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True Fitness 500U Service Manual

True fitness exercise bicycle service manual
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True Fitness Service
Exercise Bicycles
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
Manual
500R, 500U
600R, 600U
750R, 750U
Revision 9/2004

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  Summary of Contents for True Fitness 500U

  • Page 1 © 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.
  • Page 2 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.
  • Page 3 True Fitness Bicycle Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1...
  • Page 4 Test Mode *750 ONLY To Enter Diagnostic Mode Console / Display Output Console Key Input Contact Heart Rate DA (Resistance) Exit Diagnostics Support Services 800-883-8783 Page 2 Procedure • Press and hold the “Start” key as you begin pedaling. • Continue pedaling throughout the test.
  • Page 5: Table Of Contents

    SYMPTOM GUIDE 500U, 500R ECB Malfunction ..... . . Irregular or No Display ....
  • Page 6: Ecb Malfunction

    Symptom Probable Cause Control Panel MALFUNCTION 500R, 500U Defective Cables Defective ECB Control Board Optical Sensor DC Motor ECB Limit Switch Loud Continuous Tone from lower board (ECB board) Note: If motor has been bound and then freed the motor may have been weakened. If components now move freely but the motor is laboring –...
  • Page 7: Irregular Or No Display

    Symptom Probable Cause IRREGULAR OR NO DISPLAY DC Adaptor 500R, 500U Adapter Plug or Jack Control Panel Cables Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Connect DC Adapter to 110 VAC power supply. • Look for printed output on adapters label.
  • Page 8: No Rpm Reading

    Symptom Probable Cause NO RPM READING Control Panel/ RPM 500R, 500U Sensor Defective Cables Defective RPM Sensor Set Page 6 Support Services 800-883-8783 Corrective Action • Disconnect 5PA from 5PB. Set meter to check continuity between 2 and 5 of 5PB.
  • Page 9: No Polar Heart Rate

    Symptom Probable Cause NO POLAR HEART RATE Control Panel 500R, 500U Heart Rate Chest Strap External Interference Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Attach a known good heart rate transmitter around chest or use polar simulator.
  • Page 10: Irregular Or No Display

    Symptom Probable Cause IRREGULAR OR NO DISPLAY Control Panel 600R, 600U Control Board Cables AC Voltage Output Generator Output Cable Page 8 Support Services 800-883-8783 Corrective Action • Probe leads between pin 1 and 2 of 5PB. (Page 19-20) • Pedal unit up to at least 30 RPM.
  • Page 11: No Rpm Reading

    Symptom Probable Cause NO RPM Control Panel READING 600R, 600U Defective Cables Defective RPM Sensor Set Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Disconnect 5PA from 5PB. (Page 19- 20). • Set meter to check continuity between pins 2 and 5 of 5PB •...
  • Page 12: No Contact Heart Rate

    Symptom Probable Cause NO CONTACT HEART RATE Control Panel 600R, 600U Defective Cables Defective Handles Page 10 Support Services 800-883-8783 Corrective Action • 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...
  • Page 13: Handle Bar Buttons

    Symptom Probable Cause HANDLEBAR “Cruise Control” BUTTONS NOT FUNCTION 600R “Start” Button “Shift” Button “_“ Button “Select” Button “+” Button Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Remove console-mounting screws. Locate 10P7B (Page 20). • Check for continuity between pin 7 and pin 1 at 10P7B.
  • Page 14: No Resistance

    Symptom Probable Cause Console Set NO RESISTANCE 750U, 750R Defective Cables Power Resistance Brake Harness/ Lower Board Page 12 Support Services 800-883-8783 Corrective Action • Remove console bolts to access 7-pin connector. Do not disconnect console set. • Enter DA (resistance) test mode. (Page 2).
  • Page 15: Heavy Resistance

    Symptom Probable Cause HEAVY RESISTANCE 750U, 750R Console Set Defective Cables Lower control Board/Brake Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Remove the console set. • Disconnect the 7 pin connector from the back of the console set. •...
  • Page 16: Irregular Or No Display

    Symptom Probable Cause No Display Console Set 750U, 750R Brake Defective Cable Console Cable/ Lower Control Board Page 14 Support Services 800-883-8783 Corrective Action • Remove console set bolts. Verify good connection at the back of the console set. Set meter for DC volts •...
  • Page 17: No Contact Heart Rate

