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Johnson JET7000 Service Manual

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  • Page 2: Table Of Contents

    C O N S O L E E N G I N E E R I N G M O D E G U I D E JET7000 (OLD) ENGINEERING MODE GUIDE........4-1 JET7000 (OLD) TOTAL "TIME" & "DISTANCE" INSTRUCTION..4-2 JET6000/7000N ENGINEERING MODE GUIDE........4-3 JET7000E ENGINEERING MODE GUIDE..........4-4...
  • Page 3 7 : P A R T S R E P L A C E M E N T RUNNING BELT / DECK / ROLLER............7-1 MOTOR......................7-2 INCLINE MOTOR (JET6000)..............7-3 CONSOLE CABLE (JET6000)...............7-4 MOTOR BEARINGS & CARBON BRUSH..........7-5 GEAR MOTOR (JET7000 SERIES)............7-6 CONSOLE CABLE (JET7000 SERIES)..........7-7 CONSOLE CONTROL BOARD............7-8 KEY-PAD.......................7-9 ELEVATION RACK (JET7000/N)............7-10 CHAIN (JET7000/N)................7-11...
  • Page 4 SECTION 1 MAINTENANCE PROCEDURE Revision: 1.0 Date: 2001-06-01...

  • Page 5: Preventive Maintenance Schedule

    PREVENTIVE MAINTENANCE SCHEDULE JOHNSON TREADMILL Item Daily Weekly Monthly Quarterly Biannual Annual Console Mounting Inspect Bolts Frame Clean Inspect Clean Running Belt Top Inspect (Vacuum) #3 Carbon Brush Inspect Replace Power Cord Inspect Display Console Clean Inspect Handlebar Clean Inspect Handrail &...

  • Page 6: Tensioning The Belt Procedure

    TENSIONING THE BELT Caution: Running Belt: Over-tightening of If when you plant your foot on the belt, you can the roller will feel a slipping sensation then the belt has stretched and severely shorten the is slipping across the rollers. This is a normal and life of the belt and common adjustment on a new treadmill.

  • Page 7: Deck Re-Waxing Procedure

    DECK RE-WAXING PROCEDURE Frequency: Procedure: 1. After removing the running belt, clean the deck and Every 1 month. belt by using a clean towel. 2. Place the (new) running belt. 3. Place some wax on the deck about 10 cm from the edge, in such that the wax is evenly distributed across the deck.

  • Page 8: Clean The Grooves Procedure

    CLEAN THE GROOVES PROCEDURE Frequency: Procedure: Every 3 months. Remove the drive belt and check the grooves in belt for dirt or dust and clean If dirty grooves in the drive belt, motor and roller pulley, there will be noises while running. Check the grooves in motor pulley for dirt or dust...

  • Page 9: Section 2: Important Safety Instructions

    SECTION 2 IMPORTANT SAFETY INSTRUCTIONS Revision: 1.0 Date: 2001-06-01...

  • Page 10: Grounding Instructions

    IMPORTANT SAFETY INSTRUCTIONS Note: When using an electrical product, basic precautions should This product must always be followed, including the following: be grounded GROUNDING INSTRUCTIONS This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electrical current to reduce the risk of electrical shock.
  • Page 11 SECTION 3 WIRING DIAGRAM INSTRUCTION Revision: 1.0 Date: 2001-06-01...

  • Page 12: Wiring Diagram (Terminal End, Ce)

    WIRING DIAGRAM (TERMINAL END, CE) Ø I1-----A2 Ø E1-----B1 Ø I2-----A3 Ø E2-----Ground Ø A1-----C1 Ø E3-----D2 Ø A4-----C2 Ø B2-----D4 Ø C3-----AC1 of MCB Ø D1-----I3 Ø C4-----AC2 of MCB Ø D3-----I4 Ø I5-----Ground Revision: 1.0 Date: 2001-06-01...

  • Page 13: Wiring Diagram (Terminal End)

    WIRING DIAGRAM (TERMINAL END) Ø E1-----B1 Ø E2-----GROUND Ø E3-----D2 Ø D4-----B2 Ø D1-----AC1 of MCB Ø D3-----AC2 of MCB Revision: 1.0 Date: 2001-06-01...

  • Page 14: Wiring Diagram (Mcb)

    WIRING DIAGRAM (MCB) Ø A1-----Motor wire (red) Ø A2-----Motor wire (black) Ø P1-----V.R. wire (except the JET7000E) Ø P2-----Sensor wire Ø P3-----8-pin console cable Ø P4-----6-pin console cable Ø UP-----Incline (yellow) (except the JET7000E) Ø Down-----Incline (white) (except the JET7000E) Ø...

