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True Fitness 600EA, Service Manual

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True Fitness 600EA Service Manual Download Page 45

Removal & Replacement 

 

 

 

               750E & 750EA                           

Remove Belt & Tensioner Assembly

 

 
 
 
 
 

 
Step 1. 

Use 11mm box wrench to remove 
Nut and washer from belt tensioning 
screw. 
 
 
 
 
 
 
 

Step 2. 

Remove belt from belt tensioner 
Assembly and wheels.  
 
 
 
 
 
 
 

Step 3. 

Use 5mm hex wrench to remove 
Button head screw and washer 
Attaching belt tensioner assembly to 
Frame.. 
 
 
 
 
 

 
 
 
 
 

Copyright 2001 True Fitness Technology, Inc.

 

Page 43 

Step 2.  

Remove Belt. 

Step 1.  

Remove Nut. 

Step 3.  

Remove Tensioner. 

Tools Required: 

11mm Box Wrench 
5mm Hex Wrench 

Summary of Contents for 600EA

Page 1: ...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 ...

Page 2: ... 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 w...

Page 3: ...True Fitness Elliptical Service Manual START Symptom guide Wiring Diagrams Parts Manual Removal and Replacement Procedures Page 1 ...

Page 4: ...ction 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 uni...

Page 5: ...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 ...

Page 6: ... 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 cab...

Page 7: ...nsole 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...

Page 8: ...M 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 cabl...

Page 9: ...Time Zone Fax 636 272 7148 Page 7 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 pu...

Page 10: ...lay 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 least 30 RPM when performing any voltage test You may require the assistance of another person when performing voltage checks Polar Heart Rate Simulator Excessive radio electromagnetic or audib...

Page 11: ... 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 chec...

Page 12: ...tness 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 Support Services 800 883 8783 Mon Fri 8 30am 5 00pm Central Time Zone Fax 636 272 7148 Page 10 ...

Page 13: ... 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 Support Services 800 883...

Page 14: ...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 resista...

Page 15: ...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 ...

Page 16: ...e magnet is not over the pickup the voltage should be 5 VDC Does the voltage alternate between 0 VDC and 5 VDC If yes replace console assembly Turn power off remove rear cover Disconnect the sensor connector Set meter for resistance Check resistance at the 2 pins of the connector Slowly move the swing arms to rotate the wheel Does the meter show continuity when the magnet is over the pickup If no ...

Page 17: ...WIRING DIAGRAMS TAE 600 Page 16 TAE 750 Page 17 TE 750 Page 18 Page 15 ...

Page 18: ...TRUE TAE 600 WIRING DIAGRAM Page 16 ...

Page 19: ...Page 17 TRUE TAE 750 WIRING DIAGRAM ...

Page 20: ...Page 18 TRUE TE 750 WIRING DIAGRAM ...

Page 21: ...True Armed Elliptical 600B Exploded Diagram Page 20 Parts List Page 21 Page 19 ...

Page 22: ...TRUE TAE 600 PARTS DIAGRAM Page 20 ...

Page 23: ...0112024 OVAL HEX SKT TRK 8 E12 7TMB0206002C FOOT PLATE 2 E14 7TMB0304011 FOOT PLATE INSERT 2 E18 7TME0502027 FLAT WASHER 8 E19 7TME0501007 SPRING WASHER 8 E52 7TME0102027 SCREW FOOTPLATE 8 E54 7TME0505037 TEFLON WASHER 2 E55 7TME0204026 NYLON NUT 2 E56 7TME0505020 TEFLON WASHER 2 E57 7TME0502006 FLAT WASHER 2 E60 7TMB0609063B MVG ARM JOINT 2 G08 7TMB0678005A END CAP SWING ARM 2 AC1 7TSP0302022A CO...

Page 24: ...7TMB0246001 RAIL CVR LH 1 AC1 7TSP0302022A CONSOLE MAST 1 Q07 7TMB0246002 RAIL CVR RH 1 Q08 7TME0121005 MAIN CVR 19 Q09 7TME0107030 PEDESTAL CVR 14 Q10 7TME0107013 MAIN CVR 6 Q11 7TME0701001 C CLIP MAIN CVR 2 Q14 7TMB0627006B CORROSION CVR 1 Q15 7TMB0613010A RND PLUG RT SIDE CVR 2 Q16 7TMB0678018A RECTANGULER PLUG 1 R05 7TMJ3305016A POLY V WHEEL 1 R06 7TME0208006 NUT HEX HEAD 2 R09 7TME0104047 FLY...

Page 25: ...True Armed Elliptical 750 Exploded Diagram Page 24 Parts lists Page 25 Page 23 ...

Page 26: ...TRUE TAE 750 PARTS DIAGRAM Page 24 ...

