True Fitness 750E, 600EA, 750EA User Manual
True Fitness Service
Manual
Elliptical Trainers
750E
750EA
600EA
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.
True Fitness Elliptical 2 19/32 Wrench pn: 90361501
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
Elliptical
Service Manual
START
Symptom guide
Wiring Diagrams
Parts Manual
Removal and Replacement Procedures
Page 1
Test Mode *750 ONLY Procedure
•
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
DA (Resistance)
Exit Diagnostics
Press and hold the “Start” key as you
begin pedaling.
• Continue pedaling throughout the test.
-------
• Press “Enter” key – initiates the second
LED function test.
• Press “Enter” key again –all LED’s
should be on.
--------
• Press “Enter” key – RPM’s displayed in
the far right window.
--------
• Press “Enter” key –A beep should sound
when each key is pressed.
--------
• Press “Enter” key. Hold both handle
pick-ups. Heart symbol will flash and
readout will display.
-------
• Press “Enter” key – Press + to increase
resistance and – to decrease resistance.
• To quit diagnostics press “Enter” key or
stop pedaling and the unit will reset.
Page 2
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SYMPTOM GUIDE
600EA
Resistance Malfunction . . . . . . . . . . . . . . . . . . . Page 13
No Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
No Speed Reading. . . . . . . . . . . . . . . . . . . . . . . . Page 15
750E,750EA
No Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Heavy Resistance . . . . . . . . . . . . . . . . . . . . . . . . Page 6
No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
All Models
No Contact Heart Rate . . . . . . . . . . . . . . . . . . . . Page 8
No Polar Heart Rate . . . . . . . . . . . . . . . . . . . . . . Page 9
Vibration from Drive Train . . . . . . . . . . . . . . . . . . . Page 10
Knocking in Rhythm of Pedaling . . . . . . . . . . . . . Page 11
Squealing / Screeching from
Aluminum Extrusion Tubes . . . . . . . . . . . . . . . . . Page 12
Page 3
Symptom Probable Cause Corrective Action Recommended Tools
NO RESISTANCE
Page 4
750E, 750EA
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Console Set
Defective Cables
Power Resistance
• Remove console bolts to access 7-pin
connector. Do not disconnect console
set.
• Enter DA (resistance) test mode.
(Page 3).
• 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 must pedal at least
30 RPM when
performing any voltage
test. You may require the
assistance of another
person when performing
voltage checks.
Multi-meter
Symptom Probable Cause Corrective Action Recommended Tools
HEAVY
RESISTANCE
750E, 750EA
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Foreign Objects
Console Set
Defective Cables
Lower control
Board/ Brake
• Check for foreign objects causing
mechanical binding.
• Remove foreign objects.
--------
• Remove the console set.
• Disconnect the 7-pin connector from the
back of the console set.
• Pedal.
• Resistance normal? Replace console set.
--------
• Remove right side handle bar assembly
and mast cover.
• Disconnect 7- pin connector from the
lower control board.
• Pedal.
• If resistance is normal- replace cable for
console.
--------
• Remove main body cover.
• 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
Page 5
Symptom Probable Cause Corrective Action Recommended Tools
p
p
750E, 750EA
Page 6
No Display
Console Set
Brake
Defective Cable
Console Cable/
Lower Control
Board
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• 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 for
5.5 – 7.5 VDC.
• Is required voltage present?
• If yes- replace console set. If not,
continue on.
--------
• Remove right side bar assembly, right
mast cover and main body 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 right side bar assembly, right
mast cover and main body 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 mus t pedal at least
30 RPM when
erforming any voltage
test. You may require the
assist ance of another
erso n w h en perf ormin g
voltage check s.
Multi-meter
Symptom Probable Cause Corrective Action Recommended Tools
p
p
•
NO CONTACT
HEART RATE
750E, 750EA
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Wire Connections
Dirty Sensors
Console Set/
Wiring
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 mus t pedal at least
30 RPM when
erforming any voltage
test. You may require the
assist ance of another
erso n w h en perf ormin g
voltage check s.
Multi-meter
Double sided tape
Page 7
600EA.
p
p
g
Control Panel
Defective Cables
• Attach heart rate simulator 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
volta
e checks.
Polar Heart Rate
Simulator
Excessive radio,
electromagnetic or
audible noise can
cause poor heart rate
reception.
Symptom Probable Cause Corrective Action Recommended Tools
NO POLAR
HEART RATE
750E, 750EA
Page 8
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Symptom Probable Cause Corrective Action Recommended Tools
VIBRATION
FROM DRIVE
750E, 750EA
TRAIN
600EA.
Belt Tension
Brake Vibration
Wobbling Pulleys
Shaft Vibrations
Vibrating Bearings
• Remove main body cover.
• Check poly V- belt for bumps- if bump
exists, replace the belt.
