TABLE OF CONTENTS n SECTION 1: WIRING DIAGRAM CONTROL BOARD WIRING DIAGRAM (JPC/B-5100)......1-1 CONTROL BOARD WIRING DIAGRAM (JPS-5100)........1-2 CONTROL BOARD WIRING DIAGRAM (JPE-5100)........1-3 CONSOLE BACKSIDE (EAR CLIP SENSOR)...........1-4 CONSOLE BACKSIDE (HAND PULSE)...........1-5 WIRING DIAGRAM (JPC/B-5100).............1-6 WIRING DIAGRAM (JPS-5100)..............1-7 WIRING DIAGRAM (JAR-5100)..............1-8 WIRING DIAGRAM (JAE-5100)..............1-9 n SECTION 2: TROUBLESHLOOTINGS JPC/B/S/E-5100...
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TABLE OF CONTENTS n SECTION 3: PARTS REPLACEMENT GENERAL (JPC/B/S/E) CONSOLE..................3-1 CONSOLE CABLE..............3-2 CONTROL BOARD..............3-3 GENERATOR OR ELECTROMAGNET BRAKE SET....3-4 JPC/B-5100 CRANK....................3-5 PEDAL....................3-6 POLY-V BELT 400/380J6..............3-7 POLY-V BELT 500/440J8..............3-8 AXLE..................3-9 FRONT PULLEY...............3-10 BALL BEARINGS................3-11 JPS-5100 POLY-V BELT 430J6...............3-12 POLY-V BELT 430J8...............3-13 CHAIN OR SPRING..............3-14 SENSOR....................3-15 FOOT PAD....................3-16...
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TABLE OF CONTENTS n SECTION 4: PREVENTIVE MAINTENANCE CLEANING THE GROOVES............4-1 ¨ RE-LUBRICATING THE CHAIN & GEAR (for JPS)....4-2 ¨ CLEANING THE RAIL AND ROOLER(JPE5100)......4-3 ¨ n SECTION 5: SERVICE FORM FIELD FAILURE REPORT............5-1 PARTS ORDER FORM..............5-2 WARRANTY CLAIM FORM............5-3 Revision: Date: 2001/06/01...
JPC/B-5100 CONTROL BOARD WIRING DIAGRAM Ø A1 : 3-pin terminal to the generator Ø A2 : 2-pin terminal to the electromagnet Ø A3 : 4-pin terminal to the console Revision: Date: 2001/06/01...
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JPS-5100 CONTROL BOARD WIRING DIAGRAM Ø A1 : 3-pin terminal to the generator Ø A2 : 2-pin terminal to the electromagnet Ø A3 : 2-pin terminal to the output of the adapter Ø A4 : 4-pin terminal to the console Revision: Date: 2001/06/01...
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JPE-5100 CONTROL BOARD WIRING DIAGRAM Ø A1 : 3-pin terminal to the electromagnet brake set Ø A2 : 2-pin terminal to the adapter Ø A3 : 3-pin terminal to the console Ø A4: grounding wire to frame Revision: Date: 2001/06/01...
CONSOLE BACKSIDE (HAND PULSE) Ø A : console cable -> MCB A4 Ø B : hand pulse cable (right) Ø C : hand pulse cable (left) Ø D : console power switch Revision: Date: 2001/06/01...
No display on the console or the display is di (JPC/B/S/E) 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 (for JPS/JPE).
No RPM is displayed during the exercise (JPC/B/S/E) 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. u If it is not connected well. cable is not connected Ø...
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All or some of the function keys do not respond (JPC/B/S/E) Possible causes: Fix: 1. Keypad connecting 1. Remove the console cover, and then check if plug has been not fit- keypad cable is connected properly to the upper in properly. board.
Feel the resistance increase/decrease suddenly or feel no resistance (JPC/B/S) Possible causes: Fix: 1. Console is damaged 1. Remove the console and check if the console or the console cable cable has been connected properly. is not connected properly 2. Console cable is damaged, replace it with a new one.
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Feel the resistance increase/decrease suddenly or fell no resistance (JPE5100) Possible causes: Fix: 7. Console is damaged 8. Remove the console and check if the console or the console cable cable has been connected properly. is not connected properly 9. Console cable is damaged, replace it with a new one.