Page 27: ...ER PEDESTAL MOUNTING 4 C56 7TMB0401050A GRIP FIXED HANDLEBAR 2 E04 7TMB0206002C PEDAL PLATE PLASTIC 2 E05 7TMB0609025 END CAP PEDAL ARM 2 E07 7TSZEP25RAL PEDAL ARM TRACK 2 E08 7TMB0674006 RUBBER PAD PEDAL ARM TRACK 2 E10 7TME0112024 SCREW TRACK MOUNTING 8 E12 7TME0102027 SCREW PEDAL PLATE 8 E15 7TMB0304011 PEDAL PLATE COVER RUBBER 2 E18 7TME0502027 FLAT WASHER TRACK MOUNTING 8 E19 7TME0501007 SPRI...

Page 28: ...7006B COVER CENTER FRAME MEMBER 1 Q15 7TMB0613010A PLUG ROUND SIDE COVER 2 Q16 7TMB0678018A PLUG SQUARE SIDE COVER 1 R01 7TSM0330001 SHAFT ASSY PEDAL CRANK 1 R02 7TSM0330002 SHAFT ASSY SECONDARY DRIVE W SMALL POLY V WHEEL 1 R09 7TMD0604001 POLY V BELT PRIMARY DRIVE 1 R10 7TMD0601014 POLY V BELT SECONDARY DRIVE 1 R16 7TME0208008 NUT CRANK ARM 2 R21 7TME0112024 SCREW TENSIONER MOUNTING 1 R22 7TME050...

Page 29: ...e Elliptical 750 Prior to Serial 00 EL2253L Non Cartridge Bearing Exploded diagram Page 28 Parts lists Page 29 After Serial 00 EL2253L Cartridge Bearing Exploded diagram Page 31 Parts lists Page 32 Page 27 ...

Page 30: ...TRUE TE 750 PARTS DIAGRAM Non Cartridge Bearings Page 28 ...

Page 31: ...TING 4 C17 7TME0501007 SPRING WASHER PEDESTAL MOUNTING 4 E04 7TMB0206002C PEDAL PLATE PLASTIC 2 E05 7TMB0609025 END CAP PEDAL ARM 2 E07 7TSZEP25RAL PEDAL ARM TRACK 2 E08 7TMB0674006 RUBBER PAD PEDAL ARM TRACK 2 E10 7TME0112024 SCREW TRACK MOUNTING 8 E12 7TME0102027 SCREW PEDAL PLATE 8 E15 7TMB0304011 PEDAL PLATE COVER RUBBER 2 E18 7TME0502027 FLAT WASHER TRACK MOUNTING 8 E19 7TME0501007 SPRING WAS...

Page 32: ...UL SHAFT ASSY SECONDARY DRIVE 1 R05 7TMZD0112013 POLY V WHEEL SMALL 1 R09 7TMD0604001 POLY V BELT PRIMARY DRIVE 1 R10 7TMD0601014 POLY V BELT SECONDARY DRIVE 1 R16 7TME0208008 NUT CRANK ARM 2 R21 7TME0112024 SCREW TENSIONER MOUNTING 1 R22 7TME0502035 WASHER TENSIONER MOUNTING 1 R26 7TSZEP17CPS PIVOT PEDAL ARM 2 R27 7TS11317001 WHEEL PEDAL ARM 4 R28 7TME0502026 WASHER PEDAL ARM WHEEL 4 R29 7TME0112...

Page 33: ...TRUE TE 750 PARTS DIAGRAM Cartridge Bearings Page 31 ...

Page 34: ...TING 4 E04 7TMB0206002C PEDAL PLATE PLASTIC 2 E05 7TMB0609025 END CAP PEDAL ARM 2 E07 7TSZEP25RAL PEDAL ARM TRACK 2 E08 7TMB0674006 RUBBER PAD PEDAL ARM TRACK 2 E10 7TME0112024 SCREW TRACK MOUNTING 8 E12 7TME0102027 SCREW PEDAL PLATE 8 E15 7TMB0304011 PEDAL PLATE COVER RUBBER 2 E18 7TME0502027 FLAT WASHER TRACK MOUNTING 8 E19 7TME0501007 SPRING WASHER TRACK MOUNTING 8 G04 7TMB06A7001 BRACKET PULSE...

Page 35: ...POLY V WHEEL SMALL 1 R09 7TMD0604001 POLY V BELT PRIMARY DRIVE 1 R10 7TMD0601014 POLY V BELT SECONDARY DRIVE 1 R16 7TME0208008 NUT CRANK ARM 2 R21 7TME0112024 SCREW TENSIONER MOUNTING 1 R22 7TME0502035 WASHER TENSIONER MOUNTING 1 R26 7TSZEP17CPS PIVOT PEDAL ARM 2 R27 7TS11317001 WHEEL PEDAL ARM 4 R28 7TME0502026 WASHER PEDAL ARM WHEEL 4 R29 7TME0112074 SCREW PEDAL ARM WASHER 4 S02 7TME0202012 NUT ...

Page 36: ...Page 34 ...

Page 37: ...True Fitness Removal Replacement 500R 500U 600U 600R Page 35 ...