  • Page 15: Console Engineering Mode Guide

    SECTION 4 CONSOLE ENGINEERING MODE GUIDE Revision: 1.0 Date: 2001-06-01...
  • Page 16 JET-7000 (Old) Console Engineering Mode Guide 1 Press Slow, Down, and RESET keys simultaneously to enter Engineering Mode. To set up the 2 While the display read "CAL-HI", press PROGRAM system INTERVAL. The display will show C1. Please parameters: press Fast or Slow keys to set and then press Up key to set C2-C6.(refer to table 1)
  • Page 17 Console Engineering Mode Guide JET-7000 (Old) u If the distance between the front bottom edge of the frame and the floor does not meet the specifications either at the maximum or minimum incline, you have to adjust the location of the related limit switch to calibrate the incline to Spec.
  • Page 18 Total "TIME" & "DISTANCE" Instruction JET-7000 (Old) When you press Safety key and release (for ver 0.3, press down FAST & UP key) then, the display shows: TIME-WINDOW HEART RATE-WINDOW DISTANCE/CALORIES XXXX SPEED/INCLINE u The content in the TIME-WINDOW indicates the accumulated running hours of the treadmill.
  • Page 19 Console Engineering Mode Guide JET-6000/7000NEW Holding “UP” & “SLOW” keys simultaneously about 5 seconds to enter Engineering Mode. The Display will be showed "P6" . Press “SELECT” key then press “SLOW” or “FAST” to set metric(kph) British(mph) . Press “SELECT” key to store. 3 Press “DOWN”...
  • Page 20 Console Engineering Mode Guide JET-7000E Press “SLOW” , “STOP” keys simultaneously about 5 seconds to enter Engineering Mode. The Display will be showed "P6" . Press “SELECT” key then press “SLOW” or “FAST” to set metric(kph) British(mph) . Press “SELECT” key to store. Press “STOP”...

  • Page 21: Section 5: Mcb Led Instructions

    SECTION 5 MCB LED INSTRUCTIONS Revision: 1.0 Date: 2001-06-01...

  • Page 22: Mcb Led Indication

    MCB LED Indication When we designed the lower control board (MCB) for our treadmills we placed status lights (LEDs) on it to aid in field diagnosis and repair. The following is an overview of what these indicator lights mean and what can be checked with them in the field.
  • Page 23 MCB LED Indication MOTOR Light- When lit, indicates the Start Note: key has been pressed and the K1 relay Motor power has been activated, which will then allow the AC power to be present to the control board with the two big capacitors on it. If the MOTOR light is not lit after the Start key has been pressed, check the keypad, the 8-pin cable and the interconnection of the wiring mentioned above.
  • Page 24 MCB LED Indication Light- Indicates the PCB is commanding the incline Note: gear to move up. If the User is commanding the incline The incline is being to increase and this light is not lit, check cabling, verify proper PCB commanded up operation and replace it if either is defective.

  • Page 25: Pwm Mcb Led Chart

    PWM MCB LED CHART 115V +12V ILT1 ILT2 M.C.SIG DOWN OFF OR BLINKING ON and BLINKING COMES ON BRIEFLY & THEN SHUTS Revision: 1.0 Date: 2001-06-01...
  • Page 26 MCB LED-AIDED TROUBLESHOOTING CHART PROBLEM/RESULT CORRECTIVE ACTION Verify connections, power switch and circuit No operation of MCB or PCB breaker. No operation of MCB or PCB Replace MCB PCB will not power up Replace MCB Verify adequate line voltage. If line voltage is PCB will power up but the MCB adequate, MCB is damaged and needs to be will not operate...
  • Page 27 SECTION 6 TROUBLESHOOTINGS Revision: 1.0 Date: 2001-06-01...

  • Page 28: No Display On Console

    No display on console Possible causes: Fix: 1. Breaker is damaged. 1. ( refer to MCB LED layout & indication) Verify if LED 115vAC(AC) is lit. If this LED is lit, go to step 2. 2. ON/OFF switch is If LED 115vAC(AC) is not lit, verify the following: damaged.

  • Page 29: Running Speed Is Not Stable

    Running speed is not stable Possible causes: Fix: 1. AC power voltage is 1. Check the power voltage by using voltage-meter to too low. 2. Tension of drive belt or running belt is too loose. 3. Poor adjustment of MCB. see if it is within 120V+-15% or 230V+-15%.

  • Page 30: Treadmill Starts To Run By Itself

    Treadmill starts to run by itself Possible causes: Fix: 1. The console cable is 1. Replace the console cable with a new one. broken. 2. Replace the PCB. 2. PCB is out of order. 3. Replace the MCB. 3. MCB is out of order. Revision: 1.0 Date: 2001-06-01...
  • Page 31 All or some of the keys on console do not work Possible causes: Fix: 1. Keypad connecting 1. Disconnect the keypad and replace the keypad, plug is not fit-in and check again. properly. 2. Replace the keypad. 2. Keypad is damaged. 3.

