Johnson T7000 Pro Service Manual
Contents
1. 28 30 SECTION 5 MCB LED INSTRUCTIONS 31 1 T7000 Pro MCB LED PLACE AND DEFINITION 32 3 TABLE OF CONTENTS SECTION 6 TROUBLESHOOTINGS 33 1 No display on console 34 2 Running speed is not stable 35 3 Treadmill starts to run by itself 36 4 All or some of the keys on console do not work 36 5 Noises generated under motor cover 37 6 Error Messages on the Console 38 7 How to make sure whether the machine hand pulse can not work 39 40 SECTION 7 PARTS REPLACEMENT GUIDE 41 7 1 Front Plastic Shroud Removal 42 7 2 Rear Roller Replacement 43 7 3 Side Rail Replacement 44 7 4 Front Roller Replacement 45 7 5 Deck Removal 46 7 6 Running Belt Removal 47 7 7 Deck Cushion Replacement2. 48 7 8 Motor Control Board MCB Replacement 49 7 9 Motor Replacement 50 7 10 Drive Belt Replacement 51 7 11 Incline Motor Replacement 52 7 12 Console Control Board Replacement 53 7 13 Console Cable Replacement 54 7 14 Emergency Stop Switch Replacement 55 7 15 Heart Rate Board Replacement 56 4 SECTION 1 What s difference between T7000 and 7OOOPro 5 New design upper overlay The console mast has been modified to straight Motor sticker has modified the material to POLY The frame sticker has modified to T7000 Pro Hand pulse set has been improved to one piece style T7000 Pro vsT7000 outlook design change T7000 Pro vsT7000 outlook design change 6 T7000 Pro vsT7000 internal design change T7000 Pro vsT7000 internal design change Power system has been modified from DC to AC system New design tension wheel set The flat type front roller New belt spec 250J12 New design donut cushion Increase the bearing size of front and back roller New running belt with wax New running deck without wax Can
3. 7 1 Front Plastic Shroud Removal 1 Turn off the power and move the plug 2 Remove the eight fix screws of front shroud using a Phillips screwdriver Figures A amp B 43 CHAPTER 7 Part Replacement Guide 7 2 Rear Roller Replacement 1 Turn off power and disconnect the cord from the machine 2 Remove both side end caps using a Phillips screwdriver Figure A 3 Remove both roller adjustment screws using an 8 mm Allen wrench Figure B 4 Remove the roller from the running belt Figures C 5 Reverse Steps 1 4 to install a new roller A A B C 44 CHAPTER 7 Part Replacement Guide 7 3 Side Rail Replacement 1 Remove the front shroud as outlined in Section 7 1 2 Remove the end cap using a Phillips screwdriver Figure A 3 Remove the end cap bracket using a 3 mm Allen wrench Figure B 4 Slide the rail off the back of the treadmill Figures C 5 Reverse Steps 1 4 to install a new side rail A A B C 45 CHAPTER 7 Part Replacement Guide 7 4 Front Roller Replacement 1 Remove the front shroud as outlined in Section 7 1 2 Release the tension of running belt 3 Remove the fix bolt of tension wheel set using a 5 mm Allen wrench Figure A Be careful to hold the tension wheel set when fix bolt is releasing 4 Remove the fix bolts of front roller using a 5 mm Allen wrench Figure B 5 Remove the driver belt form front roller Figure C 6 Remove the front ro
4. Check the power voltage by using voltage meter to see if it is within 120V 15 or 230V 15 If the power voltage isn t within the range look for a qualified electrician for help 2 Open the motor cover if the belt has stretched and is slipping across the rollers when running Adjust the belt tension Please refer the TENSIONING THE BELT PROCEDURE Page11 12 2 Replace new MCB 3 Replace new Motor 36 Treadmill starts to run by itself Possible causes 1 The digital communication cable is broken 2 PCB is out of order 3 MCB is out of order Fix 1 Replace the console cable with a new one 2 Replace the PCB 3 Replace the MCB All or some of the keys on console do not work Possible causes 1 Keypad connecting plug is not fit in properly 2 Keypad is damaged 3 PCB is damaged Fix 1 Disconnect the keypad and replace the keypad and check again 2 Replace the keypad 3 Replace the PCB 37 Noises generated under motor cover Possible causes 1 The running belt tension is adjusted too tight 2 The bearing of front roller is not installed correctly 3 Dirty grooves of drive belt 4 The motor is damaged Fix 1 Adjust the belt tension so that the belt does not start slipping and then check if the noise has disappeared Let the treadmill run without using it for at least 5 days because sometimes the bearing will settle