• Check for proper belt tension. Belt
should be very tight, grasp belt in the
middle and twist, you should only be
able to twist it 90 degrees.
--------
• Pedal.
• Very carefully check brake for
vibration, use caution
arms cross in front of the brake.
• If vibration is found- tighten bolts and
/or replace brake.
--------
• Does pulley of either poly V- wheel
wobble? If so then tighten bolts.
• If tightening does not resolve- replace
damaged poly-v- wheels.
--------
• Check shaft assemblies. Check for
endplay on shaft assemblies.
• Check for vibration in shaft assemblies
by applying screwdriver to frame at
shaft bearings.
• If vibration is found- replace shaft
assembly.
Caution:
When
as the moving
checking for vibrations
take care to not get
caught by the pulleys,
belts and moving parts.
--------
• Check belt tensioned.
• Use screwdriver method to check
bearings on wheel shaft.
• Replace tension wheel assembly.
Long handled
screwdriver
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Page 9
Symptom Probable Cause Corrective Action Recommended Tools
KNOCKING IN
RHYTHM OF
PEDALING
Crank and Shaft
Swing Arm Bearings
• Remove main body cover.
• Check crank arm nuts for tightness.
• Is noise coming from the crank area
• If yes – remove crank, check shaft and
crank for damage.
• Replace parts as needed.
--------
• Check the moving arm bearing for
noise.
• Tighten nut and check for noise.
• If noise continues – replace moving arm
assembly.
Multi-meter
14mm socket
21mm socket
27mm socket
Page 10
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Symptom Probable Cause Corrective Action Recommended Tools
SQUEALING /
SCREECHING
FROM
ALUMINUM
EXTRUSION
TUBES
750E, 750EA,
600EA.
Cleaning Aluminum
Extrusion Tubes
Checking Rollers
Moving Arm Travel
• Remove aluminum extrusion tubes.
• Clean tracks with general purpose
cleaner. DO NOT USE PETROLIUM
BASED CLEANERS – it will degrade
the rollers.
• Clean roller.
-------
• Check rollers for bumps and flat spots.
• Do rollers spin freely?
• If rollers do not spin freely – replace
rollers.
--------
• Do the moving arms run straight down
the aluminum extrusion tubes?
• If no – loosen nut on cubic joint.
• If no help – replace moving arm
assembly.
Non- petroleum based
cleaner. (For example:
Simple Green)
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Page 11
Symptom Probable Cause Corrective Action Recommended Tools
p
p
g
600EA
RESISTANCE
MALFUNCTION
Console Set
Lower Board / Brake
Cable
Brake Coil
Console Cable
• Remove console bolts to access 7-pin
connector. Do not disconnect console
set. Set meter for DC Volts. Measure
between pin 1(red) and pin 5(blue) at 7pin connector.
• Enter DA (resistance) test mode. Page
SG-1.
• Press + key to force .9 VDC out of
panel.
• Press + to check voltage at all levels. Is
voltage displayed on meter
approximately the same as voltage
displayed in heart rate window? Noreplace console set. Yes, continue on.
--------
• Remove main body cover & locate the
cable connecting the brake and the
lower control board. Set meter to DC
volts.
• Check DC voltage between pins 2 and 4
of the power supply
• Is voltage is same as shown in heart rate
window?
• If NO – go to console cable.
• Check voltage at the 2-pin connector at
the brake. Press + to increase resistance
and voltage.
• Does the voltage start at 3.7 and
increase to 30 VDC? If no- check
continuity of cable. If cable is broken
replace it, if cable is good – replace the
lower board.
--------
• Set meter to resistance and check the
coil. Coil resistance should be 15 ohms,
+ or – 2 Ohms. If not then replace the
coil.
--------
• Set meter to resistance; perform
continuity check on wire harness.
• Check for cross continuity.
• Broken wires? Replace cable.
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
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 DISPLAY
600EA
Power Issues
Control Panel
Power Supply
Cables
• Set meter to AC voltage and test wall
outlet to 120 VAC.
• Turn power switch on
• Does power switch lamp come on?
• Yes – go to control panel.
• No- remove rear cover.
• Check voltage input to switch, is it 120
VAC? If yes – replace switch. If no –
continue on.
• Check voltage at end of power cord.
• No voltage? Replace cord.
• Check fuse in power inlet.
• Replace fuse or replace power inlet and
wires.
--------
• Check connection to the display.
• Reseat connection.
• Set meter to DC volts, unplug display
and check voltage between pin 1and pin
2.
• If 12VDC is present – replace control
panel.
--------
• Check voltage between pin 2and pin 3at
the power supply.
• If 12 VDC present – replace power
supply.
--------
• Perform a continuity check on the cables
leading to the control panel.
• Replaced damaged cables.
Multi-meter
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
Page 13
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