Jet 7000 - 6000
Contents
1. 6 11 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 7 PARTS REPLACEMENT PROCEDURE Revision 1 0 Date 2001 06 01 JOHNSON RUNNING BELT DECK ROLLER REPLACEMENT Tools required v Philips screwdriver Y T handle key 8mm 5mm Procedure side rail 7 1 1 Remove the screws from the front cover by using the screwdriver 2 Remove two rear covers from the end of the side rails 3 Pull out the two side rails 4 Elevate the machine to a proper height for removing the front roller Revision 1 0 Date 2001 06 01 JOHNSON RUNNING BELT DECK ROLLER REPLACEMENT Tools required Procedure Philips screwdriver 5 Turn the flywheel counterclockwise by using your left hand and pull out the drive belt from the wheel by using your right hand v T handle key 8mm 5mm front roller 6 Remove the bolts from the front and rear rollers by using the T handle key 8mm reor roller 7 Remove the front roller drive belt and rear roller If replacing the roller go to step 13 8 Remove 8 screws holding the deck to the frame then remove the deck with the running belt If replacing the running deck go to step 12 deck extension 9 Remove the deck extension with screwdriver 10 Flip and rotate the deck and tighten the deck extension then install a new running belt 1 Refer to REWAXING THE DECK PROCEDURE for how to lubricate the deck Or sk2. FAST key to input your weight Press the SELECT key to store 9 Press UP key to reach P9 address press SELECT key Then you can see the total running hours of the treadmill 10 Press UP key to reach P10 address press SELECT key Then you can see the total running distance of the treadmill Un Remark Hold down the UP and DOWN key about 5 seconds to reset under the P9 or P10 2 Holding the START key about 5 seconds to reset the PO P2 P4 P5 in P7 of engineering mode Define the parameters P0 Min Speed P1 Max Speed P2 Mid Speed P3 None P4 Min Slope P5 Max Slope P6 Unite mode P7 Max Time P8 User Weight P9 Total RunningTime 10 Running Distance 4 3 Revision 10 Date 2001 06 01 JOHNSON Console Engineering Mode Guide JET 7000E PO P3 P6 Total RunningTime P10 Total Running Distance P9 Press SLOW STOP keys simultaneously about 5 seconds to enter Engineering Mode The Display will be showed Press SELECT key then press SLOW or FAST to set metric kph or British mph Press SELECT key to store Press STOP key for next parameter setting Press SLO W key to reach the P0 address Then press SELECT key for setting the PO parameter refer to DISTANCE win
3. JOHNSON TABLE OF CONTENTS SECTION 1 MAINTENANCE PROCEDURE MAINTENANCE CHECK LIST euere 1 1 u JENSIONING THE BELT PROCEDURE cuca 1 2 p DECK RE WAXING PROCEDURE aussen 1 3 o CLEAN THE GROOVES 1 4 SECTION 2 IMPORTANT SAFETY INSTRUCTIONS p GROUNDING INSTROCTIONS nein 2 1 o POWER VOLTAGE INSTRUCTIONS 2 1 SECTION 3 WIRING DIAGRAM u WIRING DIAGRAM TERMINAL END CE 3 1 o WIRING DIAGRAM TERMINAL 3 2 o WIRING DIAGRAM MED une 3 3 SECTION 4 CONSOLE ENGINEERING MODE GUIDE JET7000 OLD ENGINEERING MODE GUIDE 4 1 o JET7000 OLD TOTAL TIME amp DISTANCE INSTRUCTION 4 2 JET6000 7000N ENGINEERING MODE GUIDE 4 3 o JET7000E ENGINEERING MODE GUIDE 4 4 SECTION 5 MCB LED INSTRUCTIONS E MCB LED INDICATION 5 1 PWM MCB LED CHART ida 5 2 u MCB LED TROUBLESHOOTING CHART 5 3 Revision 1 0 Date 2001 06 01 JOHNSON TABLE OF CONTENTS E SECTION 6 TROUBLESHOOTING H NO DISPLAY ON CONSOER nr 6 1 o RUNNING SPEED IS NOTSTABLE out 6 2 o TREADMILL STARTS TO RUN BY ITSELF 6 3 o ALL OR SOME OF KEYS ON CONSOLE DO NOT WORK 6 4 o
4. 6 Press to START STOP key to store OLD Hold down SAFETY and POWER keys then IV Old Version remove SAFETY key then the display shows Si or bri To choose If you want the metric mode you must remove metric or POWER key when the display shows 51 British British mode gt bri Then the display shows bye briefly and reset itself mode NEW Hold down SAFETY PROGRAM New Version INTERVAL and RESET keys then remove SAFETY To choose key then the display shows Si or bri metric or If you want the metric mode you must remove British mode PROGRAM INTERVAL and RESET keys when the display shows 51 the British mode gt bri Then the display shows bye briefly and reset itself Except the ver 0 3 4 Revision 1 0 Date 2001 06 01 JOHNSON Total TIME amp DISTANCE Instruction JET 7000 Old When you press Safety key and release for ver 0 3 press down FAST amp UP key then the display shows TIME WINDOW HEART RATE WINDOW DISTANCE CALORIES XXXX XX XXX SPEED INCLINE XX The content in the TIME WINDOW indicates the accumulated running hours of the treadmill The content in the HEART RATE amp DISTANCE CALORIES WINDOW indicate the accumulated running miles in British system only of the treadmill The content in the SPEED INCLINE WINDOW indicates the version of software e g a ama N a N B TOTAL TIME 51 hours TOTAL DISTANCE 2325