Feel slipping while pedaling (JPC/B/S/E) 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 Revision: Date: 2001/06/01...
Knocking or creaking noise (JPC/B/S/E) 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.
No pulse display on the console (Ear clip sensor) (JPC/B/S/E) Possible causes: Fix: 1. Physical difference 1. Open and close the clip of the ear clip sensor between individuals. several times with your fingers, then check again. 1.1 If there is no pulse, massage your earlobe 2.
No pulse display on console (Chest belt type) (JPC/B/S/E) 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.
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No pulse display on the console (Hand pulse type) (JPC/B/S/E) 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.
Console Diagnostics Mode (JPC/B/S/E) 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 adapter (JPE).
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Console Diagnostics Mode (JPC/B/S/E) 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.
No display on the console while any function key is pressed (JAR-5100) Possible causes: Fix: 1. Battery is not energy 1. Remove the enough battery cover from the console, then 2. Console is damaged. check if the battery ‘s voltage is greater than 1.3 VDC.
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No display is on the console while adjusting the seat, but there is display while any key is pressed (JAR-5100) Possible causes: Fix: 1. Improper adjustment of 1. Slide the seat to far end of the rail and slide it the seat.
Console function will not function properly (JAR-5100) Possible causes: Fix: 1. Batteries do not have 1. Remove the battery enough voltage. cover from the console, then check if the 2. Console is out of battery’s voltage is order greater than 1.3 voltage. If it is not enough, replace the battery and check again.
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“Count” value won’t increase while the seat is being adjusted (JAR-5100) Possible causes: Fix: 1. Improper operation of 1. Slide the seat to far end of rail and slide it back the seat adjustment. and forth several times to check if there is display on the console 2.
No display on the console (JAR-6000) Possible causes: Fix: 1. Battery is not energy 1. Remove the enough battery cover from the console, then 2. Console is damaged. check if the battery ‘s voltage is greater than 1.3 VDC. u If it is not, replace the battery and check again.
“SPM” value won’t increase while running the rower (JAR-6000) Possible causes: Fix: 1. Console RPM cable is broken or not in good contact with the connector. 2. Console is out of order 3. Speed sensor is loosely attached or 1. Remove the console and check if the console RPM broken.
No pulse display on the console (JAR-6000) Possible causes: Fix: 1. Console HR cable is broken or not in good contact with the connector. 2. HR receiver is out of order 3. Chest belt is not placed properly. 1. Remove the console and check if the console HR cable has been connected properly.
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SECTION 3 PARTS REPLACEMENT PROCEDURE Revision: Date: 2001/06/01...
CONSOLE REPLACEMENT PROCEDURE (5100series) Tools required: Procedure: u 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.
CONSOLE CABLE REPLACEMENT PROCEDURE (5100series) Tools required: Procedure: 1. Loosen the screws that u Philips hold the console to the screwdriver console holding bracket. 2. Unplug the console u Adjustable cable from the console wrench connectors. u hex key(8mm) 3. Remove the upper cover, screw u crank extractor 4.
CONTROL BOARD REPLACEMENT PROCEDURE (5100 series) Tools required: Procedure: 1. Remove the rear Fig.1 u Philips (see fig. 1) or side cover, screwdriver then the crank (for JPC/B/S) u Crank extractor Control board 2. Disconnect all the u Coin cables from the control board.
GENERATOR OR ELECTROMAGNET BRAKE SET REPLACEMENT PROCEDURE (5100series) Tools required: Procedure: 1. Remove all covers. u Philips screwdriver 2. Remove the POLY-V u Hex key (5mm) BELT (A) and disconnect the cable from the control u Ratchet Box Wrench board. (11mm) 3.
CRANK REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Crank extractor 1 Loosen the crank cover with a coin and u Coin remove it. u Open-end wrench (14&17mm) 2 With the crank extractor and open-end wrench loosen the screw attaching the crank to the axle.
PEDAL REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Open-end wrench(15 mm) 1 Using the open-end wrench loosen the screws attaching the pedal to the crank. 2 Replace the pedal with a new one. Revision: Date: 2001/06/01...
POLY V BELT 400/380J6 REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: 1. Remove the u Philips crank cover and screwdriver screw, then remove the crank. (Refer to u Hex key (4mm) page 3-5). Loosen the screws u Crank extractor from the side cover with the screwdriver, u Coin then remove the...
