5100 Series Service Manual
Contents
1. If you have any trouble in troubleshooting the failures or if you wish to complain for a mass failure to JHT you can fill out the Field Failure Report JHT will respond to your report within one day You may call JHT customer service department directly as well if you wish but before doing this it is preferred for you to send out the forms in advance 1 3 Revision 1 0 Date 2004 7 24 ZAN JOHNSON SECTION 2 EXPLODED DIAGRAM CONTENTS m W7000 EXPLODED DIAGRAM nennen 2 1 SECTION 2 Revision 1 0 Date 2004 7 24 ZAN JOHNSON W7000 EXPLODED DIAGRAM 2 1 Revision 1 0 Date 2004 7 24 ZAN JOHNSON SECTION 3 WIRING DIAGRAM E WIRING DIAGRAM CONTENTS SECTION 3 Revision 1 0 Date 2004 7 24 JOHNSON W7000 WIRING DIAGRAM 3 1 Revision 1 1 Date 2000 1 13 JOHNSON SECTION 4 TROUBLESHOOTING CONTENTS 77 No display is on the console while any function key is pressed 4 1 77 No display is on the console while adjusting the seat but there is display While any key is pressed een iZ 77 Console will not function properlv sssssesenenzenennszzznnnonanenennsnzanoea 4 3 77 Count value will not increase while adjusting the seat 4 4 Revision 1 0 Date 2004 7 24 JOHNSON No display on the console while any function key is pressed Possible causes Fix 1 Remove the battery cover from the console then check if the battery s voltage is gre2. 3 4 5 5 5 6 8 10 mm da APPENDIX JOHNSON 1 WOODEN HAMMER 2 BEARING PULLER 3 C CLIP PLIERS 4 C CLIP PLIERS APPENDIX
3. parts 5 3 Revision 1 0 Date 2004 7 24 JOHNSON SEAT REPLACEMENT PROCEDURE Tools required Philips screwdriver Open end wrench Procedure 13mm 1 Remove the bolt from the seat roller by using the open end wrench 13mm then remove the seat 2 Loosen the screws holding the seat to the bracket 3 Replace the seat with a new one 4 Reverse step 1 2 to install all the parts 5 4 Revision 1 0 Date 2004 7 24 JOHNSON DRIVE BELT 3V 530 REPLACEMENT PROCEDURE Tools required Philips screwdriver Hex key 4mm Ratchet Box Wrench 11mm 5 5 Push the console forward and pull the console out then unplug the sensor cable terminal from the female connector then remove the console and skid pad Loosen the screws from the side covers and remove it Remove tension springs set and loosen the screws attaching cable wheel axle to the frame then remove the axle and belt Loosen the screws from the shroud cover Loosen the screws attaching the hub drive train assembly to the frame then remove the axle and belt Install the belts onto the pulley of hub drive train assembly and rope axle Reverse step 1 5 to install the parts Revision 1 0 Date 2004 7 24 JOHNSON NYLON ROPE REPLACEMENT PROCEDURE Tools required Procedure 1 Follow the tension spring set refer to page 77 replacement procedure to remove the parts Philips scr
4. Count value won t increase while the seat is being adjusted Possible causes 1 Improper operation of the seat adjustment Fix 1 Slide the seat to far end of rail and slide it back 2 Console cable is and forth several times to check if there is display broken or not in good on the console contact with the connector 2 Remove the console and check if the console cable has been connected properly 3 Console is out of Reconnect the cable order Orreplace it with a new one 4 Magnet has fallen out 3 Console is damaged replace it with a new one 5 Sensor is loosely 4 Check if the magnet is positioned well attached or broken 5 Replace the sensor or re attach it 4 4 Revision 1 0 Date 2004 7 24 e iS JOHNSON SECTION 5 Parts Replacement Contents CONSOLE Replacement Procedure ss ss ssnsosnnnzzznnnnenenznosensnesnenneeneessseo L CONSOLE WIRE Replacement Procedure 11snsssnsensessnnneosnnnenennnnesense 072 SENSOR Replacement Procedure sssnnsosennnooennnoosnnnoosnna es oenosenesesensaoennnooees 5 3 SEAT Replacement Procedure simi rr 5 4 DRIVE BELT 3V 530 Replacement Procedure cccesesccceceees 5 5 NYLON ROPE Replacement Procedure cccccccsececccececceceees 5 6 TENSION SPRING SET Replacement Procedure scssccesecseoes 5 7 SECTION 5 Revision 1 0 Date 2004 7 24 JOHNSON CONSOLE REPLACEMENT PROCEDURE Tools requir
5. 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 express it will be within JHT s discretion how to charge the distributor for both the replacement parts and shipment cost A list of recommended spare parts could be provided with the shipment sales confirmation as long as the request is made to your JHT sales representative and is contained in the service manual as well Please refer to the parts list to fill out the Parts Order Form and send it to your sales representative to order the parts as required Warranty Procedure Defective electronics To receive a credit accordingly the distributor must collect the defective electronics attach a label or tag on the defective part to identify the following information as a minimum requirements which contain the production serial number symptom of failure and the warranty claim number Send the 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 manufactur