5. ON OFF switch is If LED 115vAC AC is not lit verify the following damaged 3 MCB is damaged 4 8 pin console cable is damaged 5 PCB is damaged 4 circuit pea to see if it has tripped off If it is tripped off like diagram B reset the breaker And check which part is short circuited Then replace the short circuited part 2 The switch is turned to the ON position If the switch light isn t lit replace the switch 4 Verify wire connection ACI amp AC2 the MCB refer to wiring diagram 4 Verify the ON OFF switch breaker socket wires are connected 3 Verify if LED 12v is lit If one is not lit replace MCB 4 Replace 8 pin console cable 5 Replace PCB 6 1 Revision 1 0 Date 2001 06 01 PN JOHNSON Running speed is not stable Possible causes Fix 1 Tension of drive belt Poor adjustment of AC power voltage is 1 Check the power voltage by using voltage meter to too low or running belt is too loose NGB see if it is within 120V 15 or 230V 15 MCB is damaged If the power voltage isn t within the range look for a qualified electrician for help Motor is damaged 2 Open the motor cover if the belt has stretched and is slipping across the rollers when running Adjust the belt tension 3 Remove the motor cover and run the machine at low speed the adjust the IR COMP of MCB If it hasn t been improved replace new M
6. C2 C6 refer to table 1 parameter value 35 For ver0 3 35 British 51 metric 66 1 89 Only for ver 0 3 max time Table 1 3 Press POWER key to save IL 1 Press Slow Down and RESET keys simultaneously And the display reads CAL HI To calibrate 2 While the treadmill raises to the maximum incline the elevation verify the grade should be 1596 30cm from 0 to 15 3 Press the START STOP key and the display reads CAL LO 4 While the treadmill lower to the minimum incline verify the grade should be 0 8 9cm Press the START STOP key to store 4 1 Revision 1 0 Date 2001 06 01 A JOHNSON Console Engineering Mode Guide JET 7000 Old If the distance between the front bottom edge of the frame and the floor does not meet the specifications either at the maximum or minimum incline you have to adjust the location of the related limit switch to calibrate the incline to Spec 1 Press Slow Down and RESET keys simultaneously To calibrate the 2 While the display reads CAL HI press Up speed key Then the display shows SLO 3 Read the real speed from the window of TIME The speed value on the TIME window is in British System only 4 Using the Fast or Slow keys to adjust the speed of the treadmill to 0 5mph 0 Skph Then press START STOP key and the display shows FAS 5 Using the Fast or Slow keys to adjust the speed of the treadmill to 12 4mph 20 0kph
7. NOISE GENERATED UNDER MOTOR COVER 6 5 o TREADMILL WILL NOT START quotes 6 6 HEART RATE CONTROL FUNCTION DOES NOT WORK 6 7 TREADMILL WILL NOT INCLINE UP OR DOWN 6 8 TREADMILL WILL INCLINE UP OR DOWN BY ITSELF 6 9 TREADMILL VARIES THE SPEED BY ITSELF 6 10 o ERROR MESSAGE ON CONSOLE an 6 11 B SECTION 7 PARTS REPLACEMENT o RUNNING BELT DECK Ripa 7 1 Er MOTOR esse een ae 7 2 o INCLINE MOTOR anna 7 3 o CONSOLE CABLE JET OOOO aa 7 4 o MOTOR BEARINGS 4 CARBON BRUSH een 7 5 p GEAR MOTOR JET7000 SERIES 7 6 u CONSOLE CABLE JET7000 SERIES 7 7 o CONSOLE CONTROL nase 7 8 E KEYPAD aiii plates 7 9 u ELEVATION RACK TETTOOO Nossa peana 7 10 CHAIN SET ZOOOIN Jessi dela 7 11 B SECTION 8 SERVICE FORM u MEBEEDSTATUSREPORE u a da 8 1 m FIELD FAILURE REPORT asian al 8 2 Ei PARIS ORDER ace 8 3 E WARRANTY CLAIM FORM 8 4 Revision 10 Date 2001 06 01 JOHNSON SECTION 1 MAINTENANCE PROCEDURE Revision 1 0 Date 2001 06 01 PREVENTIVE MAINTENANCE SCHEDULE JOHNSON TREADMILL Console Mounting i Bolts nspect Clean Handrail amp i Handlebar I t amp Re waxing Vacuum 1 1 Revision 1 0 Date
8. Note The incline is being commanded up Note The incline is being commanded down Note RPM signal from the speed sensor magnet pair P Light Indicates the PCB is commanding the incline gear to move up If the User is commanding the incline to increase and this light is not lit check cabling verify proper PCB operation and replace it if either is defective If the problem persists replace the MCB If the light is lit but the incline is not moving check and verify incline gear and its connection to the board If this problem persists replace MCB DN Light Indicates the PCB is commanding the incline gear to move down If the User is commanding the incline to decrease and this light is not lit check cabling verify proper PCB operation and replace it if either is defective If the problem persists replace the MCB If the light is lit but the incline is not moving check and verify incline gear and its connection to the board If this problem persists replace MCB SPEED Light Indicates the MCB is receiving the revolution signal from the speed sensor magnet pair If this light is not lit verify the speed sensor reed switch and magnet installed in the front roller If this problem persists replace MCB 5 1 Revision 1 0 Date 2001 06 01 MCB LED CHART 5 2 OFF OR BLINKING COMES ON BRIEFLY amp THEN SHUTS Revision 1 0 Date 2001 06 01 JOHNSON MCB LED AIDED TROUBLESHOOTING