POLY V BELT 500/440 J8 REPLACEMENT PROCEDURE (JPC/B Tools required: Procedure: 1. Remove the crank cover u Philips and screw, then remove the screwdriver crank. (Refer to page 3-5) Loosen the screws u Hex key (4mm) from the side cover with the screwdriver, then remove u Open end footpad, guard and side...
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AXLE REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: 1. Remove the crank cover u Philips and screw, then remove the screwdriver crank. (Refer to page 3-5). Loosen the screws from the u Hex key side cover with the (4mm) screwdriver, then remove the footpad, guard and side covers.
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PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Philips 1. Remove the crank cover screwdriver and screw, then remove the crank. (Refer to page 3-5) u C-clip pliers Loosen the screws from the side cover with the u Crank extractor screwdriver, then remove footpad, guard and side u Coin...
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PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Philips 5. Remove the c-clip (C) by using the c-clip pliers and screwdriver remove the metal pulley from the generator using the Bearing Puller. u C-clip pliers 6. Remove the c-clip (D) by using the c-clip pliers and u Crank extractor remove the idler using the Bearing Puller.
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BEARING REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Philips 1. Loosen the screws from screwdriver the side covers with the screwdriver then remove u Hex key (4mm) crank using pulley (refer to page 3-5). Loosen the u Bearing puller screws from the side cover with the screwdriver, then u C-Clip pliers remove footpad, guard and...
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BEARING REPLACEMENT PROCEDURE (JPC/B) Tools required: Procedure: u Philips 5. Remove the C-clip (c) with screwdriver the C-Clip Pliers and then remove the pulley Assembly by u Hex key (4mm) using the Bearing Puller. u If the Ball Bearing failed, u Bearing puller replace pulley assembly.
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POLY V BELT 430J6 REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: u Philips 1. Loosen the screws screwdriver from the side cover with the screwdriver. u Hex key (4mm) 2. Loosen the 430J6 and 430J8 belts. 3. Loosen the screws from the front pulley by using hex key (4mm).
POLY V BELT 430J8 REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: 1. Loosen the screws of the u Philips side cover with the screwdriver. screwdriver u Hex key (4mm) 2. Remove the 430J6 and 430J8 belts from the pulley. u Open end wrench 3.
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POLY V BELT 430J8 REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: 7. Tighten the screws holding the both-end bearing housings u Philips to the frame. screwdriver 8. Tighten the screws in both the chain tension springs. u Hex key (4mm) 9. Tighten the screws that hold the bearing housing to the u Open end frame.
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CHAIN & SPRING REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: 1. Loosen the screws from the side u Philips covers with the screwdriver. screwdriver 2. Loosen the screws from both u Hex key (4mm) springs by using the hex key (4mm). u C-Clip Pliers 3.
SENSOR REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: u Philips 1. Loosen the screws from screwdriver the side cover with the screwdriver. 2. Disconnect the sensor cable from the control board. 3. Loosen the screws holding the sensor to the frame. 4.
FOOTPAD REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: u None 1. Pull out the worn footpad slowly from one of the corners of the pad backside with one of your hands. 2. Replace the pad with a new one. 3-16 Revision: Date: 2001/06/01...
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BEARING REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: u Philips 1. With the screwdriver to screwdriver remove the side covers of the steeper. u Hex key (4mm) 2. Loosen the POLY-V belt u Bearing puller 430J8 & 430J6. u C-Clip pliers 3.
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BEARING REPLACEMENT PROCEDURE (JPS) Tools required: Procedure: u Philips screwdriver 6. Remove the C- clip with the C-Clip u Hex key (4mm) Pliers and then remove the Idler u Bearing puller Assembly by using the Bearing Puller. u C-Clip pliers u If the Ball Bearing failed, u Wooden hammer...
CRANK REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: u Puller u Wooden 1 Remove the joint screw between hammer handlebar and handrail links. 2 Remove all of the covers. u Hexagonal socket wrench 3 Remove the nut(A) then pull the (19&13mm) crank and pedal set out u Philips 4 Remove the c-clip (B) then with...
PEDAL REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: u Philips screwdriver u Two-faced 1 Tear down the rubber footpad and clean it masking tape 2 Remove screw (A) then replace pedal with a new one. 3 Attach the rubber footpad. 3-19 Revision: Date: 2001/06/01...
