Johnson E7000 Service Manual
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Johnson E7000 Service Manual

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E7000 Service Manual
2004/08/29 Ver-1

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Summary of Contents for Johnson E7000

  • Page 1 E7000 Service Manual 2004/08/29 Ver-1...
  • Page 2 TABLE OF CONTENTS SECTION 1: LIMITED WARRANTY……………………………………..1-1 SECTION 2: EXPLODED DIAGRAM…………………………………….2-1 SECTION 3: WIRING DIAGRAM…………………………………………3-1 SECTION 4: TROUBLE SHLOOTING…………………………………...4-1 SECTION 5: PARTS REPLACEMENT……………………………………5-1 SECTION 6: PREVENTIVE MAINTENANCE…………………………...6-1 APPENDIX : RECOMMENDED TOOLS...

  • Page 3: Table Of Contents

    SECTION 1 LIMITED WARRANTY Comments and Questions………...………..……..………...1-2 Scope of Warranty…………………….…...…………1-2 Intended Use………………………..……..….……….1-2 Warranty Period………..………..…………….1-3 Defects Replacement…………………………...………….1-3 Safety Stock of Warranty Parts………………………..1-3 Warranty Procedure………………..………………..1-3 Technical Support..............1-4...

  • Page 4: Comments And Questions

    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: Warranty Period

    Generally, if not otherwise specified, JHT provides one and a half year warranty for all JHT products starting from the date of production. Warranty coverage for each product will be detailed in the respective product owner’s manual. 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.

  • Page 6: Technical Support

    defective electronics back to JHT in a routine basis (monthly is preferred). Fill out the warranty claim form and send it to JHT. Defective motors: The distributor may choose by himself the disposition of the failed motors under warranty. You can either send the motors to your local motor manufacturer’s authorized dealer for repair or you can remove the name plate, attaching a label on it to identify the failure symptom and send it back to JHT on a routine basis (monthly is preferred).
  • Page 7 SECTION 2 EXPLODED DIAGRAM CONTENTS EXPLODED DIAGRAM….…………..….………………....2-2...
  • Page 9 SECTION 3 WIRING DIAGRAM CONTENTS CONTROL BOARD WIRING DIAGRAM….…………..….………………...3-2...

  • Page 10: Control Board Wiring Diagram

    E 7000 CONTROL BOARD WIRING DIAGRAM A1 : 3-pin terminal to the electromagnet brake set A2 : 2-pin terminal to the adapter A3 : 3-pin terminal to the console grounding wire to frame...
  • Page 11 SECTION TROUBLE SHOOTING Pedal speed has to be over 30 rpm CONTENTS No display on the console or the display is dim……..…………..…..4-2 No RPM is displayed during the exercise ..…………..………..4-3 Feel slipping while pedaling………………………………………..4-4 Knocking or creaking noise………………………………………….….4-5 No pulse is displayed on the console (Chest belt type)…………………..……4-6 No pulse is displayed on the console (Handle pulse type).……………….…...4-7 Console diagnostics mode…………..………………………………………..4-8...

  • Page 12: No Display On The Console Or The Display Is Dim

    註解: No display on the console or the display is di Possible causes: Fix: 1. Console is damaged or 1. First, Check if the adapter is connected properly for the console cable is not both input & output ends. Remove the console, then connected properly.

  • Page 13: No Rpm Is Displayed During The Exercise

    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 14: Feel Slipping While Pedaling

    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 Adjust it...

  • Page 15: Knocking Or Creaking Noise

    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 16 No pulse display on console (Chest belt type) Possible causes: Procedure: 1. Chest belt is not placed properly. 1. Place the chest belt in the correct position. 2. Chest belt is <Remark 1> damaged. 2. Replace the chest belt 3. Console is damaged. with a new one.
  • Page 17 No pulse display on the console (Hand pulse type) Possible causes: Procedure: 1. Connection of hand 1. Remove the console to check if the terminal of hand pulse cable. pulse cable has been connected to PCB well. 2. Hand pulse cable is damaged.

  • Page 18: Console Diagnostics Mode

    Console Diagnostics Mode STEP 1 Sit on your bike, Press and hold down the "RESET” key then start pedaling to reach a pedal speed of approximately 30rpm. Dot Matrix Display will be scanned slowly starting from LEDs of the bottom row to the top; each segment of the 7-segments will be scanned simultaneously STEP 2 If one of LEDS is not lit, replace the PCB.
  • Page 19 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 20: Section 5: Parts Replacement

    SECTION Spare Parts Replacement CONSOLE........………..........5-2 CONSOLE CABLE.........………........5-3 CONTROL BOARD..........………......5-4 GENERATOR OR ELECTROMAGNET BRAKE SET........5-5 CRANK..............……….…………..5-6 PEDAL............………..………..……....5-7 POLY-V BELT 430J6..........………..…….5-8 POLY-V BELT 430J12..........……….....5-9 PULLEY AXLE…………………....……………………...…..……….…5-10 AXLE…………………………………………..……...…………………….5-11 RPLLER…………………………………………………….…………………...5-12 SENSOR………………………………………………..……..………...………..5-13...