9. miles SOFTWARE VERSION 0 1 4 2 Revision 10 Date 2001 06 01 JOHNSON Console Engineering Mode Guide JET 6000 7000NEW 1 Holding UP amp SLOW keys simultaneously about 5 seconds to enter Engineering Mode 2 The Display will be showed P6 Press SELECT key then press SLOW or FAST to set metric kph or British mph Press SELECT key to store 3 Press DOWN key to reach PO address Then press SELECT key for setting the P0 parameter refer to DISTANCE window Press FAST OR SLOW key to adjust speed When the speed display 0 5mph 0 8kph on SPEED window then TI mmaamummam DISTANCE OCO BB as SPEED press SELECT key to store Follow the step 3 for setting the P1 12mph 19 2kph and P2 6mph 9 6kph Press UP key to reach PS address press SELECT key Then press FAST key until the deck raise to the max incline Then press SELECT to store 6 Press DOWN key to reach P4 address press the SELECT key Then press SLOW key until the deck lowers to min incline Press SELECT key to store 7 Press UP key to reach P7 address press SELECT key Then press SLOW or FAST key to adjust the values to 99 Press the SELECT key to store 8 Press UP key to reach P8 address press SELECT key Then press SLOW or
10. the Flywheel clockwise by using left hand and use right hand to push the drive belt on to grooves of WAX the front roller pulley Name CHRIS TIAN 6 Install the front rear rollers Adjust the roller fixed Content bolts to center the running belt at speed 4mph 6 4kph SUNWAYLUBE 1180 7 Turn on the power and then press the start key then Viscosity Grade 68 hold down the fast key until the window indicates 2 Viscosity 40C 68 0 mph 3 kph and then step on the belt for 5 minutes 100C 9 1 to ensure the wax has been evenly distributed Viscosity Index 100 underneath the belt Pour Point C 12 Flash Point C 216 1 3 Revision 1 0 Date 2001 06 01 JOHNSON CLEAN THE GROOVES PROCEDURE Frequency Procedure Every 3 months Remove the drive belt and check the grooves in belt for dirt or dust and clean it If dirty grooves in the drive belt motor and roller pulley there will be noises while running e 2 Check the grooves in motor pulley for dirt or dust and clean it 3 Check the grooves in roller pulley for dirt or dust and clean it 1 4 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 2 IMPORTANT SAFETY INSTRUCTIONS JOHNSON IMPORTANT SAFETY INSTRUCTIONS Note When using an electrical product basic precautions should This product must always be followed including the following be grounded GROUNDING INSTRUCTIONS This product must be grounded If it should malfunction or breakdow
11. the PCB and MCB 5 Use the T handle key 5mm to remove the screws holding the console base to the stanchion and remove the console base 7 7 Revision 1 0 Date 2001 06 01 JOHNSON CONSOLE CABLE REPLACEMENT JET 7000 series Tools required Procedure v Philips screwdriver lt v T handle key Smm 6 Remove the left stanchion protrusion out and pull out both cables 7 Install the new cable into the left stanchion protrusion 8 Install the stanchion protrusion onto the stanchion 9 Install the console base onto the stanchion and tighten it 10 Install the console base plate and tighten the screws 11 Install the left handle bar and tighten it 12 Install the front cover and tighten the screws 7 7 Revision 1 0 Date 2001 06 01 Tools required Procedure v Philips screwdriver 1 Use screwdriver to loosen the screws of Y Nutdriver 6mm console base plate 2 Disconnect the console cables from the PCB 3 Use the Nutdriver 6mm to loosen the screws holding the PCB to the base to remove the PCB 4 Replace with a new PCB and tighten the screws 5 Reconnect the cables with PCB by referring to wiring diagram 6 Install the console base plate 7 Turn on the power Enter the Engineering Mode Refer to the console engineering mode guide for details of calibration 7 8 Revision 10 Date 2001 06 01 Tools required 1 With the scre
12. 2001 06 01 JOHNSON TENSIONING THE BELT Caution Running Belt Over tightening of If when you plant your foot on the belt you can the roller will feel a slipping sensation then the belt has stretched and severely shorten the is slipping across the rollers This 15 a normal and life of the belt and common adjustment on a new treadmill To may cause further eliminate this slipping tension both the rear rollers damage to other Allen bolts 1 4 TURN as shown above Try the components treadmill again to check for slipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 pes p turn at a time tension Perfect Tension o f Running Belt 0 6 0 9 lbs Drive Belt If you have tensioned the running belt and are still experiencing a slipping adjust the tension screw Then try the treadmill again to check for slipping Perfect Tension of Drive Belt 65kow 1 2 Revision 10 Date 2001 06 01 lt JOHNSON DECK RE WAXING PROCEDURE Frequency Procedure Every 1 month 1 After removing the running belt clean the deck and belt by using a clean towel 2 Place the new running belt 3 Place some wax on the deck about 10 cm from the edge in such that the wax is evenly distributed across the deck 4 Tighten the deck screws and assemble the rear roller first then assemble the front roller 5 Replace the drive belt on the transmission pulley by turning
