JohnsonFit Matrix Retail A30, Service Manual

Page 1: ...1 JOHNSON Issue date 2017 2 20 Edition 01 Doc No SM TM AF 009 Revision date Edition time 01 Page 35 Approval Review Editor Kyle Schweitzer Alex Tang Dora Feng A30 A50 Service manual ...

Page 2: ...Matrix Retail A30 Matrix Retail A50 A30 A50 Frame Resistance System Internal ECB Induction Brake Handle Bar Type Stationary DA Arm foam wrapped Stationary DA Arm Power Supply Yes 9 ft 2 75m Yes 8 ft 2 44m ...

Page 3: ...3 5 No RMP Display 16 3 3 6 No Resistance Or Incorrect Resistance 17 3 3 7 Heart Rate Function Issues 20 3 3 8 Pedals Slipping 21 3 3 9 Knocking and Creaking Noise 22 3 3 10 Handlebar Keypad Failure 23 CHAPTER 4 PART REPLACEMENT GUIDE 4 1 Console Replacement 24 4 2 Heart Rate Grip Replacement 25 4 3 Upper Handle Bar Replacement 26 4 4 Lower Handle Bar Replacement 27 4 5 Pedal Arm Replacement 28 4 ...

Page 4: ...4 4 10 Front Cover Replacement 33 4 11 Side Cover Replacement 34 4 12 LCB ECB Motor Replacement 35 4 13 Elevation Motor Replacement 36 4 14 Drive Axle Replacement 37 4 15 Generator Replacement 38 ...

Page 5: ...5 CHAPTER 1 Serial Number Location ...

Page 6: ...6 CHAPTER 1 Serial Number Location ...

Page 7: ...7 CHAPTER 1 Serial Number Location ...

Page 8: ...8 CHAPTER 2 Console Browse Please refer to XR XER XIR service manual to get more details ...

Page 9: ...9 CHAPTER 3 Troubleshooting 3 1 ELECTRICAL DIAGRAM A30 ...

Page 10: ...10 CHAPTER 3 Troubleshooting 3 1 ELECTRICAL DIAGRAM A50 ...

Page 11: ...11 CHAPTER 3 Troubleshooting 3 1 ELECTRICAL DIAGRAM A30 50 Connection Console Connection ...

Page 12: ...12 CHAPTER 3 Troubleshooting 3 2 MCB Connections A30 MCB 1 AC input connector 2 Incline connector 3 ECB connector 4 Console connector ...

Page 13: ...13 CHAPTER 3 Troubleshooting 3 2 MCB Connections A50 MCB CN1 Incline Motor Connector CN2 Console Connector CN3 RPM feedback wire connector ...

Page 14: ...e from console and use a multi meter to check the voltage through the console cable Normally it should be 12VDC between pin1 pin8 If no voltage is present the console cable or LCB is defective Test voltage at LCB if voltage is present replace console If not replace LCB 2 If the voltage through the console cable is 12VDC the console is defective Replace it FIGURE A Console cable s connectors with U...

Page 15: ... Solution 1 Check the connection of the console cable at the UCB 2 Remove the console cable from the J5 socket on the console Pedal the machine Set your multi meter to DC voltage Place both terminals on pins 1 4 of the console cable There should be a reading of more than 5 5VDC If voltage is more than 5 5VDC replace the console If voltage is less than 5 5VDC or the new console does not resolve the...

Page 16: ...console re connect the console wire 2 Speed sensor wire defective Check the gap between the speed sensor and magnet on pulley It is normal within 5mm Fig A Adjust the gap if it is too large Test sensor with Ohm meter with pin1 and pin2 pass magnet by sensor to test 3 Lost magnet of pulley Re install a new magnet Fig B 4 Console defective Replace the console set ...

Page 17: ...pe points to bottom left side the resistance will be reverse Adjust the head of steel rope to the correct position Notes in the highest resistance level the cable should have no tension see ECB motor replacement section 2 Press key or to adjust the resistance A If ECB motor cannot move the resistance will not be changed The ECB motor or console cable is defective Check the console cable inserted i...

Page 18: ... the resistance is still too heavy check the gap between orange block and the bottom It should be within 1 2 mm If the gap is larger than 1 2 mm the resistance will be heavier than normal Adjust the cable to the correct gap range 3 If all above conditions are ok and the resistance is still too heavy inside magnet is defective Replace the ECB flywheel ...

Page 19: ...e connection between the power resistor and LCB fig 1 2 Check the Connection wire between consoles to LCB Try to plug off and plug on connector Page 13 CN2 3 Check the power resistor whether 10KΩ by multi meter Fig 2 if not replace power resistor 4 If yes Replace LCB Fig1 Fig2 ...

Page 20: ...onnected correctly Check continuity of the HR grip wiring Place one terminal of a multi meter set for resistance on the HR grip wiring at the HR grip and the other terminal on the HR grip wiring at the console An ohm reading of around 1 should be expected If the reading is higher than 1 replace the HR grip wiring Also test continuity of one terminal and to the frame ground to test for a pinched wi...