  • Page 32: Noise Generated Under Motor Cover

    Noises generated under motor cover Possible causes: Fix: 1. The running belt 1. Adjust the belt tension so that the belt does not tension is adjusted too start slipping and then check if the noise has tight. disappeared. 2. The bearing of front roller is not installed correctly.

  • Page 33: Treadmill Will Not Start

    Treadmill will not start Possible causes: Fix: 1. MCB is damaged. Open motor cover, verify wire connection A1 and A2 (motor wire) on the MCB then plug in the power cord 2. 6-pin console cable and turn on the power switch. Then press “POWER, is damaged.

  • Page 34: Heart-Rate-Control Function Does Not Work

    Heart-Rate-Control function does not work Possible causes: Fix: 1. Transmitter does not Center the contact with user's transmitter on your chest very well. chest below the pectoral muscle(breast) 2. Transmitter(Polar- as shown, then check again. belt) is at low battery status.

  • Page 35: Treadmill Will Not Incline Up Or Down

    Treadmill will not incline up or down Possible causes: Fix: 1. Enter to Engineering Mode to see if the incline 1. The incline settings motor will be activated. are not correct. 2. The 8-pin console Use a new 8-pin console cable to connect cable is damaged.

  • Page 36: Treadmill Will Incline Up Or Down By Itself

    Treadmill will incline up or down by itself Possible causes: Fix: 1. The 8-pin console 1. Use a new 8-pin console cable to connect PCB to cable is damaged. MCB. Then turn the power on, press "POWER, START, UP, DOWN" keys to see if this fix the 2.

  • Page 37: Treadmill Varies The Speed By Itself

    Treadmill varies the speed by itself Possible causes: Fix: 1. Keypad is stuck. 1. Remove the keypad and verify the keypad is stuck. If it is stuck, replace with a new keypad. 2. PCB is damaged. 3. Grounding 2. If speed or incline still changes by itself, replace the PCB and refer to "Engineering Mode Guide"...

  • Page 38: Error Message On Console

    Engineering Mode parameter values • Re-plug or replace the Incline Motor(Jet6000) • Re-plug or replace the VR(Jet7000) Err3 VR is open loop or short • Re-plug or replace the 8-pin console cable • MCB or PCB is damaged No elevating after press the “up”...
  • Page 39 SECTION 7 PARTS REPLACEMENT PROCEDURE Revision: 1.0 Date: 2001-06-01...
  • Page 40 RUNNING BELT/DECK/ROLLER REPLACEMENT Tools required: Procedure: ü Philips screwdriver 1. Remove the screws from the front cover ü T-handle key by using the (8mm,5mm) screwdriver. 2. Remove two rear covers from the end of the side rails. 3. Pull out the two side rails.

  • Page 41: Section 7 : P A R T S R E P L A C E M E N T O Running Belt / Deck / Roller

    RUNNING BELT/DECK/ROLLER REPLACEMENT Tools required: Procedure: ü Philips 5. Turn the flywheel screwdriver counterclockwise by using your left hand and pull out ü T-handle key the drive belt from the (8mm,5mm) wheel by using your right hand. 6. Remove the bolts from the front and rear rollers by using the T-handle key (8mm).
  • Page 42 RUNNING BELT/DECK/ROLLER REPLACEMENT Tools required: Procedure: ü Philips screwdriver 12. Replace the deck and put the old running belt through the deck and place the deck with the running belt on ü T-handle key the frame. (Go to step 14.) (8mm,5mm) 13.

  • Page 43: Motor

    MOTOR PLACEMENT Tools required: Procedure: ü Philips screwdriver 1. Remove screws from the front cover by using the screwdriver and remove it. ü T-handle wrench 2. Remove cables connecting to the motor and lower board, (14mm) remove also the ground wire by using the screwdriver. 3.

  • Page 44: Incline Motor (Jet6000)

    INCLINE MOTOR REPLACEMENT (JET6000) Tools required: Procedure: ü Philips screwdriver 1. Remove screws from the front cover by using ü Wrench (14mm) the screwdriver to open the cover. ü Wrench ( 17mm) 2. Disconnect cables from the connectors of the incline motor and MCB and also disconnect the ground wire.

  • Page 45: Console Cable Replacement

    CONSOLE CABLE REPLACEMENT (JET6000) Tools required: Procedure: 1. Remove screws from the ü Philips screwdriver motor cover by using the screwdriver. ü T-handle key (5mm). 2. Remove screws from the right support with the T- handle key (5mm). 3. Remove the screws from the console cover. 4.