13. CB 4 Replace new motor 6 2 Revision 1 0 Date 2001 06 01 N JOHNSON Treadmill starts to run by itself Possible causes Fix 1 The console cable is 1 Replace the console cable with a new one broken 2 Replace the PCB 2 PCB is out of order 3 Replace the MCB 3 MCB is out of order 6 3 Revision 1 0 Date 2001 06 01 JOHNSON All or some of the keys on console do not work Possible causes Fix 1 Keypad connecting 1 Disconnect the keypad and replace the keypad plug is not fit in and check again properly 2 Replace the keypad 2 Keypad is damaged 3 PCB is damaged 3 Replace the PCB 6 4 Revision 1 0 Date 2001 06 01 JOHNSON Noises generated under motor cover Possible causes Fix 1 The running belt 1 Adjust the belt tension so that the belt does not tension is adjusted too start slipping and then check if the noise has tight disappeared 2 The bearing of front roller is not installed correctly 3 Dirty grooves of drive belt 4 The motor is damaged Let the treadmill run without using it for at least 5 days because sometimes the bearing will settle and become quiet then check if the noise has disappeared 5 Dust in the rack JET 7000 2 Replace the front roller with a new one to see if the noise disappear 3 Remove drive belt and check the grooves in belt for dirt or dust and clean if necessary Clean also the motor pulley and the roller pull
14. CHART PROBLEM RESULT CORRECTIVE ACTION m operation of MCB or PCB No operation of MCB or PCB PCB will not power up PCB will power up but the MCB will not operate Will not operate the motor MCB in current limit mode Will not operate the motor Verify connections power switch and circuit breaker Replace MCB Replace MCB Verify adequate line voltage If line voltage is adequate MCB is damaged and needs to be returned to manufacturer Verify connections to the P3 and the keypad If the connections look good verify the 8 pin cable and the keypad If problem still persist replace the MCB The MCB is experiencing a discontinuous over current events Check for mechanical wear and or defective motor If on mechanical wear and motor good replace MCB and return defective MCB to manufacturer Check and verify the P3 and P4 cables are good replace the PCB If the problem persists replace the MCB Incline does not move Verify connections to the P3 amp incline motor If the connections look good replace MCB PCB Verify connections to the P3 amp incline motor If the connections look good replace MCB PCB 5 3 Revision 10 Date 2001 06 01 JOHNSON SECTION 6 TROUBLESHOOTINGS Revision 1 0 Date 2001 06 01 No display on console Possible causes Fix 1 Breaker 15 damaged 1 refer to MCB LED layout amp indication Verify if LED 115vAC AC is lit If this LED is lit go to step 2 2
15. E2 Ground gt Al Cl gt E3 D2 gt 4 2 gt B2 D4 gt C3 AC1 of MCB gt D1 13 gt C4 AC2 of MCB gt D3 14 3 1 Revision 1 0 Date 2001 06 01 JOHNSON WIRING DIAGRAM TERMINAL END El Ec ES D1 AC1 of MCB BREAKER UN UFF SOCKET SWITCH gt EI Bl gt E2 GROUND gt E3 D2 gt 4 2 gt gt D3 AC2 of MCB 3 2 Revision 1 0 Date 2001 06 01 gt gt gt gt gt gt gt gt gt gt gt A1 Motor wire red A2 Motor wire black P1 V R wire except the JET7000E P2 Sensor wire P3 8 pin console cable P4 6 pin console cable UP Incline yellow except the JET7000E Down Incline white except the JET7000E ELEV COMMMON Incline black except the JET7000E AC CE C3 of Capacitor Non CE D1 of On Off switch AC2 CE C4 of Capacitor Not CE D3 of On Off switch 3 3 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 4 CONSOLE ENGINEERING MODE GUIDE Revision 1 0 Date 2001 06 01 5 lt JOHNSON JET 7000 Old Console Engineering Mode Guide L Press Slow Down and RESET keys To set up the simultaneously to enter Engineering Mode system 2 While the display read CAL HI press PROGRAM parameters INTERVAL The display will show Cl Please VS amo N SS Q W SEN a A Ou B press Fast or Slow keys to set C1 and then press Up key to set
16. dow Press FAST OR SLOW key to adjust speed When the speed display 0 5mile 0 8km on SPEED window then press SELECT key to store Press STOP key for next parameter setting IT aaa TG DISTANCE mus SPEED Follow the step 3 for setting the P1 12mph 20kph and P2 6mph I0kph Press FAST key to reach PZ address press SELECT key Then press SLOW or FAST key to adjust the values to 99 Press the SELECT key to store Press STOP key for next parameter setting Press FAST key to reach P8 address press SELECT key Then press SLOW FAST key to input your weight Press the SELECT key to store Press STOP key for next parameter setting Press FAST key to reach P9 address press SELECT key Then you can see the total running hours of the treadmill Press STOP key for next parameter setting Press FAST key to reach P10 address press SELECT key Then you can see the total running distance of the treadmill Press STOP key for next parameter setting Press the Safety Key to finish Remark Holding the FAST and SLOW key about 5 seconds to reset the accumulated in P9 or P10 of engineering mode Holding the START key about 5 seconds to reset the PO P2 in P7 of engineering mode Define the parameters Min Sp
