Johnson E7000, Service Manual

Page 1: ...E7000 Service Manual 2004 08 29 Ver 1 ...

Page 2: ... 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: ... LIMITED WARRANTY 1 1 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: ...Facsimile 886 4 25683456 E mail service johnsonfitness com Scope of Warranty S Sc co op pe e o of f W Wa ar rr ra an nt ty y All JHT products are warranted against defects in workmanship and materials Any repairs to the parts itself especially the electronics parts will then void the warranty unless the rework is authorized in a written format by JHT in advance This warranty will also not cover an...

Page 5: ...HT to service their customers in time Distributors are advised to purchase the spare parts at 2 3 of the total value of each shipment along with the shipment order or to always keep in their stock at least 2 to 5 pieces of each spare parts especially the electronics parts of the different model If there is any importer or distributor failed to do so and wish that JHT send the replacement parts by ...

Page 6: ...ization and shipping arrangement This may not be required for the mechanical defects Once it is authorized by JHT the distributor should pack the parts in the most appropriate way and send the package by the way as advised by JHT Issuing Credit It is within JHT s discretion to issue a credit or send parts with no charge to the distributors after the returned parts have been verified to be really d...

Page 7: ...2 1 SECTION 2 EXPLODED DIAGRAM CONTENTS EXPLODED DIAGRAM 2 2 ...

Page 8: ...2 2 ...

Page 9: ...SECTION 3 WIRING DIAGRAM CONTENTS CONTROL BOARD WIRING DIAGRAM 3 2 3 1 ...

Page 10: ...E 7000 CONTROL BOARD WIRING DIAGRAM A2 A4 A1 A3 A1 3 pin terminal to the electromagnet brake set A2 2 pin terminal to the adapter A3 3 pin terminal to the console A4 grounding wire to frame 3 2 ...

Page 11: ...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 4 1 ...

Page 12: ...e terminals on the control board 3 Control board is damaged 4 Generator is damaged If it is replace the console and check again 2 Open the side covers of the bike and check if all the wire harnesses are connected properly to the terminals of the control board 3 Unplug the console cable from the control board and check if the voltage on the 1 st and 4 th pin of control board is greater than 5V DC I...

Page 13: ... well Connect the terminal properly If cable is damaged replace it with a new one 2 Console is damaged replace it with a new one 3 Open the side covers of the fitness then replaces the control board with a new one 4 Check if the sensor is misaligned If it is place the sensor in the correct position 5 Open the side covers of the stepper and check if the connection of the sensor is connected properl...

Page 14: ...feel slipping while pedaling Possible causes 1 Belt tension is not enough 4 4 2 Poly v Belt is damaged Fix 1 Re adjust the belt tension 2 Replace poly v belt with a new one Adjust it ...

Page 15: ... arm too loose 2 Crank or axle is wear out 3 Belt tension is too loose or poly v belt is too dirty 4 Rail or roller is too dirty Fix 1 Re tighten it 2 Replace it with a new one 3 Re adjust the belt tension and clean the poly v belt 4 Clean the rail and roller 4 5 ...

Page 16: ... Procedure 1 Place the chest belt in the correct position Remark 1 2 Replace the chest belt with a new one 3 Replace the console with a new one Remark 1 The correct operation of a Chest Belt 1 Moisten the electrodes that are located on both ends of the belt 2 The belt functions will most effective when placed close to the heart and to the skin ...

Page 17: ...ion of hand pulse cable 2 Hand pulse cable is damaged 3 Console is damaged Procedure 1 Remove the console to check if the terminal of hand pulse cable has been connected to PCB well OR 2 Replace the hand pulse cable with a new one OR 3 Replace the console with a new one 4 7 ...

Page 18: ...y 2 Dot Matrix Display will be scanned slowly starting from LEDs at the leftmost column to the right 3 Each 7 segments display will be scanned one by one If one of LEDS is not lit replace the PCB 1 Press the ENTER key 2 Dot Matrix and 7 segments will display lighted up If one of LEDS is not lit replace the PCB 1 Press the ENTER key 2 Dot Matrix Display will show RPM 3 RPM window will show current ...

Page 19: ...y to increase or decrease resistance If there is no resistance please refer to section 4 4 section 4 5 1 Press the ENTER key 2 Dot Matrix Display will show KEY on it 3 Ready for you to enter any key of all 18 keys other than RESET now to verify the function of the key 4 The RPM window will show you a reference number accordingly while pressing a number or function key 5 TIME window will show you t...

Page 20: ...s 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 5 1 ...