    Symptom Probable Cause NO CONTACT HEART RATE Dirty Sensors 750U, 750R Console Set/ Wiring Wire Connections Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Corrective Action • Verify hand pulse sensors are clean. -------- • Set meter for continuity. • Remove Console set.
  • Page 18: No Polar Heart Rate

    Symptom Probable Cause NO POLAR HEART RATE Control Panel 750U, 750R Defective Cables Defective ECB Control Board Page 16 Support Services 800-883-8783 Corrective Action • Attach known good heart rate transmitter around chest or use Polar simulator. • Do not touch the hand pulse sensors. •...
  • Page 19: Wiring Diagrams

    WIRING DIAGRAMS TR / TU 500 600 U 600 R TR/TU 750 Page 18 Page 19 Page 20 Page 21 Page 17...
  • Page 20 TR/ TU 500 WIRING DIAGRAM Page 18...
  • Page 21 TU 600 WIRING DIAGRAM Page 19...
  • Page 22 TR 600 WIRING DIAGRAM Page 20...
  • Page 23 TR/ TU 750 WIRING DIAGRAM Page 21...
  • Page 24 Page 22...
  • Page 25 True Recumbent Bike 500 TU 500 Exploded Diagram TU 500 Parts List TR 500 Exploded Diagram TR 500 Parts List Pg 22 Pg 23 Pg 25 Pg 26 Page 23...
  • Page 26 Page 24...
  • Page 27 TU 500 EXERCISE BIKE REF. PART # DESCRIPTION 7T010800 FRONT STABILIZER WITH BOLTS 7T000200 TRANSPORTATION WHEEL HIT 7T000300 FTONT STABILIZER END CAP 7T000400 CRANK PULLEY WITH CAPS AND BEARINGS 1 SET 7T000600 BOLT BELT TENSION 7T010900 BRAKE ASSY 7T001700 ALUMINUM IDLER ASSY 7T001800 ECB DC MOTOR WITN SCREWS 7T002000...
  • Page 28 7T002600 7T002700 7T002800 7T012700 7T005800 7T004700 7T004800 7T013000 7T012901 7T012902 7T012903 7T012904 7TU50100 ASSY HDW. KIT 7TU50200 COMPUTER SCREW KIT 7TU60200 FRONT STABILIZER HDW. KIT 7TU60500 HANDLE BAR HDW. KIT 7TU60600 CD HOLDER HDW. KIT 7TU60700 TOOL KIT 7TU60300 REAR STABILIZER HDW KIT Page 26 REAR STABILIZER WITH BOLTS ADJUSTING STAND KIT...
  • Page 29 TR 500 Exercise Bike Page 27...
  • Page 30 REF # PART# 7T000100 Front Stabilizer w/Bolts 7T000200 Transportation Wheel Kit 7T000300 Front Stabilizer End Cap 7T000400 Crank Pulley w/E Caps & Bearings 7T005800 RPM Sensor w/Wire & Nut 7T000600 Bolt - Belt Tension 7T000700 Cable Assembly - 6 Pin Lower 7T000800 Cable Assembly - 5 Pin Lower 7T000900 Shroud Trim Cap 7T001000 Console Mast Set...
  • Page 31 7T002500 Transportation Handle Set w/Screws 7T002600 Rear Stabilizer w/Bolts 7T002700 Adjusting Stand Kit 7T002800 Rear Stabilizer End Cap 7T002900 Roller Set (A) Rt Ft & RR 7T003000 Roller Set (B) Center 7T003100 Seat Bottom w/Bolts 7T003200 Fore and Aft Adjusting Lever w/Bolts 7T003300 Seatback w/Bolts 7T003400 Seat Shuttle 7T003500 Bottle Holder w/Screws...