Page 21: ...way bearing is damaged Solution 1 Remove the shrouds and check the belt tension Tighten the drive belt tension if needed by moving the spring tension clip to another hole The generator bolt should be tightened to 85 ft lbs 2 If the belts are tensioned correctly belt tension range should be 175 190HZ The one way bearing is damaged replace the drive assembly ...

Page 22: ...uring incline check to make sure the Teflon washers are installed at the incline motor connection point Lubricate the guide rod of the incline motor with grease to reduce the abrasion with washer c The belt tension is not high enough or the belts are too dirty Remove the covers and check the belt tension Tighten the drive belt tension if needed by moving the spring tension clip to another hole It ...

Page 23: ...ctor is 180 degree reverses on circuit board b Check if use correct handlebar connection wire 2 Inspection the Handlebar keypad as below procedures a When handlebar key does not work firstly measure the pins with AVO meter to check if the keypad is bad Pic1 b Measure the resistance of keypad Ω position on AVO meter press keypad keypad is good if the value 200Ω c Same as step2 measure the other sid...

Page 24: ... 2 Remove the 4 screws holding the Console to the frame Figure B 3 Disconnect all connections from the console and remove the console from console mast Figure C FIGURE A FIGURE B FIGURE C 4 Reverse steps to install the console Notes Carefully push the wires into the console and mast until they are clear of the console mast connection ...

Page 25: ...25 CHAPTER 4 Part Replacement Guide 4 2 HEART RATE GRIP REPLACEMENT 1 Remove 3 screws from the heart rate grip 2 Separate the covers and disconnect all wires ...

Page 26: ...art Replacement Guide 4 3 UPPER HANDLEBAR REPLACEMENT 1 Lift up on the cap by handlebar pivot joint Figure A Figure A 2 Loosen the two sets screws then you can pull the handle bar out of pivot joint Figure B Figure B ...

Page 27: ...acement Guide 4 4 LOWER HANDLEBAR REPLACEMENT 1 Remove bolt from the pivot joint which is marked 1 and remove the cap marked 2 Figure A Figure A 2 Remove cap bolt and screws to take off the Lower handlebar Figure B Figure B ...

Page 28: ...28 CHAPTER 4 Part Replacement Guide 4 5 PEDAL ARM SET REPLACEMENT 1 Remove the following lower handlebar see section 4 4 2 Remove the bolt shown in Fig A remove the pedal arm Figure A ...

Page 29: ...MENT 1 Remove the 4 screws which fix the front cover 2 in front and 2 in rear Figure A B Figure A Figure B 2 Remove the 2 screws of the two side of rear cover to remove it Figure C 3 After removing the side cover you will see the console mast Figure D Figure C Figure D ...

Page 30: ...AST REPLACEMENT 1 Remove the following console section 4 1 console mast covers section 4 6 2 Remove the 4 bolts in front and rear Figure A B Figure A Figure B 3 Pull off the console mast guide the console wires to protect from damage Figure D Figure C ...

Page 31: ...rm see section4 5 2 Remove the plastic cover Figure A then remove the link arm bolt Figure B 3 Remove the bolt which fix the link arm and connected tube Figure C D Then remove the link arm Notes torque for the link arm bolt is 800kgf cm Figure C D 4 Reverse steps to replace link arm ...

Page 32: ...nk arm you can see the crank Remove the nut and screws to remove the plastic cover of the crank Figure A 3 After remove the cover remove the crank arm bolt to remove the crank a two jaw puller might be needed Figure B Figure A Figure B 4 The torque on crank bolts must be 800kgf cm Figure C Figure D Figure C Figure D ...

Page 33: ...ER 4 Part Replacement Guide 4 10 FRONT COVER REPLACEMENT 1 Remove the console mast covers section4 6 2 Remove the two screws to take off the front cover Figure A 3 Reverse steps to replace front cover Figure A ...

Page 34: ...PLACEMENT 1 Remove the following console mast covers see section4 6 Front cover see section4 10 crank arms see section4 9 2 Remove the 9 screws which fix the side cover 3 Remove the 2 screws as Fig B 4 Reverse steps to install side cover Figure A Figure B ...

Page 35: ...ole section4 1 console mast covers section4 6 2 Remove the 2 screws to replace LCB Fig A 3 Remove the 4 screws to replace the ECB motor Fig B Figure A Figure B Note Note the circuit board could become damaged during this procedure from electrostatic discharge We recommend wearing an ESD wrist strap ...

Page 36: ...ve the following console section4 1 console mast covers section4 6 2 Remove 4 bolts except H38 the torque of other bolts should be 500kgf cm Fig A B C Figure A B C 3 Reverse steps to install elevation motor Notes when install H38 bolt please twist negetive direction half round ...