5. 2 lubrication 3 overload C 01AB Inverter Error internal error of inverter 1 check MCB error by PU 01 2 MCB replacement C 01AD Inner electron over temperature motor over loading when the user over 130kg to make motor over loading and Inner electron over temperature Lubrication running belt C 02A0 main motor fail the belt does not move when it supposes to move 1 connection check power input 2 motor resistance check 3 MCB replacement C 02A1 Over AC power input voltage power input voltage over range check power input C 02A2 Over low DC bus voltage power input voltage over range check power input C 02A8 Inverter circuit of motor driver fail motor resistance close 1 motor check or replace C 02AD LCB over temperature LCB over temperature 1 check MCB temp by PU 01 2 check cool fan 3 MCB replacement C 02B5 Inverter sensor the normal rated current over 150 can hold 60 sec Inverter sensor the normal rated current over 10 5Amps can hold 60 sec motor check or replace C 02B6 Speed up have over current Software discover Lubrication C 02B7 Speed down have over current Software discover MCB replacement C 02B8 Running status over current Software discover 1 connection check 2 lubrication 3 overload C 02B9 The inner memory IC data write error MCB fail MCB replacement C 02BA The inner memory IC data read error MCB fail MCB replacement C 02B
6. both the rear rollers Allen bolts 1 4 TURN as shown above Try the treadmill again to check for slipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 turn at a time Perfect Tension of Running Belt Perfect Tension of Running Belt 0 9 1 1 lbs 0 9 1 1 lbs Frequency Every 1 months 12 Drive Belt If you have tensioned the running belt and are still experiencing a slipping adjust the tension screw of spring Then try the treadmill again to check for slipping 13 Purpose Purpose To ensure the maximum life of your treadmill follow these steps at regular intervals The timing of running belt and deck maintenance The timing of running belt and deck maintenance 1 Each 6 months to lubricate by wax powder 2 One year to flip the running deck 3 Two years or over 6 000 hrs of usage to replace new running belt and deck 4 In the regular maintain If the motor over current that has to lubricate by wax powder Take a motor current reading while a 70 90 kg user is walking on the machine at 5KM If it is over limited current wax the deck The limit current for each motor as below The limit current for each motor as below Recheck the motor current as above If the motor current is still over limited current Please flip the deck or replace the belt Limited Current Normal Current Motor type 5 5A lt 5A 220V AC 110V AC 20A lt 15A 110V DC 11A lt 9A 220V DC DECK R
7. and become quiet then check if the noise has disappeared 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 pulley grooves and check if the noise has disappeared 4 The motor bearing is damaged Replace the motor 38 Error Messages on the Console Class Level Class Level Class C The machine will be stop Class B To make a record in error log only The machine keep working Class Level Error Code Description Conditioned Solution B 0140 Incline motor operation fail when the elevation is supposed to move it does not move When the error happens the elevation will be locked The command initialize is needed to unlock the elevation 1 connection check 2 MCB LED check 3 incline motor check or replace C 01A0 Incline motor disconnection when the elevation position cable is not connected 1 connection check 2 MCB LED check 3 incline motor check or replace C 01A4 Main motor U phase disconnection Main motor U phase disconnection 1 connection check U C 01A5 Main motor V phase disconnection Main motor V phase disconnection 2 connection check V C 01A6 Main motor W phase disconnection Main motor W phase disconnection 3 connection check W C 01A8 main motor over current main motor over current 7Amps 1 connection check