17. e the motor mount screws not too tight at this time so that the tension adjustment can be made Place the drive belt on the transmission pulley turn the flywheel clockwise by using your left hand and place the drive belt on to grooves of the front roller pulley Adjust the belt tension adjusting screw until the tension is within 80 90lbs Tighten the motor mount screws remark1 Reconnect cables and the ground wire Turn on the power and enter the Engineering Mode to check if the extreme speeds are within the correct range Try to step on the belt at low speed to check if the belt slips Install the front cover and secure the screws Remarkl The centerline of motor shaft has to parallel with the centerline of roller 7 2 Revision 1 0 Date 2001 06 01 JOHNSON INCLINE MOTOR REPLACEMENT JET6000 Tools required Procedure 1 Remove screws from the front cover by using the screwdriver to open the cover v Philips screwdriver v Wrench 14mm Y Wrench 17mm 2 Disconnect cables from the connectors of the incline motor and MCB and also disconnect the ground wire 3 To prevent the frame from falling down heavily while removing the incline motor put a support with proper height under the front of frame 4 Remove the bolts and the nuts from the incline motor by using the wrenches 14 17 5 Replace the incline motor with a new one 6 Reconnect cables and the grounding wire to the connecto
18. eed P1 Max Speed P2 Mid Speed None P4 None P5 None Unite mode P7 Max Time P6 User Weight 4 4 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 5 MCB LED INSTRUCTIONS Revision 1 0 Date 2001 06 01 ILT2 IL T Note Use a multi meter to test the power socket 210 250 Note For PCB Upper board When we designed the lower control board MCB for our treadmills we placed status lights LEDs on it to aid in field diagnosis and repair The following is an overview of what these indicator lights mean and what can be checked with them in the field 1 1 5 AC _Light When lit this indicates that eS the MCB has power applied If this LED is off check connections power switch position fuses and circuit breakers If the AC light is not lit the MCB will not operate 1 2V Light when lit this indicates the presence of the regulated 12 volt direct current supply necessary for the operation of the PCB If dim the supply voltage may be marginal and if out not present or inadequate If the light 15 not lit the console will not operate If the AC light 15 lit and the 12V light is not check for shorted cabling or a defective upper console 5 1 Revision 10 Date 2001 06 01 MCB LED Indication Note Motor power Note over 25 3 Amps when ILT is lit under 25 3 Amps when ILT1 is lit If ILT1 is not lit check the fuse Note A control command fro
19. ent shall be properly grounded to the frame and the frame shall be earthed through the third prone pin of the power socket 6 9 Revision 1 0 Date 2001 06 01 lt JOHNSON Treadmill varies the speed by itself Possible causes Fix 1 Keypad is stuck 1 Remove the keypad and verify the keypad is stuck If it is stuck replace with a new keypad 2 PCB is damaged 3 Grounding 2 If speed or incline still changes by itself replace the PCB and refer to Engineering Mode Guide to re program all the parameters 3 Each component shall be properly grounded to the frame and the frame shall be earthed through the third prone pin of the power socket Remarks The symptom here is the speed indication on the console will vary with the speed 6 10 Revision 1 0 Date 2001 06 01 JOHNSON Error message on console JET6000 7000N Error e cause solution En2 P0 P1 P2 P4 P5 have a wrong e Re calibrate all parameter E parameter values values in Engineering Mode Re plug or replace the Incline Motor Jet6000 Re plug or replace the Err3 VR is open loop or short Re plug or replace 8 pin console cable MCB 15 damaged Err6 No elevating after press Re calibrate the P4 P5 or down key about 5 seconds parameter values JET7000E Error cause solution ps e Re calibrate all parameter EEPROM Checksum error values in Engineering Mods
