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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
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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 (All
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True Fitness Bicycle Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1
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Test Mode *750 ONLY Procedure To Enter Diagnostic • Press and hold the “Start” key as you Mode begin pedaling. • Continue pedaling throughout the test. ------- D Console / Display • Press “Enter” key – initiates the second Output LED function test. • Press “Enter” key again –all LED’s I should be on. -------- A RPM • Press “Enter” key – RPM’s displayed in the far righ
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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 C
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Symptom Probable Cause Correc tive Action ECB Control Panel • Power on unit. Check for 5VDC between pins 1 and 2. (Page 18) MALFUNCTION • No 5VDC? Replace control panel. 500R, 500U • Check for 6VDC or more between pins 5 and 6 of 6PA while issuing a resistance command. • No 6VDC or more? Replace control panel. -------- Defective Cables • Perform continuity check on upper section and lower section cables. • Replace broken cables. --------
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Symptom Probable Cause Correc tive Action Recommended Tools IRREGULAR OR NO DISPLAY DC Adaptor • Connect DC Adapter to 110 VAC power Multi-meter 500R, 500U 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. -------- Adapter Plug or • Connect DC plug to Bike. Does it seat Jack into the socket p
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Symptom Probable Cause Correc tive Action Recommended Tools NO RPM READING Control Panel/ RPM Multi-meter • Disconnect 5PA from 5PB. Set meter to 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 continuity change from off to on? • If yes – cables and sensor are good – Replace Control Panel. • If no – Go to Defective RPM Set.
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Symptom Probable Cause Correc tive Action Recommended Tools NO POLAR HEART RATE Control Panel Heart Rate Simulator • Attach a known good heart rate 500R, 500U transmitter around chest or use polar simulator. • If control panel does not display a heart rate – replace Control Panel. -------- Heart Rate Chest • If heart rate registers with use of HR Strap simulator but not chest strap – replace chest strap.
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Symptom Probable Cause Correc tive Action Recommended Tools IRREGULAR OR NO DISPLAY • Probe leads between pin 1 and 2 of 5PB. Control Panel Multi-meter 600R, 600U (Page 19-20) • Pedal unit up to at least 30 RPM. • Is voltage 5 VDC? • If not 5 VDC – replace Control Panel. -------- Control Board • Disconnect 6PG from 6PH. • Pedal. • Check DC voltage between pins 2 and 3 for 5 VDC. • No 5 VDC? – Replace
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Symptom Probable Cause Correc tive Action Recommended Tools • Disconnect 5PA from 5PB. (Page 19- NO RPM Control Panel Multi-meter 20). READING • Set meter to check continuity between 600R, 600U 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. -------- Defective Cables Defective RPM • Check continuity
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Symptom Probable Cause Correc tive Action Recommended Tools NO CONTACT HEART RATE Control Panel Multi-meter 600R, 600U • 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 ye
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Symptom Probable Cause Correc tive Action Recommended Tools HANDLEBAR “Cruise Control” BUTTONS DO • Remove console-mounting screws. Multi-meter NOT FUNCTION Locate 10P7B (Page 20). 600R • 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. -------
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Symptom Probable Cause Correc tive Action Recommended Tools Console Set • Remove console bolts to access 7-pin Note: NO RESISTANCE connector. Do not disconnect console 750U, 750R set. You must pedal at least • Enter DA (resistance) test mode. 30 RPM when performing any voltage (Page 2). test. You may require the • Press + key to force .7 VDC out of assistance of another panel. person when performing voltage checks. • Set meter for DC Volts. Mea
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Symptom Probable Cause Correc tive Action Recommended Tools HEAVY RESISTANCE Multi-meter 750U, 750R • Remove the console set. Console Set • Disconnect the 7 pin connector from the back of the console set. • Pedal. • Resistance normal? Replace console set. -------- Defective Cables • Remove pedal and if 3 piece crank remove crank arm. • Remove right side cover assembly. • Disconnect 7- pin connector from the lower
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Symptom Probable Cause Correc tive Action Recommended Tools No Display Note: 750U, 750R Console Set • Remove console set bolts. Verify good connection at the back of the console You must pedal at least set. Set meter for DC volts 30 RPM when performing any voltage • Pedal. test. You may require the • Measure between #1 and #4 wires (Page assistance of another 21) for 5.5 – 7.5 VDC. person when performing voltage checks. • Is required voltage p
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Symptom Probable Cause Correc tive Action Recommended Tools NO CONTACT Note: HEART RATE Dirty Sensors • Verify hand pulse sensors are clean. 750U, 750R You must pedal at least -------- 30 RPM when performing any voltage test. You may require the Console Set/ assistance of another • Set meter for continuity. person when performing Wiring • Remove Console set. voltage checks. • Check for continuity in both sets of hand pulse sensors
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Symptom Probable Cause Correc tive Action Recommended Tools NO POLAR Note: HEART RATE Control Panel • Attach known good heart rate 750U, 750R transmitter around chest or use Polar You must pedal at least simulator. 30 RPM when performing any voltage • Do not touch the hand pulse sensors. test. You may require the • Start pedaling assistance of another • Check display for heart rate. person when performing voltage checks. --------
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WIRING DIAGRAMS TR / TU 500 Page 18 600 U Page 19 600 R Page 20 TR/TU 750 Page 21 Page 17
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TR/ TU 500 WIRING DIAGRAM Page 18