  • Page 21: Console

    CONSOLE REPLACEMENT PROCEDURE Tools required: Procedure: Philips 1. Loosen the screws (arrow) from the console using the screwdriver 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. 4.

  • Page 22: Console Cable

    CONSOLE CABLE REPLACEMENT PROCEDURE Tools required: Procedure: Philips 1. Loosen the screws that screwdriver hold the console to the console holding bracket. Adjustable 2. Unplug the console wrench cable from the console connectors. hex key(8mm) 3. Remove the upper cover, crank extractor screw coin...
  • Page 23 CONTROL BOARD REPLACEMENT PROCEDURE Tools required: Procedure: Fig.1 Philips 1. Remove the rear screwdriver (see fig. 1) or side cover, then the crank Crank extractor (for JPC/B/S) Control board Coin 2. Disconnect all the cables from the Adjustable control board. wrench 3.

  • Page 24: Generator Or Electromagnet Brake Set

    GENERATOR OR ELECTROMAGNET BRAKE SET REPLACEMENT PROCEDURE Tools required: Procedure: 1. Remove all covers. Philips screwdriver 2. Remove the POLY-V BELT and disconnect the cable Hex key (5mm) from the control board. Ratchet Box Wrench 3. Loosen the tension (11mm) screws and screw from the generator (electromagnet...

  • Page 25: Crank

    CRANK REPLACEMENT PROCEDURE Tools required: Procedure: Puller 1 Remove the joint screw between handlebar and handrail links. Wooden 2 Remove all of the covers. hammer 3 Remove the nut(A) then pull the Hexagonal crank and pedal set out socket wrench (19&13mm) 4 Remove the c-clip (B) then with wooden hammer tap the crank...

  • Page 26: Pedal

    PEDAL REPLACEMENT PROCEDURE Tools required: Procedure: Philips screwdriver 1 Tear down the rubber footpad and clean it Two-faced masking tape 2 Remove screw (A) then replace pedal with a new one. 3 Attach the rubber footpad.

  • Page 27: Poly-V Belt 430J6

    POLY V BELT 430J6 REPLACEMENT PROCEDURE Tools required: Procedure: 1 Remove all covers. (Except the Philips right cover). screwdriver 2. Loosen the 430J6 belts then hex key replace it with a new one. (6 mm) Install the side covers and the parts Hexagonal socket wrench...

  • Page 28: Poly-V Belt 430J12

    POLY V BELT 430 J12 REPLACEMENT PROCEDURE Tools required: Procedure: 1 Remove all of the covers. (except the left cover). Philips screwdriver 2 Remove the pedal arm and crank 3 Loosen the screws then Hex key (6mm) remove poly v belt and replace it with a new Hexagonal socket wrench...

  • Page 29: Pulley Axle

    PULLEY AXLE REPLACEMENT PROCEDURE Tools required: Procedure: 1 Remove all of the covers Philips and poly v belts. screwdriver 2 Remove the screw (A) and Hex key washer (6mm) 3 Pull pulley (B) out then C-Clip Pliers knock axle set out with the wooden hammer.

  • Page 30: Axle

    AXLE ASSEMBLY REPLACEMENT PROCEDURE Tools required: Procedure: 1 Remove all of the covers. Philips screwdriver 2 Loosen the nut (A) and remove it ,another side is same C-clip pliers 3 Loosen the tension adjustment screw of idler pulley, then remove the poly v belt puller 4 Follow the Hex key (6mm)
  • Page 31 ROLLER REPLACEMENT PROCEDURE Tools required: Procedure: Philips 1. Remove the all of cover. screwdriver 2. Move the pedal arm back Hex key (4mm) then pick up it. 3. Loosen the screw (A) holding the wheel to the frame with the hex key (4mm), and then replace it with a new one.

  • Page 32: Sensor

    SENSOR REPLACEMENT PROCEDURE Tools required: Procedure: 1. Remove the rear cover. Philips screwdriver 2. Disconnect the sensor cable from the control board. Hex key (5mm) 3. Loosen the screws that hold the sensor to the frame. Ratchet Box Wrench (11mm) 4.
  • Page 33 SECTION MAINTENANCE PROCEDURE CONTENTS CLEANING THE GROOVES…………….…...…...………6-2 C L E A N I N G T H E R A I L A N D R O O L E R … … … … … … ..6 - 3...
  • Page 34 CLEANING THE GROOVES Frequency: Every 3 Procedure: to 4 months. Remove the Poly-V belts and check the grooves of the belt for dirt or dust and clean If there is any dust in the it if any. grooves of the Poly-V belts and pulleys, noises will be generated during operation..
  • Page 35 CLEANING THE RAIL AND ROLLER Frequency: Every 1-2 months. (For club) Every 6 months. (For home) Clean here Procedure: 1. Remove the roller plate cover. 2. Clean the rail and roller.
  • Page 36 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 37 1 WOODEN HAMMER 2 BEARING PULLER 3 C-CLIP PLIERS 4. C-CLIP PLIERS...

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