20. eplace the carbon brush If replacing the carbon brush to step 10 3 Prior to disassembling the end caps you must make a mark on the end cap 4 Usethe nutdriver 5 16inch to remove bolts holding the end caps to the main enclosure of the motor 5 Tap the shaft carefully with a wooden hammer to remove the end caps Revision 10 Date 2001 06 01 JOHNSON MOTOR BEARINGS amp CARBON BRUSH REPLACEMENT Tools required v Nutdriver 5 16inch Bearing puller Wooden hammer Procedure 6 Remove the bearings of both sides by using the bearing puller 7 Install the new bearings to the shaft by using the wooden hammer 8 Put on the two end caps and use the nutdriver 5 16inch to lock the caps to the main enclosure 9 Install the carbon brush and the carbon brush cover The end of the procedure 10 Replace the carbon brush with a new one 11 Install the carbon brush and the carbon brush cover 12 Turn the power on let the treadmill run for about 1 hour at 3 0kph to allow the proper seating of the brush 7 5 Revision 1 0 Date 2001 06 01 JOHNSON GEAR MOTOR REPLACEMENT JET 7000 series Tools required Procedure v Philips 1 Release screws of front screwdriver cover by using screwdriver to open the cover Y T handle key 14mm Y Ratchet Box 2 Disconnect remove cables from the Gear motor and lower Wrench 11mm board and also disconnect the ground wire ten
21. ey grooves and check if the noise has disappeared 4 The motor bearing is damaged Refer to motor bearings replacement procedure Replace the motor 5 JET 7000 Remove the rack cover and check the rack for any dust Clean the rack 6 5 Revision 1 0 Date 2001 06 01 Treadmill will not start Possible causes Fix 1 MCB is damaged Open motor cover verify wire connection Al and A2 motor wire on the MCB then plug in the power cord 2 6 pin console cable and turn on the power switch Then press POWER is damaged START FAST buttons 3 PCB is damaged 1 Verify the LED indicator of MOTOR is lit If that LED MOTOR is not lit replace MCB 4 Motor is damaged 2 Verify if LED M C SIG is lit If it is not lit replace 6 pin console cable 3 If LED M C SIG is still not lit replace PCB 4 Replace Motor 6 6 Revision 1 0 Date 2001 06 01 JOHNSON Heart Rate Control function does not work Possible causes 1 Transmitter does not contact with user s chest very well 2 Transmitter Polar belt is at low battery status 3 Transmitter Polar belt is damaged 4 Heart rate control board is damaged 5 PCB is damaged Fix l Center the transmitter on your chest below the pectoral muscle breast as shown then check again 2 Remove the battery cover of the transmitter Replace a new battery and check again Actually as moisture may activate the transm
22. in wheel in such the way that the minimum elevation control dog touches the minimum elevation limit switch 7 Install the chain latch 8 Adjust the chain tension then tighten the Gear motor mount screws by using T handle wrench 14mm 9 Turn on the power and enter the Engineering Mode to check if the minimum and maximum elevations are within the range 10 Install the front cover and secure the screws 7 11 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 8 SERVICE FORM Revision 1 0 Date 2001 06 01 JOHNSON MCB LED Status Report AC 115V Light LED On LED Off MTR Light LED On LED Off LED Dim LED Off When you press the UP or DOWN key the LED status is Up Light Dn Light LED On LED Off These LEDs are only for JET 7000 MCB In order to fill out this Report properly please use the PWM MCB CHART and MCB LED aided troubleshooting which you can find in the Service Manual Please fill out this Report at the moment before repairing the problem Serial number MCB Reported Approximate hours of use Company Name 8 1 Revision 10 Date 2001 06 01 JOHNSON Field Failure Report Name of Distributor Warranty Yes No Failure Intermittent Persistent Product Serial number Failure Symptom Pls refer
23. ip this step if replacing the deck Go to step 14 7 1 Revision 10 Date 2001 06 01 JOHNSON RUNNING BELT DECK ROLLER REPLACEMENT Tools required Philips screwdriver Y T handle key 8mm 5mm Procedure 12 Replace the deck and put the old running belt through the deck and place the deck with the running belt on the frame Go to step 14 13 Replace the front roller and rear roller Go to step 15 14 Tighten the deck screws 15 Assemble the rear roller first then assemble the front roller 16 Place the drive belt on the transmission pulley by turning the flywheel clockwise by using left hand and place the drive belt on to grooves of the front roller pulley by using your right hand 17 Install the front rear rollers Adjust the running belt tension bolts to center the running belt at high speed 18 Try to step on the belt to check if the belt slips 19 Install the side rails and secure the end covers 20 Install the front cover and secure the screws 7 1 Revision 10 Date 2001 06 01 Tools required Y Philips screwdriver Y T handle wrench 14mm Y Ratchet Box Wrench 11mm Procedure 11 12 Remove screws from the front cover by using the screwdriver and remove it Remove cables connecting to the motor and lower board remove also the ground wire by using the screwdriver Remove the motor mount screws by using the T handle wrench Replace the motor Secur