Page 38: ...48 Removal and Replacement 600 Series Elliptical Remove Crank Page 37 Remove Belt Wheel Page 38 Remove Brake Page 40 750E 750EA Series Elliptical Remove Belt Tensioner Assembly Page 43 Remove Small Poly V Pulley Page 44 Remove Crank 235 Diameter Poly V Pulley Page 46 Remove Hub Assembly Page 47 Page 36 ...

Page 39: ... Step 2 Place 15mm socket end of crank Puller over axle nut Loosen the axle Nut by turning the crank puller counter Clockwise with a crescent wrench Step 3 Remove crank assembly from hub Copyright 2001 True Fitness Technology Inc Page 37 Step 1 Wood Block Placement Tools Required Crank Puller Crescent Wrench Block of wood Step 2 Axel Nut Removal Step 3 Remove Crank Assembly from Hub ...

Page 40: ... 2 Loosen and remove axel nuts on Brake both sides Step 3 Push belt over edge and off of wheel Copyright 2001 True Fitness Technology Inc Page 38 Step 2 Remove Axel Nuts Step 1 Loosen Belt Tensioning Nuts Step 3 Remove Belt from Wheel Tools Required 15mm Socket nd Ratchet 11mm Box End Wrench 5mm Hex Wrench Phillips Screw Driver ...

Page 41: ...m hex screws from Bearing fixtures on both sides of belt Wheel axel Step 5 Lift belt wheel assembly from bearing Fixtures Copyright 2001 True Fitness Technology Inc Page 39 Step 5 Lift belt wheel assembly from bearing Fixtures Step 4 Remove screws from Bearing Fixtures ...

Page 42: ...Step 2 Disconnect electrical terminal at Brake Step 3 Disconnect electrical terminal from The console set at the control box Located above the brake Copyright 2001 True Fitness Technology Inc Page 40 Step 2 Disconnect Electrical Terminal at Brake Step 1 Brake Bracket Removal Step 3 Disconnect Cable from Control Box Tools Required Phillips Screw Driver ...

Page 43: ...ding control box above the brake To the frame Remove control box Step 5 Pull backwards on the brake and Magnet assembly to free it from Slotted axle flanges Lift brake Out Copyright 2001 True Fitness Technology Inc Page 41 Step 5 Lift Brake Magnet Assembly Out Step 4 Control Box Removal ...

Page 44: ... Continued Step 6 Remove Phillips head screws From brackets on both sides of Brake Step 7 Remove brackets to free belt Copyright 2001 True Fitness Technology Inc Page 42 Step 7 Remove Brake Brackets Belt Step 6 Remove Screws from Bracket ...

Page 45: ...ng screw Step 2 Remove belt from belt tensioner Assembly and wheels Step 3 Use 5mm hex wrench to remove Button head screw and washer Attaching belt tensioner assembly to Frame Copyright 2001 True Fitness Technology Inc Page 43 Step 2 Remove Belt Step 1 Remove Nut Step 3 Remove Tensioner Tools Required 11mm Box Wrench 5mm Hex Wrench ...

Page 46: ...ew in pulley Step 2 Use Hammer Handle to prevent Rotation of large wheel when Removing pulley Copyright 2001 True Fitness Technology Inc Page 44 Step 2 Prevent Rotation of Fly Wheel Step 1 Loosen Set Screw Tools Required 3mm Hex Wrench 4mm Hex Wrench Bicycle Crank Puller Hammer Handle Adjustable Wrench ...

Page 47: ... 4mm hex wrench to remove Screw and washer holding the Small Poly V wheel on Step 4 Remove Poly V wheel using bicycle Crank puller and adjustable wrench Remove key from shaft Copyright 2001 True Fitness Technology Inc Page 45 Step 4 Use Puller to Remove Step 3 Remove Center Screw ...

Page 48: ...o prevent counter clockwise Rotation Step 2 Remove center nut using 21mm socket ratchet Copyright 2001 True Fitness Technology Inc Page 46 Step 2 Prevent Rotation of Fly Wheel Step 1 Block to Prevent Rotation Tools Required Block of Wood to Block Crank 21mm Socket Ratchet Metric Cotter less Crank Puller 10mm Hex Wrench ...

Page 49: ...clockwise rotation Step 4 Place metric cotter less crank puller Over end of crank shaft Turn puller clock wise with 10mm Hex wrench to remove crank Step 5 Pull crank arm off of crank shaft And set moving arm aside Copyright 2001 True Fitness Technology Inc Page 47 Step 4 Pull Crank Step 3 Block to Prevent Rotation Step 5 Move Arm Aside ...

Page 50: ... flat blade Screwdriver To remove wheel from frame slip Shaft through bearing Step 3 Pull wheel and hub assembly out as A unit Bearings and axle cannot be Field serviced Copyright 2001 True Fitness Technology Inc Page 48 Step 2 Remove Clip Step 1 Remove Large Hex Nut Step 3 Pull Assembly Out Tools Required Elliptical Wrench pn 90361501 Channel Lock Pliers Flat Blade Screwdriver ...

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