  • Page 32 Page 30...
  • Page 33 True Upright Bike True Recumbent Bike 600 TU 600 Exploded Diagram TU 600 Parts List TR 600 Exploded Diagram TR 600 Parts List Pg- 29 Pg- 30 Pg- 32 Pg- 33 Page 31...
  • Page 34 TU 600 PARTS DIAGRAM Page 32...
  • Page 35 TU 600 BIKE REF # PART NUMBER DESCRIPTION 7T010800 FRONT STABILIZER WITH BOLTS 7T000200 TRANSPORTATION WHEEL KIT 7T000300 FRONT STABILIZER END CAP 7T011400 DRIVE BELT KIT 7T004900 DO NOT ORDER 7T005000 POLY V PULLEY SET KIT SECONDARY 7T012000 LEFT COMPLETE W/ MODEL SHROUD DECALS 7T001302 SIDE COVER SCREW 7T001202...
  • Page 36 7T011800 7T011900 7T012901 7T012902 7T012903 7T012904 7TU60100 7TU60200 7TU60300 Page 34 MODEL DECAL LEFT WHITE MODEL DECAL RIGHT WHITE DECAL A DECAL B DECAL C DECAL D PARTS KIT FRONT STABILIZER SCREW KIT REAR STABILIZER SCREW KIT...
  • Page 37 TR 600 PARTS DIAGRAM Page 35...
  • Page 38 REF. # PART # 24-1 7T011600 24-2 7T001202 24-3 7T001303 24-4 7T001302 24-5 7T011700 24-6 7T001306 24-7 7T011800 24-8 7T001308 24-9 7T001309 24-10 7T012300 24-11 7T001311 24-12 7T001312 7T001400 7T002100 7T002200 7T002300 7T006500 7T002400 7T002500 7T002600 7T002700 7T002800 7T002900 7T003000 7T003100 7T003300 7T003200...
  • Page 39 7T006200 CONSOLE MAST W/BOLTS 20-1-1 7T006201 CABLE ASSY 12 PIN UPPER 20-1-2 7T006202 CABLE ASSY 52 PIN UPPER 7T006300 COMPUTER SET 660RIU LT FRT 7T003700 ROLLER SET SEAT LT RR 7T006400 IDLER ARM SHAFT KIT 40-1 7T001201 REAR SHROUD RT 24-2 7T001202 ROUND CROSS SCREW...
  • Page 40 Page 38...
  • Page 41 True Upright Bike TU 750 Exploded Diagram (Prior to serial # 02-UP0161C (3) Piece Crank) TU 750 Parts List (Prior to serial # 02-UP0161C (3) Piece Crank) TU 750 Exploded Diagram (After serial # 02-UP0161C (1) Piece Crank) TU 750 Parts List (After serial # 02-UP0161C (1) Piece Crank) Pg- 37 Pg- 38...
  • Page 42 TU 750 PARTS DIAGRAM (3 PIECE CRANK) Page 40...
  • Page 43 TU 750 3 PIECE CRANK REF # PART# DESCRIPTION 7TSP0101006 FRAME 7TSZCB24CSM UPRIGHT HANDLE BAR 7TSW0150005 SEAT POST 7TSZCB24FST FRONT GROUNDING BAR ASSEMBLY 7TSM0209004 CONSOLE SET 7TMD0208006 BRAKE ASSEMBLY 7TME0701001 C CLAMP SIDE COVER 7TME0107014 SCREW SIDE COVER 7TMJ1208001 SIDE COVER BRACKET 7TMJ1278001 HAND PULSE SENSOR 7TMB06A7001...
  • Page 44 Q06R 7TMB0609028 Q06L 7TMB0609026 7TMB0609035 7TSZCB24SCV-L SIDE COVER ASSY. LEFT 3 PC. CRANK 7TSZCB24SCV-R SIDE COVER ASSY. RIGHT 3 PC. CRANK 7TSZRB40PAX 7TMD0602018 7TME0103022 7TME0514002 7TME0104014 7TME0502092 7TMJ3247002 7TMJ1245003 7TME0204010 7TME0201012 7TME0502127 7TME0502115 7TSZRB40DAX 7TMD0405001 7TMD0406001 7TMD0402002 7TMD0403002 7TMD0602013 7TMB0622001 7TME01132012 7TME0112088 7TMJ1914002...