24. itter please dry transmitter after use OR 3 Transmitter is damaged Replace the Transmitter OR 4 Heart rate control board is damaged Replace the Heart rate control board OR 5 PCB is damaged Replace the PCB 6 7 Revision 1 0 Date 2001 06 01 JOHNSON Treadmill will not incline up or down Possible causes 1 The incline settings are not correct 2 The 8 pin console cable is damaged 3 PCB is damaged 4 MCB is damaged 5 Variable Resistance is damaged Fix 1 Enter to Engineering Mode to see if the incline motor will be activated OR Use a new 8 pin console cable to connect PCB and MCB to see if the incline motor will be activated 9 OR Replace PCB 9 OR Replace MCB 2 Enter to Engineering Mode and verify if the number in the right window varies as the elevation changes 9 OR gt Replace 8 pin cable and check gt Replace Variable Resistance gt Replace PCB and check Enter the Engineering Mode to re calibrate the incline 6 8 Revision 1 0 Date 2001 06 01 JOHNSON Treadmill will incline up or down by itself Possible causes 1 The 8 pin console cable is damaged 2 MCB is damaged 3 PCB is damaged 4 Grounding of the treadmill is poor Fix Use anew 8 pin console cable to connect PCB to MCB Then turn the power on press POWER START UP DOWN keys to see if this fix the problem Replace MCB Replace PCB Each compon
25. m the PCB to the MCB M O T O Light When lit indicates the Start key has been pressed and the K1 relay has been activated which will then allow the AC power to be present to the control board with the two big capacitors on it If the MOTOR light 15 not lit after the Start key has been pressed check the keypad the 8 pin cable and the interconnection of the wiring mentioned above If the problem persist return the board to JMI ILT l ILT Light When ILTI is lit indicates the current to the motor is under 25 3 Amps When ILT2 is lit indicates the current to the motor has reached the peak current trip point of 25 3 Amps The MCB might be broken down if the over current situation persists for a while It is recommended that the treadmill should be thoroughly examined for wear or damaged components which might have lead to the extended current limit condition Besides treadmill might have to re waxed at this time M C SIC Light Indicates the control PWM e e from the PCB is present It will blink at the control frequency used by the PCB when the PCB commands speed If the control signal should exceed 95 percent duty cycle the PWM light shuts off and sets the MCB to a safe shutdown mode In the event this should occur the power to the treadmill should be removed the cabling checked for shorts and the PCB replaced If this problem persists replace the MCB 5 1 Revision 10 Date 2001 06 01 MCB LED Indication
26. n grounding provides a path of least resistance for electrical current to reduce the risk of electrical shock This product is equipped with a cord having an equipment grounding WARNING conductor and a grounding plug The plug must be plugged Connect this appliance into an appropriate outlet that is properly installed and grounded to a properly in accordance with local codes and ordinances grounded outlet only See grounding GROUNDED OUTLET ADAPTER Instructions D wm 9 SCREW TAS FOR j GROUNDED GROUNDING SCREW OUTLET BOX GROUNDING PIN DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician of serviceman if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will fit the outlet have a proper outlet installed by a qualified electrician Note Power voltage 110v model POWER VOLTAGE INSTRUCTIONS 95v 140 Power voltage 110v model 95v 140v 220v model 210v 250v Power voltage 220v model 210v 250v 2 1 Revision 1 0 Date 2001 06 01 JOHNSON SECTION 3 WIRING DIAGRAM INSTRUCTION Revision 1 0 Date 2001 06 01 JOHNSON WIRING DIAGRAM TERMINAL END CE C2 EA c4 I3 I4 IS n FALTEM El a pr Ei i D3 D4 n LINDA LIFT SI RET SWITCH gt 2 gt El B1 gt 2 A3 gt
27. n wheel 8 Attach the new elevation rack on to the transportation wheel and attach C clip then attach the elevation rack onto the incline gear and install the covers 9 Remove the support 10 Install and tighten the left right stanchion and connect console cables to the MCB 11 Turn on the power and enter the Engineering Mode to check if the minimum and maximum elevations are within the limits 12 Install the front cover and secure the screws 7 10 Revision 1 0 Date 2001 06 01 JOHNSON CHAIN REPLACEMENT JET 7000 series Tools required Procedure v Philips 1 Turn on power and keep the incline at the minimum screwdriver elevation Then turn off power v T handle 2 Remove the front cover wrench 14mm Y Ratchet Box Wrench 11mm 3 To prevent the frame from falling down heavily while replacing the chain please put a support with proper height 9cm under the front of frame before replacement Gear Motor 4 Release the Gear motor mount screws by using the T handle wrench 14mm and loosen the chain tension adjusting screw by using a Ratchet Box wrench 11mm 7 11 Revision 1 0 Date 2001 06 01 PN JOHNSON CHAIN REPLACEMENT JET 7000 series Tools required Philips screwdriver v T handle wrench 14mm Ratchet Box Wrench 11mm Procedure chain latch 5 Remove the chain latch to separate and then take out the chain 6 Install the chain onto main cha