8. 1 Johnson T7000 Pro Johnson T7000 Pro Service Manual Service Manual 2 TABLE OF CONTENTS SECTION 7 WHAT S DIFFERENCE BETWEEN T7000 AND T7OOOPro 4 1 T7000 Pro vsT7000 outlook design change 5 2 T7000 Pro vsT7000 internal design change 6 3 T7000 Pro vsT7000 console mast design change 7 4 T7000 Pro vsT7000 tension wheel set design change 8 SECTION 2 MAINTENANCE PROCEDURE 9 1 MAINTENANCE CHECK LIST 10 2 TENSIONING THE BELT PROCEDURE 11 12 3 DECK RE WAXING PROCEDURE 13 14 4 CLEAN THE GROOVES PROCEDURE 15 SECTION 3 WIRING DIAGRAM INSTRUCTION 16 1 T7000 Pro TM512 MCB WIRING FOR 110V 220V 17 2 T7000 Pro TM512 MCB WIRING DEFINITION OF PIN 18 3 T7000 Pro TM512 PCB WIRING 19 4 T7000 Pro TM512 ELECTRICAL BLOCK DIAGRAM 20 SECTION 4 CONSOLE FUNCTIONAL FLOW DIAGRAM 21 1 OPERATION T7000 Pro MANUAL 22 26 2 OPERATION T7000 Pro MANUAL Engineer mode 27 2 1 Key Behalf Functions
9. C Ground connection or fuse error MCB fail MCB replacement C 02BD Inverter hardware interrupt error MCB fail MCB replacement 39 How to make sure whether the machine hand pulse can not work 1 Please make sure then user hold the hand pulse whether windows show picture Remark Heart rate figure show up on the screen about in 5 10 sec 2 If the heart rate figure still doesn t show up on the screen Please inspect according to the step as below Step 1 Using multi meter to confirm the wire has conduct 40 Step 2 Please check the connection Check whether the heart rate cable is touching hand pulse metal both of left hand and right hand Besides the other side of the heart rate cable should be connected with HR board Step 3 If you can t find any problem with above step and the heart rate figure still can t show up Please replace the heart rate board 41 SECTION 7 Part Replacement Guide 7 1 Front Plastic Shroud Removal 7 2 Rear Roller Replacement 7 3 Side Rail Replacement 7 4 Front Roller Replacement 7 5 Deck Removal 7 6 Running Belt Removal 7 7 Deck Cushion Replacement 7 8 Motor Control Board MCB Replacement 7 9 Motor Replacement 7 10 Drive Belt Replacement 7 11 Incline Motor Replacement 7 12 Console Control Board Replacement 7 13 Console Cable Replacement 7 14 Emergency Stop Switch Replacement 7 15 Heart Rate Board Replacement 42 CHAPTER 7 Part Replacement Guide
10. E WAXING PROCEDURE 14 1 2 scale for one machine per one time around 5gm Wax powder set including 1 One big bottle with 1kg wax powder 2 A small bottle for maintenance The wax powder set Parts number MTOOL 052 Price US 30 MTOOL 052 WAXING PROCEDURE WAXING PROCEDURE 1 Warm deck and belt by walking on treadmill for 3 or more minutes at a minimum speed of 3 mph 4 8 kph 2 Turn off and unplug the treadmill 3 Sprinkle approximately 1 2 scales of wax under the running belt It is useful to lightly blow the wax to the center of the belt 4 Turn the unit on and walk the wax in for 3 4 minutes at 1 mph Walk all over the belt to ensure smooth wax distribution 5 Once wax is walked into the belt and deck repeat procedure for checking the motor current to ensure that the belt and deck are not to worn for wax to improve the friction Be careful to monitor wax buildup on the rollers too much wax can cause issues and technicians need to monitor the rollers if they continually wax units 15 CLEAN THE GROOVES PROCEDURE Frequency Every 3 months Procedure 1 Remove the drive belt and check the grooves in belt for dirt or dust and clean it If dirty grooves in the drive belt and motor there will be noises while running Caution 2 Check the grooves in motor pulley for dirt or dust and clean it 16 SECTION 3 WIRING DIAGRAM INSTRUCTION 17 T7000 Pro TM512 MCB WIRING JP3 JP4