6. JOHNSON W7000 Service Manual ZAN JOHNSON TABLE OF CONTENTS SECTION 1 LIMITED WARRANTY SECTION 2 EXPLODED DIAGRAM SECTION 3 WIRING DIAGRAM SECTION 4 TROUBLE SHOOTING SECTION 5 PARTS REPLACEMENT SECTION 6 PREVENTIVE MAINTENANCE APPENDIX RECOMMENDED TOOLS SECTIONI Revision 1 0 Date 2004 7 24 ZAN JOHNSON SECTION 1 LIMITED WARRANTY Comments and QueStIONS ccccccsesscccccssesscccccccecs 1 1 Scope of Watt isis 1 1 Intended Use 1 1 Safety Stock of Warranty PartS eeeeeoeeoeooeooooocccccococoocol l Warranty Time Peri dica aiii 1 1 Defects Repla ementi u a 1 2 Defects Return Procedure u Technical SMP PO liinda 1 3 SECTION Revision 1 0 Date 2004 7 24 ZAN JOHNSON 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 Customer Service Johnson Health Technology Company P O BOX 22 100 Taichung Taiwan R O C Telephone 886 4 25667100 Facsimile 886 4 25683456 E mail service johnsonfitness com Scope of Warranty All JHT products are warranted against defects in workmanship and materia
7. ater than 1 3 VDC If it is not replace the battery and check again 1 Battery is not energy enough 2 Console is damaged 2 Replace the console with a new one Revision 1 0 Date 2004 7 24 JOHNSON No display is on the console while adjusting the seat but there is display while any key is pressed Fix Possible causes 1 Slide the seat to far end of the rail and slide it 1 Improper adjustment of back and forth several times to check if there is the seat display on the console 2 Console cable has not 2 Remove the console and check if the terminal of been connected well to console cable is connected properly the connector or broken Reconnect the cable gt Ifthe cable is damaged replace it with a 3 Console is damaged new one 4 Magnet is missing or not 3 Console is damaged replace it with a new one positioned well 4 Re position the magnet 5 Sensor is damaged or loosely attached 5 Replace it with a new one or re attach it Revision 1 0 Date 2004 7 24 JOHNSON Console function will not function properly Possible causes 1 Batteries do not have Fix enough voltage 1 Remove the battery cover from the 2 Console is out of console then check order if the battery s voltage is greater than 1 3 voltage If it is not enough replace the battery and check again 2 Replace the console with anew one 4 3 Revision 1 0 Date 2004 7 24 JOHNSON
8. ed none Procedure 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 5 Revision 1 0 Date 2004 7 24 JOHNSON CONSOLE WIRE REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver Open end wrench 8 amp 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 3 Unplug the console wire from the rail 4 Loosen the bolts attaching the bracket to the rail then remove the rail 5 Replace console wire with a new one 6 Reverse step 1 2 to install the parts 5 Revision 1 0 Date 2004 7 24 JOHNSON SENSOR REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver Open end wrench 8 amp 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 Loosen the nut attaching the female connector to the rail with the open end wrench Pull the old cable from the front end until the new cable threads all the way through the rail 5 Reverse step 1 5 to install the
9. er 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 1 2 Revision 1 1 Date 2004 7 24 ZAN JOHNSON 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 Defect Return After finishing the above processes with each kind of component the distributors are then required to contact JHT for a returned authorization 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 defective If the parts returned has been verified to be non defective and is good enough to be used it will be sent back to the distributor The distributor will be responsible for all the shipping cost incurred No credits will be issued on the defective returns that can be proved to fail due to misuse neglect or abuse Technical support
10. ewdriver Hex key 4mm Open end 2 Loosen the wrench screws attaching 14mm the rope to the rope wheel 3 Cut down the rope and remove it 4 Replace it with a new rope first thread the rope through the guide hole of the rope wheel and tie a knot put the bracket onto the knot then tighten the screws 5 Thread the other end of the rope through the square hole of the bracket and the wheel in the handle holder cover then tie the rope to the handle bar 6 Turn forward the rope wheel until the handle touches the handle holder 7 Reverse step 1 6 to install the parts 5 6 Revision 1 0 Date 2004 7 24 JOHNSON TENSION SPRING SET REPLACEMENT PROCEDURE Tools required Philips Screwdriver Hex key 4mm Remove the console and skid pad Loosen the screws from the side covers with the screwdriver then remove side covers Loosen the belts 500 440J8 amp 400 380J6 from the pulley With the hex key loosen the screws from the tension spring set Replace it with a new one then turn the set CW about 2 5 3 turns Reverse the step 1 3 to install the parts Revision 1 0 Date 2004 7 24 As JOHNSON APPENDIX RECOMMENDED TOOLS A OPEN END WRENCH 17mm B OPEN END WRENCH 14mm A B C D E F G C RATCHET BOX WRENCH 11mm kab D PHILIPS SCREWDRIVER E SLOTTED SCREWDRIVER F CRANK EXTRACTOR G MULTIMETER HEX KEYS 1 5 2 2 5
11. ls 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 any damage failure or loss caused by accident misuse neglect abuse improper assembly or failure to follow instructions or warning in the owner s manual Intended Use JHT products may be warranted for just home use only all distributors are advised to consult the owner s manual for the limitations of the application 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 1 1 Revision 1 1 Date 2004 7 24 ZAN JOHNSON Defects Replacement 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 Safety Stock of Warranty Parts All the importers and distributors are required to keep an inventory of spare parts especially for those of which are recommended by JHT to service their customers in time
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