Johnson C7000 Service Manual
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Johnson C7000 Service Manual

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C7000 Service Manual
Revision: 1.0 Date: 2004/7/25

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Summary of Contents for Johnson C7000

  • Page 1 C7000 Service Manual Revision: 1.0 Date: 2004/7/25...
  • Page 2 TABLE OF CONTENTS SECTION 1: LIMITED WARRANTY SECTION 2: EXPLODED DIAGRAM SECTION 3: WIRING DIAGRAM SECTION 4: TROUBLE SHLOOTING SECTION 5: PARTS REPLACEMENT SECTION 6: PREVENTIVE MAINTENANCE APPENDIX : RECOMMENDED TOOLS...
  • Page 3 SECTION 1 LIMITED WARRANTY Comments and Questions Scope of Warranty Intended Use Warranty Time Period Defects Replacement Safety Stock of Warranty Parts Defects Return Procedure Technical Support...

  • Page 4: Limited Warranty

    Limited Warranty Johnson Health Technology Company and its employees are committed to providing our customers with the state-of-art designed and manufactured fitness equipment. This Limited Warranty and Service Procedure states JHT’s warranty policy and warranty procedures. Comments and Questions We welcome comments and questions regarding our products. Please contact us at...
  • Page 5 The distributor should send out the replacement parts without charge within 24 hours for any customer’s warranty claim due to defects of JHT workmanship or materials and the defects occurs during the warranty period. The distributor should also send out the replacement with charge within 24 hours for the service claims due to accident, abuse, neglect, or for the claims with the warranty expired.
  • Page 6 Defective Mechanical Components/Accessories: To receive a credit or the free replacement parts for the defective mechanical component under warranty, simply fill out a warranty claim form attached with the photo, graph or other media that could show us the outlook of the failure. Send all the information to JHT for approval.
  • Page 7 SECTION 2 EXPLODED DIAGRAM CONTENTS C7000 EXPLODED DIAGRAM...
  • Page 8 C7000 EXPLODED DIAGRAM...
  • Page 9 SECTION 3 WIRING DIAGRAM CONTENTS CONTROL BOARD WIRING DIAGRAM WIRING DIAGRAM...
  • Page 10 CONTROL BOARD WIRING DIAGRAM A1 : 3-pin terminal to the generator A2 : 2-pin terminal to the electromagnet A3 : 4-pin terminal to the console...
  • Page 11 WIRING DIAGRAM...