  • Page 45 TU 750 PARTS DIAGRAM (1 PIECE CRANK) Page 43...
  • Page 46 REF.# PART# 7TSP001006 7TSZCB24CSM 7TSW0150005 7TSZCB24FST 7TSM0209004 7TMD0208006 7TME0701001 7TME0107014 7TMJ1208001 7TMJ1278001 7TMB06A7001 7TME0102069 7TMB0201028 7TMB0601006 7TME0102043 7TME0111014 7TMB0605006 7TMJ1291001 7TMB1001018 7TME0204019 7TME0501007 7TMB0103001 7TSZCB24RST 7TMB0304006 7TME0112024 7TME0112044 7TME0502108 7TMB0705001 7TMC0501027 7TMC0549002 7TMC0203004 7TMC0736002 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMB06B8001 Page 44 7TME0107043 7TME0107043 TU 750 1PC CRANK...
  • Page 47 7TMN1101006 7TMB030402A 7TMZE0112119 7TMB0604018 Q06R 7TMB0609028 Q06L 7TMB0609026 7TMB0609035 7TSZCB24SCV-L 7TSZCB24SCV-R 7TSZRB40PAX 7TMD0602018 7TME0103022 7TME0514002 7TME0104014 7TME0502092 7TMJ3247002 7TMJ1245003 7TME0204010 7TME0201012 7TME0502127 7TME0502115 7TSZRB40PAX-1 7TMD0405001 7TMD0406001 7TSM0915027A 7TMD0403002 7TMD0602013 7TMB0622001 7TME0113012 7TME0112088 7TMJ1914002 7TME1104002 7TME0502084 7TME0104014 7TME0201003 7TMG0214009 7TMG0102053D FRAME SEAT ADJ KNOB BLUE FOOT PAD FRONT...
  • Page 48 7TMG0102036 7TMG0214009C 7TMG0214016C 7TMH0205023 7TME0601017 7TMB0237002 Page 46 MODEL DECAL WHITE SIDE CVR DECAL SILVR SIDE CVR DECAL SILVR OWNERS MANUAL ASSEMBLY KIT UPPER FRAME CVR...
  • Page 49 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) TR 750 Exploded Diagram (After 08/05/2001 & Prior to Serial # 02-RE0283C (3) Piece Crank) TR 750 Parts List (After 08/05/2001 &...
  • Page 50 Page 48...
  • Page 51 TR750 PRIOR 8-5-01 (3 PIECE CRANK) REF. # PART # DESCRIPTION 7TSP0203003 SEAT SLIDE WELDMENT 7TSZRB40SLP SEAT SLIDE PLATE LOCK 7TSP0206006 SEAT HANDLE BAR WELDMENT 7TSP0212003 CONCOLE HANDLE BAR WELDMENT 7TSZRB40FST FRONT GROUNDING BAR ASSY. 7TSM0209004 CONSOLE ASSEMBLY 7TMD0208006 BRAKE ASSY 7TME0701001 C CLAMP-SIDECOVER 7TME0107014...
  • Page 52 7TSW2221005 7TMB0304006 7TME0112109 7TME0112024 7TME0502108 7TME0902007 7TMC0501027 7TMC0520002 7TMC0550001 7TMC0203004 7TMC0736002 7TMC0535006 7TMB06B8001 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMB0601005 Q06R 7TMB0609028 Q06L 7TMB0609026 7TMB0609035 7TME0104055 7TSZRB40SCV-L SIDE COVER LEFT WITH DECALS 7TSZRB40SCV-R SIDE COVER RIGHT WITH DECALS 7TSZRB40PAX 7TMD0602018 7TME0104014 7TME0502092 7TMJ3247001 7TMJ1245003 7TME0204010...
  • Page 53 TR 750 PARTS DIAGRAM After 08/05/01 and Prior to Serial # 02-RE0283C Page 51...