28. rs and the frame 7 Remove the support under the frame 8 Turn on the power and enter the Engineering Mode to check if the extreme inclines are within the correct range 9 Install the front cover and secure the screws 7 3 Revision 1 0 Date 2001 06 01 5 lt JOHNSON CONSOLE CABLE REPLACEMENT JET6000 Tools required Procedure 1 Remove screws from the motor cover by using the screwdriver v Philips screwdriver Y T handle key Smm 2 Remove screws from the right support with the T handle key 5mm 3 Remove the screws from the console cover 4 Disconnect the console cable from the PCB and MCB 5 Pull out the snap bushing first 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 right support and the console bare 7 Connect the console cable to PCB and MCB 8 Install the console cover and tighten the screws 9 Install the front cover and tighten the screws 7 4 Revision 1 0 Date 2001 06 01 JOHNSON MOTOR BEARINGS amp CARBON BRUSH REPLACEMENT Tools required v Nutdriver 5 16inch Bearing puller Wooden hammer Coin Procedure mark here 7 5 1 Remove the screws of carbon brush cover and the carbon brushes with the coin 2 Check the surface of carbon brush if smooth If the surface of carbon brush is pitted rough or with burn marks r
29. sion screw 3 prevent the frame from falling down heavily while remove the incline motor please put the support with a proper height 9cm under the front end of frame 4 Loosen the Gear motor mount screws by using T handle wrench 14mm to remove the Gear motor and replace with a new one 7 6 Revision 1 0 Date 2001 06 01 JOHNSON GEAR MOTOR REPLACEMENT JET 7000 series Tools required v v Philips screwdriver T handle Wrench 14mm Ratchet Box Wrench 11mm Procedure 5 Install the chain onto main chain wheel and tighten the fixed bolts of gear motor Use Ratchet Box wrench 11mm to adjust the chain tension screw which is located at the back end of the gear motor 6 Reconnect cables and ground wire by referring to the wiring diagram Remove the support under the frame 7 Turn on the power and enter the Engineering Mode to check if the extreme incline is within the correct range 8 Install the front cover and secure the screws 7 6 Revision 1 0 Date 2001 06 01 JOHNSON CONSOLE CABLE REPLACEMENT JET 7000 series Tools required Procedure v Philips screwdriver 1 Remove screws from the front cover by using the screwdriver and remove it Y T handle key Smm 2 Use the T handle key Smm to remove screws of the left handle bar and remove it 3 With the screwdriver remove the screws from the console base plate 4 Disconnect the console cable from
30. to the service manual for the symptom of failure Parts Replaced When parts needed please fill out a Parts Order Form as detailed as possible Prepared By Company Stamp 8 2 Revision 10 Date 2001 06 01 JOHNSON Distributor Delivery Terms CIP FCA FOB Warranty Yes No Product Product Drawing Part Number Part Name Remark Please refer to the spare part kit for all the information that are to be filled out above Date Place Signature Company Stamp 8 3 Revision 1 0 Date 2001 06 01 JOHNSON Warranty Claim Form Claim Dealer Name Page DE seeds Pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS AUTHORIZED BY 8 4 Revision 1 0 Date 2001 06 01
31. wdriver loosen the screws from the console base cover v Philips screwdriver 2 Disconnect the plug of keypad from the PCB 3 Remove the safety key and the overlay 4 Replace with a new keypad and connect it with PCB 5 Install the console base plate and tighten the screws 6 Place the new overlay on the console correctly and press it firmly on the edges 7 Install the safety key 7 9 Revision 10 Date 2001 06 01 JOHNSON ELEVATION RACK REPLACEMENT JET 7000 series Tools required Procedure Philips 1 Turn on the power and keep the incline at the minimum screwdriver elevation Then turn off the power T handle 2 Remove the front cover key 5mm 3 Disconnect console cables from the MCB 4 Use the T handle key 5mm to loosen screws and remove the stanchion together with console base 5 To prevent the frame from fall down heavily while remove the elevation rack amp outer pinion amp rack cover please put a support with proper height 9cm under the front of frame before the replacement 6 Loosen the screws from the right left rack amp pinion outer cover by using T handle key 5mm and remove the covers 7 10 Revision 1 0 Date 2001 06 01 JOHNSON ELEVATION RACK REPLACEMENT JET 7000 series Tools required Procedure Philips screwdriver v T handle key 5mm 7 Remove the elevation rack Then remove the C clip of the transportation wheel to remove the transportatio
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