  • Page 12: Troubleshooting

    SECTION TROUBLESHOOTING Pedal speed has to be over 30 rpm CONTENTS No display on the console or the display is dim o RPM is displayed during the exercise ll or some of the function keys do not response Feel the resistance increase/decrease or fell no resistance Feel slipping while pedaling nocking or creaking noise o pulse is displayed on console...
  • Page 13 註解: No display on t he console or the display is di Possible causes: 1. Console is damaged or First, Check if the adapter is connected properly the console cable is not both input & output ends . Re move the console, then connected properly.
  • Page 14 註解: No RPM is displayed during the exercise Possible causes: Fix: 1. Console cable is 1. Remove the console and check if the terminal of damaged or the console console cable is connected properly to the console. cable is not connected If it is not connected well.
  • Page 15 All or some of the function keys do not respond Possible causes: Fix: 1. Remove the console cover, and then check if 1. Keypad connecting keypad cable is connected properly to the upper plug has been not board. fit-in properly. If it has not been connected well, reconnect it to the terminal and check again.
  • Page 16 Feel the resistance increase/decrease suddenly or feel no resistance Possible causes: Fix: 1. Console is damaged or the console cable 1. Remove the console and check if the console is not connected cable has been connected properly. properly 2. Console cable is damaged, replace it with a new 2.
  • Page 17 Feel slipping while pedaling Possible causes: Fix: 1 Belt tension is not 1 Re-adjust the belt tension. enough 2 Replace poly v belt with a new one. 2 Poly v Belt is damaged...
  • Page 18 Knocking or creaking noise Possible causes: Fix: 1 Re-tighten it. 1 Pedal is on crank arm too loose 2 Replace it with a new one 2 Crank or axle is wear 3 Re-adjust the belt tension and clean the poly v belt 3 Belt tension is too loose or poly v belt is 4 Clean the rail and roller.
  • Page 19 No pulse display on console (Chest belt type) Possible causes: Procedure: 1. Chest belt is not 1. Place the chest belt in placed properly. the correct position. <Remark 1> 2. Chest belt is damaged. 2. Replace the chest belt with a new one. 3.
  • Page 20 No pulse display on the console (Hand pulse type) Possible causes: Procedure: 1. Remove the console to check if the terminal of hand 1. Connection of hand pulse cable has been connected to PCB well. pulse cable. 2. Hand pulse cable is damaged.
  • Page 21 Console Diagnostics Mode STEP 1 1. Sit (stand) on your bike (stepper), Press and hold down the "RESET” key then (for stepper turn the power on) start pedaling to reach a pedal speed of approximately 30rpm.OR Press and hold down the "RESET” key then plug the STEP 2 adapter (JPE).
  • Page 22 Console Diagnostics Mode 1. Press the ENTER key. SETP 5 2. In the Dot Matrix Display there will be two hearts on it, which will light up completely in turn 3. “STEPS/MINS” windows will show the current heart rate while you are wearing a HAND PULSE SENSOR or POLAR CHEST BELT.
  • Page 23 SECTION SECTION Spare Parts Replacement Spare Parts Replacement Contents Contents GENERAL 5-1 GENERAL 5-1 C7000 C7000...
  • Page 24 SECTION GENERAL Contents CONSOLE CONSOLE CABLE CONTROL BOARD GENERATOR OR ELECTROMAGNET BRAKE SET...
  • Page 25 CONSOLE REPLACEMENT PROCEDURE Tools required: Procedure: Philips screwdriver 1. Loosen the screws (arrow) from the console using the screwdriver. 2. Disconnect the console cables from the console connectors. 3. Replace the console with a new one and reconnect the console cable to the connector.
  • Page 26 CONSOLE CABLE REPLACEMENT PROCEDURE Tools required: Procedure: Philips screwdriver 1. Loosen the screws that hold the console to the console holding bracket. Adjustable wrench 2. Unplug the console cable from the console connectors. hex key(8mm) 3. Remove the upper cover, screw crank extractor 4.
  • Page 27 GENERATOR OR ELECTROMAGNET BRAKE SET REPLACEMENT PROCEDURE Tools required: Procedure: 1. Remove all covers. Philips screwdriver 2. Remove the POLY-V BELT and Hex key (5mm) disconnect the cable from the control board. Ratchet Box Wrench (11mm) 3. Loosen the tension screws and screw from the generator (electromagnet brake set.) 4.
  • Page 28 SECTION Contents CRANK PEDAL POLY-V BELT 400/380J6 POLY-V BELT 500/440J8 AXLE FRONT PULLEY BALL BEARINGS...
  • Page 29 CRANK REPLACEMENT PROCEDURE Tools required: Crank extractor Procedure: Coin 1 Loosen the crank Open-end cover with a coin and wrench remove it. (14&17mm) 2 With the crank extractor and open-end wrench loosen the screw attaching the crank to the axle. 3 Using the crank extractor and open-end wrench to extract the crank then replace it with a new one.
  • Page 30 PEDAL REPLACEMENT PROCEDURE Tools required: Procedure: Open-end wrench(15 1 Using the open-end wrench loosen the screws attaching the pedal to the crank. 2 Replace the pedal with a new one.
  • Page 31 POLY V BELT400/380J6 REPLACEMENT PROCEDURE Tools required: Procedure: 1. Remove the crank cover and screw, then remove the Philips screw crank. Loosen the screws from the side cover with driver the screwdriver, then remove the footpad, guard and side cover. Hex key (4mm) 2.
  • Page 32 POLY V BELT 500/440 J8 REPLACEMENT PROCEDURE Tools required: Philips Procedure: screwdriver Remove the crank cover Hex key and screw, then rem (4mm) the crank. (Refer to section 5-2.1). Loosen Open end the screws from the side wrench cover with the (14mm) screw driver, then...
  • Page 33 AXLE REPLACEMENT PROCEDURE Tools required: ocedure: Remove the crank cov Philips and screw, then remove screwdriver the crank. Loose n the screws from the side Hex key (4mm) cover with the screwdriver, th en remove C-Clip Pliers the footpad, guard and side covers.
  • Page 34 PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT PROCEDURE ools required: Pr cedure: Philips screwdriver Remove the crank cover and screw, then remove the crank. Loosen the screws from the side cover with C-clip pliers the screwdr iver, then remove footpad, guard and side cover. Crank extractor Loosen the screw (A) and remove it (for th axle-pulley assembly of the new design).
  • Page 35 PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT PROCEDURE Tools required: Procedure: Philips screwdriver 5. Remove the c-clip (C) by using the c-clip pliers and remove the metal pulley from the generator using C-clip pliers the Bearing Puller. Crank extractor 6. Remove the c-clip (D) by using the c-clip pliers and remove the idler using the Bearing Puller.
  • Page 36 BEARING REPLACEMENT PROCEDURE Tools required: Procedure: Philips 1. Loosen the screws from screwdriver the side covers with the screwdriver then remove Hex key (4mm) crank using pulley (refer to section 5-2.1). Loosen Bearing puller the screws from the side cover with the C-Clip pliers screwdriver, then remo footpad, guard and side...
  • Page 37 BEARING REPLACEMENT PROCEDURE Tools required: rocedure: Philips screwdriver Remove the C-clip (c) with the C-Clip Plier Hex key (4mm) and then remove the pulley Assembly b Bearing puller using th e Bearing Puller. C-Clip pliers If the Ball Bearing failed, rep lace pulley Wooden hammer assembly.
  • Page 38 SECTION MAINTENANCE PROCEDURE CONTENTS CLEANING THE GROOVES...

  • Page 39: Cleaning The Grooves

    CLEANING THE GROOVES Frequency: Procedure: Every 3 to 4 months. Remove the Poly-V belts and check the grooves of the belt for dirt or dust and clean it if any. If there is any dust in the grooves of the Poly-V belts and pulleys, noises will be generated during operation..
  • Page 40 APPENDIX RECOMMENDED TOOLS A: OPEN-END WRENCH (17mm) B: OPEN-END WRENCH B C D E F (14mm) C: RATCHET BOX WRENCH (11mm) D: PHILIPS SCREWDRIVER E: SLOTTED SCREWDRIVER F: CRANK EXTRACTOR G: MULTIMETER HEX KEYS 1.5, 2, 2.5, 3, 4, 5, 5.5, 6, 8, 10 (mm)
  • Page 41 1 WOODEN HAMMER 2 BEARING PULLER 3 C-CLIP PLIERS 4. C-CLIP PLIERS APPENDIX...

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