  • Page 54 TR 750 AFTER 8/5/01 PRIOR TO 02-RE0283C REF. # PART # AD5 7TSZRB40SAS AG2 7TSP0212003 AN1 7TSM0209004 AS1 7TMD0208006 B26 7TME0701001 B27 7TME0107014 B35 7TMJ3251001 D76 7TMB1001005 D77 7TMB1002002 D78 7TME0112013 D79 7TME0112014 D80 7TME0501006 D81 7TME0112024 D82 7TME0501007 G06 7TMB0401021 G06 7TSP0206006 G08 7TMJ1278001 G09 7TMB06A7001...
  • Page 55 Q07 7TMB0609035 Q08 7TME0104055 Q11 7TSZRB40SCV-L SIDE COVER LEFT Q12 7TSZRB40SCV-R SIDE COVER RIGHT R03 7TSZRB40PAX R06 7TMD0602018 T02 7TMD0405001 T03 7TMD0406001 T04 7TMD0402002 T05 7TMD0403002 T06 7TMD0602013 T08 7TMB0622001 T09 7TME0113012 V02 7TMG0214008 V03 7TMG0214014 V08 7TMG0222006 7TSZRB40DAX 7TMB0705001 7TMZE0112119 7TMB0304020A 7TMJ1208001...
  • Page 56 TR 750 PARTS DIAGRAM After Serial # 02-RE0283C (1 Piece Crank) Page 54...
  • Page 57 TR 750 AFTER SERIAL # 02-RE0283C NEW SEAT ASSEMBLY-1 PIECE CRANK REF. # PART # DESCRIPTION AD5 7TSZRB40SAS SEAT SLIDE SET 7TSZRB40SER-1 SEAT ROLLER ASSY. AG1 7TSP0206006 SEAT HANDLE BAR AG2 7TSP0212003 CONSOLE HANDLE BAR FRONT GROUNDING BAR ASSY. AN1 7TSM0209004 CONSOLE ASSY.
  • Page 58 P17 7TMJ1393002 7TME0102027 7TME0204003 7TME0502082 7TMB0601005 Q06R 7TMB0609028 Q06L 7TMB0609026 Q07 7TMB0609035 Q08 7TME0104055 Q11 7TSZRB40SCV-L1 SIDE COVER LEFT Q12 7TSZRB40SCV-R1 SIDE COVER RIGHT R03 7TSZRB40PAX R06 7TMD0602018 R17 7TME0104014 R20 7TME0502092 S01 7TMJ3247001 S02 7TMJ1245003 S03 7TME0204010 S04 7TME0201012 7TSZRB40PAX-1 BOTTOM BRACKET WHEEL ASSY 7TSZRB40KIT T04 7TSM0915027A...
  • Page 59 True Fitness Removal & Replacement 500R 500U 600U 600R Page 57...
  • Page 60 Remove Access Covers – All Bikes 500R Remove Small Poly V Pulley Remove Belt & Tensioner Assembly Remove Crank Hub Assembly 500U Remove Small Poly V Pulley Remove Belt & Tensioner Assembly Remove Crank Hub Assembly 600U Remove Right Belt Poly-V Pulley Remove Right Side Tensioner Assembly Remove Belt &...
  • Page 61 Removal & Replacement Remove Access Covers ~ 500R, 500U, 600R & 600U Tools Required: Pedal Wrench Phillips Screwdriver Step 1. Use pedal wrench to remove both pedals from pedal cranks. Note: Left pedal loosens clockwise. Right pedal loosens counter- clockwise.
  • Page 62 Removal & Replacement Remove Access Covers ~ 500R, 500U, 600R & 600U (continued) Note: Electrical connections are on 500 series bikes only. Step 3. Disconnect electrical power adapter. Step 4. Rotate crank handle forward to 2 o’clock Position to allow removal of cover.
  • Page 63: Remove Small Poly V Pulley