  • Page 46: Motor Bearings & Carbon Brush

    MOTOR BEARINGS & CARBON BRUSH REPLACEMENT Tools required: Procedure: 1. Remove the screws of ü Nutdriver carbon brush cover and the (5/16inch) carbon brushes with the coin. ü Bearing puller 2. Check the surface of carbon brush if smooth. ü Wooden- If the surface of carbon brush hammer...
  • Page 47 MOTOR BEARINGS & CARBON BRUSH REPLACEMENT Tools required: Procedure: ü Nutdriver (5/16inch) ü Bearing puller ü Wooden hammer 6. Remove the bearings of both sides by using the bearing puller. 7. Install the new bearings to the shaft by using the wooden hammer.
  • Page 48 GEAR MOTOR REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips 1. Release screws of front screwdriver cover by using screwdriver to open the cover. ü T-handle key (14mm) ü Ratchet Box 2. Disconnect remove cables from the Gear motor and lower Wrench (11mm) board and also disconnect the ground wire.
  • Page 49 GEAR MOTOR REPLACEMENT (JET-7000 series) Tools required: Procedure: 5. Install the chain onto main chain wheel and tighten the ü Philips fixed bolts of gear motor. Use Ratchet Box wrench screwdriver (11mm) to adjust the chain-tension-screw, which is located at the back end of the gear, motor. ü...

  • Page 50: Console Cable (Jet7000 Series)

    CONSOLE CABLE REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips screwdriver 1. Remove screws from the front cover by using ü T-handle key the screwdriver and (5mm). remove it. 2. Use the T-handle key (5mm) to remove screws of the left handle bar and remove it.
  • Page 51 CONSOLE CABLE REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips screwdriver ü T-handle key (5mm). 6. Remove the left stanchion protrusion out and pull out both cables. 7. Install the new cable into the left stanchion protrusion. 8. Install the stanchion protrusion onto the stanchion. 9.
  • Page 52 PCB REPLACEMENT Tools required: Procedure: ü Philips screwdriver 1. Use screwdriver to loosen the screws of ü Nutdriver (6mm) console base plate. 2. Disconnect the console cables from the PCB. 3. Use the Nutdriver (6mm) to loosen the screws holding the PCB to the base to remove the PCB.

  • Page 53: Key-Pad

    KEYPAD REPLACEMENT Tools required : Procedure: ü Philips screwdriver 1. With the screwdriver loosen the screws from the console base cover. 2. Disconnect the plug of keypad from the PCB. 3. Remove the safety key and the overlay. 4. Replace with a new keypad and connect it with PCB. 5.

  • Page 54: Elevation Rack (Jet7000/N)

    ELEVATION RACK REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips 1. Turn on the power and keep the incline at the minimum screwdriver elevation. Then turn off the power. ü T-handle 2. Remove the front cover. key(5mm) 3. Disconnect console cables from the MCB.
  • Page 55 ELEVATION RACK REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips screwdriver ü T-handle key(5mm) 7. Remove the elevation rack. Then remove the C clip of the transportation wheel to remove the transportation wheel. 8. Attach the new elevation rack on to the transportation wheel and attach C clip, then attach the elevation rack onto the incline gear and install the covers.
  • Page 56 CHAIN REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips 1. Turn on power and keep the incline at the minimum screwdriver elevation. Then turn off power. ü T-handle 2. Remove the front cover. wrench(14mm) ü Ratchet Box Wrench (11mm) To prevent the frame from falling down heavily while replacing the chain, please put a support with proper height (9cm) under the front of frame before replacement.

  • Page 57: Chain (Jet7000/N)

    CHAIN REPLACEMENT (JET-7000 series) Tools required: Procedure: ü Philips screwdriver ü T-handle wrench(14mm) ü Ratchet Box Wrench (11mm) 5. Remove the chain latch to separate and then take out the chain. 6. Install the chain onto main chain wheel in such the way that the minimum elevation control dog touches the minimum elevation limit switch.

  • Page 58: Section 8: Service Form

    SECTION 8 SERVICE FORM Revision: 1.0 Date: 2001-06-01...

  • Page 59: Mcb Led Status Report

    LED Off : LED Off: LED Dim: LED Off : *ILT1 Light (JET7000) * ILT2 Light (JET7000) LED On : LED On : LED Off: LED Off : When you press the UP or DOWN key, the LED status is :...

  • Page 60: Field Failure Report

    Field Failure Report Name of Distributor : … … … … … … … … Report # … … … … … … … ..Warranty ( ) Yes ( ) No Failure ( ) Intermittent ( ) Persistent Product : … … … … … … … … … Serial number: …...
  • Page 61 Parts Order Distributor: … … … … … … ..….. Order # … … … … … … … … … … … Delivery Terms: ( ) CIP ..... Delivery Address: ( ) FCA ( ) FOB ..................................

  • Page 62: Warranty Claim Form

    Warranty Claim Form Claim no: ......Dealer Name: ..........Page ..of ...Pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS # AUTHORIZED BY: ......Revision: 1.0 Date: 2001-06-01...

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Jet6000

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