Page 21: ...edure 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 4 Tighten the screws that hold the console to the bracket ...

Page 22: ...upper cover screw 4 Remove the screw A and take bracket out for JPE Remove the crank and side cover for JPC B S 5 Disconnect the console cable from the connectors and then tie the old cable to the new one with a rigid string 6 Pull the old cable from the top end until the new cable threads all the way through the support 7 Reconnect the console cables to both the console and control board 8 Tighte...

Page 23: ...extractor Coin Adjustable wrench Procedure 1 Remove the rear see fig 1 or side cover then the crank for JPC B S 2 Disconnect all the cables from the control board 3 Replace it with a new one 4 Reconnect all the cables 5 Reverse step 1 3 to install the side cover Fig 1 Control board ...

Page 24: ...ew one 5 Secure the tension screw and the screws holding the generator electromagnet brake set to the frame not too tight at this time so that the tension adjustment can be made 6 Install the POLY V BELT on the front and rear pulley 7 Use the wrench 11mm to adjust the belt tension by adjusting the tension screw until you can only press with your thumb the POLY V BELT down about 1 1 5cm then tighte...

Page 25: ...lip pliers Adjustable wrench Procedure 1 Remove the joint screw between handlebar and handrail links 2 Remove all of the covers 3 Remove the nut A then pull the crank and pedal set out 4 Remove the c clip B then with wooden hammer tap the crank out 5 Replace the crank with a new one Reverse step 1 4 to install the 6 parts A Tap here B ...

Page 26: ...CEMENT PROCEDURE Tools required Philips screwdriver Two faced masking tape 5 7 Procedure 1 Tear down the rubber footpad and clean it 2 Remove screw A then replace pedal with a new one 3 Attach the rubber footpad A ...

Page 27: ... PROCEDURE Tools required Philips screwdriver hex key 6 mm Hexagonal socket wrench 13mm Procedure 1 Remove all covers Except the right cover 2 Loosen the 430J6 belts then replace it with a new one Install the side covers and the parts ...

Page 28: ... 9 Hex key 6mm Hexagonal socket wrench 19 13mm Puller Adjustable wrench Procedure 1 Remove all of the covers except the left cover 2 Remove the pedal arm and crank 3 Loosen the screws then remove poly v belt and replace it with a new one 4 Reverse step 1 3 to install the parts A ...

Page 29: ...ly v belts 2 Remove the screw A and washer 3 Pull pulley B out then knock axle set out with the wooden hammer 4 Remove the nut C then tap the axle out 5 Replace the axle with a new one then install the c clip by using c clip pliers 6 Reverse the step 1 4 to install the parts Note To clean the bearing housing and apply adhesive on the outer race of bearing is necessary B A C ...

Page 30: ...overs 2 Loosen the nut A and remove it another side is same 3 Loosen the tension adjustment screw of idler pulley then remove the poly v belt 4 Follow the procedures below to install the axle Step1 pull crank out Step2 remove the c clip Step3 tap axle assy out Step4 remove the nut then tap axle out A Step5 replace the axle with a new one Step6 reverse all of the steps to install the parts ...

Page 31: ...wdriver 5 12 Hex key 4mm Procedure 1 Remove the all of cover 2 Move the pedal arm back 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 4 Reverse the steps to install the side cover A ...

Page 32: ...ver Hex key 5mm Ratchet Box Wrench 11mm Procedure 1 Remove the rear cover 2 Disconnect the sensor cable from the control board 3 Loosen the screws that hold the sensor to the frame 4 Replace the sensor with a new one 5 Reverse the step 1 3 to install the parts Sensor ...

Page 33: ...SECTION 6 MAINTENANCE PROCEDURE CONTENTS CLEANING THE GROOVES 6 2 CLEANING THE RAIL AND ROOLER 6 3 6 1 ...

Page 34: ...s and pulleys noises will be generated during operation Procedure 1 Remove the Poly V belts and check the grooves of the belt for dirt or dust and clean it if any 2 Check the grooves in the pulley for dirt or dust and clean it if any 3 Check the grooves in the roller pulley for dirt or dust and clean it if any ...

Page 35: ...6 3 CLEANING THE RAILAND ROLLER Frequency Every 1 2 months For club Every 6 months For home Procedure 1 Remove the roller plate cover 2 Clean the rail and roller Clean here ...

Page 36: ...OMMENDED TOOLS A OPEN END WRENCH 17mm B OPEN END WRENCH 14mm A B C D E F G 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 1 2 3 4 ...