    Rotation of large wheel when Removing pulley. Step 2. Use 4 mm wrench to loosen set screw in pulley. Copyright 2001 True Fitness Technology, Inc. Note: Leave belt in place to help lock pulley Step 1. Prevent Rotation of Fly Wheel Step 2.
  • Page 64 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.
  • Page 65: Remove Belt & Tensioner Assembly

    5mm Hex Wrench Snap Ring Pliers Step 1. Remove small poly-V pulley. Step 2. Remove keyway using flat blade Screwdriver as required. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Small Poly-V Pulley Step 2. Remove Keyway 500R Page 63...
  • Page 66 Removal & Replacement Remove Belt & Tensioner Assembly (continued) Step 3. Remove snap ring from belt Tensioner. Step 4. Remove belt tensioner. Page 64 Copyright 2001 True Fitness Technology, Inc. Step 2. Remove Snap Ring Step 3. Remove Belt Tensioner 500R...
  • Page 67: Remove Crank Hub Assembly

    Note: The hex nut bearing has left- handed threads. Turn clockwise to loosen. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Crank Nut Step 2. Remove Keyed Washer Step 3. Remove Hex Nut Bearing 500R Page 65...
  • Page 68 Slide brake towards seat to allow pulley to clear frame. Step 5. Use crescent wrench to remove hex nut bearing. Page 66 Copyright 2001 True Fitness Technology, Inc. Step 4. Pull Hex Nut Bearing Free Step 5. Remove Large Pulley Assembly 500R...
  • Page 69 Slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Copyright 2001 True Fitness Technology, Inc. Step 6. Twist Unit Thru Hub Frame Step 7. Drive spanner nut off to remove bearing Step 8. Remove Bearing & Washer...
  • Page 70: 500U

    Step 2. Use 4 mm wrench to loosen set screw in pulley. Page 68 Copyright 2001 True Fitness Technology, Inc. Note: Leave belt in place to help lock pulley Step 1. Prevent Rotation of Fly Wheel Step 2. Loosen Set Screw...
  • Page 71: Remove Belt & Tensioner Assembly

    5 mm-Hex Wrench Snap Ring Pliers Step 1. Remove small poly-v pulley. Step 2. Remove keyway, using flat blade Screwdriver as required. Copyright 2001 True Fitness Technology, Inc Step 1. Remove Small Poly-v Wheel Step 2. Remove keyway 500U Page 69...
  • Page 72 Use 17 mm box wrench to loosen Nut from belt tensioning screw. Step 3. Prevent Wheel Rotation 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...
  • Page 73 Remove belt from belt tensioner Assembly and wheels. Step 6. Remove snap ring from belt tensioner. Step 7. Remove belt tensioner. Copyright 2001 True Fitness Technology, Inc Step 5. Remove Belt Step 6. Remove Snap Ring. Step 7. Remove belt tensioner 500U Page 71...
  • Page 74: Remove Crank Hub Assembly

    Note: The Hex nut bearing has left- handed threads. Turn clockwise to loosen. Page 72 Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Crank Nut. Step 2. Remove Keyed Washer Step 3. Remove Hex Nut Bearing 500U...
  • Page 75 Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Copyright 2001 True Fitness Technology, Inc. Step 4. Pull Hex Nut Bearing Free. Step 4. Pull Hex Nut Bearing Free. Step 5. Twist Unit Thru Hub Frame.
  • Page 76 Remove bearing & washer by slipping off crank. Note: Pulley and crank are a welded assembly (cannot be separated). Page 74 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove Bearing & Washer Copyright 2001 True Fitness Technology, Inc 500U...
  • Page 77: Remove Right Belt Poly-V Pulley

    Snap Ring Pliers Step 1. Use pliers or needle nose pliers to remove the belt tensioning spring Step 2. Remove the belt. Copyright 2001 True Fitness Technology, Inc. Step 1. Belt Tensioning Spring Step 2. Remove Belt 600U Page 75...
  • Page 78 Remove the snap ring and washers. Step 5. Remove the small poly-V pulley. Page 76 Copyright 2001 True Fitness Technology, Inc. Step 3. Prying with snap ring pliers Step 4. Remove the snap ring and washers Step 5. Remove the small poly-V pulley...
  • Page 79: Remove Right Side Tensioner Assembly

    Step 2. Slide tensioner assembly off pivot shaft. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Snap Ring Step 2. Slide Tensioner Assembly 600U Page 77...
  • Page 80: Remove Belt & Tensioner Assembly

    4 bolts holding the brake bracket to the frame. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Page 78 Step 1. Remove Locking Screw Copyright 2001 True Fitness Technology, Inc. Step 2. Loosen Bracket Bolts 600U...
  • Page 81 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...
  • Page 82 Remove the loosened bottom screws. Step 7. Remove brake and belt assembly. Page 80 Copyright 2001 True Fitness Technology, Inc. 600U & 600R Step 5. Disconnect Wiring Harness. Step 6. Remove Loosened Screws Step 7. Remove Brake & Belt Assembly...
  • Page 83: Remove Left Side Belt From Assembly

    Remove snap ring. Step 2. Carefully pry bearing out of housing. Step 3. Remove inner snap ring. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Snap Ring. Step 2. Pry Bearing Out of Housing Step 7. Remove Inner Snap Ring 600U...
  • Page 84 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket. Step 4. Remove Screws & Washers. 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.
  • Page 85: Remove Left Side Poly-V Wheel

