.
Note:
You must pedal at le ast 30 RPM when
erforming any voltage test. You may require the assistan ce of another
erson when performing
e checks.
volta
Polar Heart Rate Simulator
Page 16
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
WIRING DIAGRAMS
TR / TU 500 Page 18
600 U Page 19
600 R Page 20
TR/TU 750 Page 21
Page 17
Page 18
TR/ TU 500 WIRING DIAGRAM
TU 600 WIRING DIAGRAM
Page 19
Page 20
TR 600 WIRING DIAGRAM
TR/ TU 750 WIRING DIAGRAM
Page 21
Page 22
True Upright Bike
500
True Recumbent
Bike 500
TU 500 Exploded Diagram Pg 22 TU 500 Parts List Pg 23 TR 500 Exploded Diagram Pg 25 TR 500 Parts List Pg 26
Page 23
Page 24
TU 500 EXERCISE BIKE
REF.
PART # DESCRIPTION QTY
#
2 7T010800 FRONT STABILIZER WITH BOLTS 1 SET 3 7T000200 TRANSPORTATION WHEEL HIT 1 SET 4 7T000300 FTONT STABILIZER END CAP 2 PCS 5 7T000400 CRANK PULLEY WITH CAPS AND BEARINGS 1 SET 6 7T000600 BOLT BELT TENSION 1 PC 7 7T010900 BRAKE ASSY 1 SET 8 7T001700 ALUMINUM IDLER ASSY 1 SET
9 7T001800 ECB DC MOTOR WITN SCREWS 1 SET 10 7T002000 ECB CONTROL BOARD WITH SCREWS 1 SET 11 7T001900 ECB LIMIT SWITCH WTH SCREWS 1 SET
^12-
7T011000 LEFT SHROUD WITH DECALS 1 SET
1
^12-
2 7T001302 SCREW 1 PC
^12-
3 7T001202 SCREW 6 PCS.
^12-
7T001303 SCREW 3 PCS.
4
^12-
7T011100 RIGHT SHROUD WITH DECAL 1 SET
5
^12-
7T001306 HEX NUT SIDE COVER 3 PCS.
6
^12-
7 7T011200 DECAL---WHITE----RIGHT 1 PC
^12-
8 7T001311 SHROUD DECAL B WHITE 1 PC
^12-
7T001312 SHROUD DECAL D WHITE 1 PC
9
^12-
7T011300 DECAL---WHITE----LEFT 1 PC
10
^12-
7T001308 SHROUD DECAL-A WHITE 1 PC
11
^12-
7T001309 SHROUD DECAL C WHITE 1 PC
12 13 7T001400 PEDALSET WITH STRAPS 1 SET 14 7T004000 HANDLE BAR 6 PIN WITH BOLTS 1 SET
14­1-1 7T004001 CABLE ASSY 6 PIN UPPER 1 PC. 14-
7T004002 CABEL ASSY 5 PIN UPPPER 1 PC.
1-2
15 7T004100 BOTTLE CAGE WITH SCREWS 1 SET 16 7T001100 COMPUTER WITH SCREWS 1 SET 17 7T003800 DC JACK 1 PC 18 7T003900 ADAPTER 9VDC 1.2A 1 PC 19 7T004200 CD PLAYER HOLDER WITH SCREWS 1 SET 20 7T004300 SEAT ADJUSTING KNOB 1 PC 21 7T000900 SHROUD TRIM CAP 1 PC 22 7T004400 SEAT POST SLEAVE 1 PC 23 7T004500 SEAT POST 24 7T004600 SADDDLE WITH CLAMP 1 PC
1 PC
Page 25
Page 26
25 7T002600 REAR STABILIZER WITH BOLTS 1 SET 26 7T002700 ADJUSTING STAND KIT 1 SET 27 7T002800 REAR STABILIZER END CAP 2 PCS 28 7T012700 POLY V BELT 1 PC 29 7T005800 RPM SENSOR WITH WIRE AND NUT 1 SET 30 7T004700 CABLE ASSY 5 PIN LOWER SPEED SENSE 1 PC 31 7T004800 CABLE ASSY 6 PIN LOWER SECTION 1 PC
7T013000 MODEL DECAL SILVER 1 SET 7T012901 DECAL A SILVER 1 PC 7T012902 DECAL B SILVER 1 PC 7T012903 DECAL C SILVER 1 PC 7T012904 DECAL D SILVER 1 PC 7TU50100 ASSY HDW. KIT 1 SET 7TU50200 COMPUTER SCREW KIT 1 SET 7TU60200 FRONT STABILIZER HDW. KIT 1 SET 7TU60500 HANDLE BAR HDW. KIT 1 SET 7TU60600 CD HOLDER HDW. KIT 1 SET 7TU60700 TOOL KIT 1 SET 7TU60300 REAR STABILIZER HDW KIT 1 SET
TR 500 Exercise Bike
Page 27
REF # PART# DESCRIPTION QTY.
02 7T000100 Front Stabilizer w/Bolts 1 SET 03 7T000200 Transportation Wheel Kit 1 SET 04 7T000300 Front Stabilizer End Cap 2 PCS 05 7T000400 Crank Pulley w/E Caps & Bearings 1 SET 06 7T005800 RPM Sensor w/Wire & Nut 1 SET 07 7T000600 Bolt - Belt Tension 1 PC 08 7T000700 Cable Assembly - 6 Pin Lower 1 PC 09 7T000800 Cable Assembly - 5 Pin Lower 1 PC 10 7T000900 Shroud Trim Cap 1 PC 11 7T001000 Console Mast Set 1 SET 11-1-1 7T001001 Cable Assy, 6 Pin Upper 1 PC 11-1-2 7T004700 Cable Assy, 5 Pin Upper 1 PC 12 7T001100 Computer Set 1 SET 13-1 7T001201 Rear Shroud - Right 1 PC 13-2 7T001202 Screw, Sidecover 10 PCS 13-3 7T001203 Rear Shroud - Left 1 PC 13-4 7T001204 Screw, Rear Cover 1 PC 14-1 7T001301 500R Shroud - Left Complete w/ Model Decal and Shroud Decals 1 SET 14-2 7T001302 Screw - Side Cover 1 PC 14-3 7T001303 Screw 3 PCS
TR 500
Page 28
14-5 7T001305 500R Shroud - Right Complete w/ Model Decal and Shroud Decals 1 PC 14-6 7T001306 Hex Nut - Side Cover 3 PCS 14-7 7T001307 Model Decal for 500R - Left (Wht) 1 PC 14-8 7T001308 Shroud Decal - A (Wht) 1 PC 14-9 7T001309 Shroud Decal - C (Wht) 1 PC 14-10 7T001310 Model Decal for 500R - Right (Wht) 1 PC 14-11 7T001311 Shroud Decal - B (Wht) 1 PC 14-12 7T001312 Shroud Decal - D (Wht) 1 PC 15 7T001400 Pedal Set w/Straps 1 SET 16 7T001500 Poly-v Belt 1 PC 17 7T010700 TR500 Brake Assy 1 SET 18 7T001700 Aluminum Idler Assembly 1 SET 19 7T001800 ECB DC Motor w/Screws 1 SET 20 7T001900 ECB Limit Switch w/Screws 1 SET 21 7T002000 ECB Control Board w/Screws 1 SET 22 7T002100 Aluminum Rail Trim Cap 1 PC 23 7T002200 Aluminum Rail w/Bolts 1 SET 24 7T002300 Stopper Kit 1 SET
25
7T002400 Fore and Aft Adjusting Rack w/Bolts 1 SET
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