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POLY V BELT 430J6 REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: 1 Remove all covers. (Except the right cover). u Philips screwdriver 8. Loosen the 430J6 belts then replace it with a new one. u hex key (6 mm) Install the side covers and the parts Hexagonal socket wrench...
POLY V BELT 430 J12 REPLACEMENT PROCEDURE (JPE5100 Tools required: Procedure: 1 Remove all of the covers. (except the left cover). u Philips screwdriver 2 Remove the pedal arm and crank (refer to page 3-18 & 3-19) u Hex key (6mm) 3 Loosen the screws then remove poly v belt and u Hexagonal...
PULLEY AXLE REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: 1 Remove all of the covers u Philips and poly v belts. screwdriver 2 Remove the screw (A) and u Hex key washer (6mm) 3 Pull pulley (B) out then u C-Clip Pliers knock axle set out with the wooden hammer.
AXLE ASSEMBLY REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: 1 Remove all of the covers. u Philips screwdriver 2 Loosen the nut (A) and remove it ,another side is same u C-clip pliers 3 Loosen the tension adjustment screw of idler pulley, then remove the poly v belt u puller 4 Follow the...
ROLLER REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: u Philips 1. Remove the all of cover. screwdriver 2. Move the pedal arm back u 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.
SENSOR REPLACEMENT PROCEDURE (JPE5100) Tools required: Procedure: u Philips screwdriver 1. Remove the rear cover. u Hex key (5mm) 2. Disconnect the sensor cable from the control board. u Ratchet Box Wrench 3. Loosen the screws that hold the sensor to the frame. (11mm) 4.
CONSOLE REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: u none 1. Push the console forward and pull the console out and unplug the sensor cable terminal from the connector then remove the console. 2. Replace console with a new one. 3-26 Revision: Date: 2001/06/01...
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CONSOLE WIRE REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: u Philips screwdriver u Open-end wrench (8&15mm) 1. Push the console forward and pull the console up, then unplug the sensor wire terminal from the connector then remove the console 2. With the open-end wrench loosen the nut and with the Philips screwdriver loosen the screws from the female connector.
SENSOR REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: u Philips screwdriver u Open-end wrench (8&15mm) 1. Unplug the console wire from the rail 2. Loosen the bolts attaching the bracket to the rail then remove it 3. Loosen the screws attaching the sensor to the rail then tie a new sensor to bad sensor with a rigid string 4.
SEAT REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: 1. Remove the bolt from u Philips the seat roller by screwdriver using the open-end wrench (13mm) then u Open-end wrench remove the seat (13mm) 2. Loosen the screws holding the seat to the bracket.
DRIVE BELT 3V-530 REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: 1. Push the console forward u Philips and pull the console out, then screwdriver unplug the sensor cable terminal from the female connector then u Hex key (4mm) remove the console and skid pad.
NYLON ROPE REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: Follow the tension u Philips spring set (refer to page 3-32) screwdriver replacement procedure to remove the parts. u Hex key (4mm) Loosen the u Open end screws attaching the wrench rope to the rope (14mm) wheel.
TENSION SPRING SET REPLACEMENT PROCEDURE (JAR) Tools required: Procedure: 1. Remove the console and u Philips skid pad (Refer to page 3-26). screwdriver Loosen the screws from the side covers with the u Hex key (4mm) screwdriver then remove side covers. 2.
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 Check the generated during operation..
RE-LUBRICATING THE CHAIN & GEAR (JPS) Frequency: Procedure: Every 3-4 months. 1. Remove the side covers of the stepper. 2. Add some lubricating oil to the chains. 3. Add some lubricating oil to the gears. 4. Start to step the machine, repeating several times to allow the lubricating oil to be fully mixed with the chains and gears.
CLEANING THE RAIL AND ROLLER (JPE5100) Frequency: Procedure: Every 1-2 months. (For club) Every 6 months. (For home) Clean here 1. Remove the roller plate cover. 2. Clean the rail and roller. Revision: Date: 2001/06/01...
Warranty Claim Form Claim no: ......Dealer Name: ..........Page ..of ...Pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS # AUTHORIZED BY: ......Revision: Date: 2001/06/01...