    Note: Crank not welded to pulley so (1) extra step showing separating these for 600U set. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Snap Ring on Right Side Step 2. Slide Shaft Through Frame 600U Page 83...
  • Page 86: Remove Crank Hub Assembly

    Note: The Hex nut bearing has left- handed threads. Turn clockwise to loosen. Page 84 Step 1. Remove Crank Nut. Step 3. Remove Hex Nut Bearing Copyright 2001 True Fitness Technology, Inc. Step 2. Remove Keyed Washer 600U...
  • Page 87 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. Copyright 2001 True Fitness Technology, Inc. Page 85...
  • Page 88 Step 9. Pull crank thru pulley to remove. Page 86 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove Bearing & Washer Step 9. Pull Crank Thru Pulley to Remove Copyright 2001 True Fitness Technology, Inc 600U...
  • Page 89: Remove Left Belt Poly-V Pulley

    Snap Ring Pliers Step 1. Use pliers, or needle nose pliers, to remove the belt tensioning spring. Step 2. Remove the belt. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Belt Tensioning Spring Step 2. Remove Belt 600R Page 87...
  • Page 90 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. Step 2. Remove Small Poly-V Pulley Page 88 Copyright 2001 True Fitness Technology, Inc.
  • Page 91: Remove Left Side Tensioner Assembly

    Step 2. Slide tensioner assembly off pivot shaft. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Snap Ring Step 2. Slide Tensioner Assembly 600R Page 89...
  • Page 92: Remove Belt & Tensioner Assembly

    4 bolts holding the brake bracket to the frame. Note: Frame is slotted to allow brake bracket to slide when bolts are loose. Page 90 Step 1. Remove Locking Screw Copyright 2001 True Fitness Technology, Inc. 600R Step 2. Loosen Bracket Bolts...
  • Page 93 Step 3. Pry on Brake to Loosen Belt. Step 4. Remove brake belt from larger poly-V wheel. Step 4. Remove Belt Page 91 Copyright 2001 True Fitness Technology, Inc.
  • Page 94 Remove the loosened bottom screws. Step 7. Remove brake and belt assembly. Page 92 Step 5. Disconnect Wiring Harness. Step 6. Remove Loosened Screws Step 7. Remove Brake & Belt Assembly Copyright 2001 True Fitness Technology, Inc. 600U & 600R...
  • Page 95: Remove Right Side Belt From Assembly

    Remove snap ring. Step 2. Carefully pry bearing out of housing. Step 3. Remove inner snap ring. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Snap Ring. Step 2. Pry Bearing Out of Housing Step 7. Remove Inner Snap Ring 600R...
  • Page 96 Use 4 mm Hex Wrench to remove Screws and washers holding Brake to bracket. Step 4. Remove Screws & Washers. Step 5. Remove brake bracket until belt Can be removed. Step 5. Remove Bracket to Check Belt Page 94 Copyright 2001 True Fitness Technology, Inc.
  • Page 97: Remove Right Side Poly-V Wheel

    Note: Crank not welded to pulley so (1) extra step showing separating these for 600U set. Copyright 2001 True Fitness Technology, Inc. Step 1. Remove Shaft Snap Ring on Right Side Step 2. Slide Shaft Through Frame 600R Page 95...
  • Page 98: Remove Crank Hub Assembly

    Note: The Hex nut bearing has left- handed threads. Turn clockwise to loosen. Page 96 Copyright 2001 True Fitness Technology, Inc. 600R Step 1. Remove Crank Nut. Step 2. Remove Keyed Washer Step 3. Remove Hex Nut Bearing...
  • Page 99 Frame. Step 6. Twist assembly thru frame hub. Pull assembly until clear of frame. Copyright 2001 True Fitness Technology, Inc. Step 4. Pull Hex Nut Bearing Free. Step 5. Remove Large Pulley Assembly. Step 6. Twist Unit Thru Hub Frame.
  • Page 100 Step 9. Pull crank thru pulley to remove.. Page 98 Step 7. Drive Spanner Nut Off to Remove Bearing Step 8. Remove Bearing & Washer Step 9. Pull Crank Thru Pulley to Remove Copyright 2001 True Fitness Technology, Inc 600R...

This manual is also suitable for:

600r500r750u600u750r