11. U N L V W W Motor wire black V Motor wire white U Motor wire red L Power Input black N Power Input white JP3 Console cable JP4 Elevation motor cable 18 T7000 Pro TM512 MCB WIRING DEFINITION OF PIN JP4 Elevation cable 6pin AMP 350762 4 Incline motor does turn on power COMMON 6 Incline motor does move to down DOWN driver 5 Incline motor does move to up UP driver 4 Incline place signal test ground Ground E driver 3 Incline place signal Position 2 Incline place signal test power VDC 1 Definition Name Pin 1 2 3 4 5 6 19 T7000 Pro TM512 PCB WIRING FOR 110V 220V J3 JP2 U N L V W J19 Digital communication wire port J5 Hand Pulse receiver J6 inbuilt receive implement J17 Emergency stop key J19 J6 For analogy system use only J5 J17 20 T7000 Pro TM512 Electrical block diagram 21 SECTION 4 CONSOLE FUNCTIONAL FLOW DIAGRAM 22 OPERATING T7000 Pro 23 24 25 26 27 T7000 Pro MANUAL Engineer mode How to enter into the engineering mode How to enter into the engineering mode 1 Press amp Hold both ELEVATION and SPEED at the same time for 3 5 sec Then the display will show MANAGER MENU 2 Press the SPEED or to select you want and press the ENTER key enter Engine
12. bration must ALWAYS be run after replacing the console see Section 3 2 A B C 54 CHAPTER 7 Part Replacement Guide 7 13 Console Cable Replacement 1 Turn off power and disconnect the cord from the machine 2 Open the upper console cover as outlined in Section 7 12 2 3 Disconnect the console wire from CCB Figure A 4 Connection the defect wire and new wire Figure B 5 Pull the defect wire from lower outlet of console mast 6 Reconnect console wire to MCB and CCB A B 55 CHAPTER 7 Part Replacement Guide 7 14 Emergency Stop Switch Replacement 1 Turn off power and disconnect the cord from the machine 2 Open the upper console cover as outlined in Section 7 12 2 3 Use a Phillips screwdriver to remove two screws of the cover of Emergency key Figure A 4 Use a Phillips screwdriver to remove two screws of the base of Emergency key Figure B 5 Turn open the Emergency switch Figure C 6 Reverse Steps 1 5 to install a new Emergency key set A B C 56 CHAPTER 7 Part Replacement Guide 7 15 Heart Rate Board Replacement 1 Turn off power and disconnect the cord from the machine 2 Open the upper console cover as outlined in Section 7 12 2 3 Disconnect the wires from each side of the Heart Rate Board Figure A 4 Use a Phillips screwdriver to remove two screws one from each side of the Heart Rate Board mounting bracket Figure B 5 Be sure to fully s
13. celed the speed sensor 7 New fix bracket Console mast in straight type T7000 Pro T7000 T7000 Pro vsT7000 console mast design change T7000 Pro vsT7000 console mast design change 8 T7000 Pro vsT7000 tension wheel set design change T7000 Pro vsT7000 tension wheel set design change T7000 Pro vsT7000 roller set design change T7000 Pro vsT7000 roller set design change Flat type pulley and increase bearing size 9 SECTION 2 MAINTENANCE PROCEDURE 10 MAINTENANCE CHECK LIST Clean Motor Clean Vacuum Control Box Inspect Running Belt Flip Re waxing Inspect Running Deck Inspect Clean V Belt Inspect Running belt Tension Test Emergency Button Inspect Clean Rear Roller Inspect Clean Front Roller Inspect Clean Handrail amp Handlebar Inspect Clean Display Console Inspect Power Cord Inspect Clean Frame Inspect Console Mounting Bolts Annual Biannual Quarterly Monthly Weekly Daily Item Johnson T7000 Pro TREADMILL PREVENTIVE MAINTENANCE SCHEDULE 11 TENSIONING THE BELT PROCEDURE Caution Over tightening of the roller will severely shorten the life of the belt and may cause further damage to other components Running Belt If when you plant your foot on the belt you can feel a slipping sensation then the belt has stretched and is slipping across the rollers This is a normal and common adjustment on a new treadmill To eliminate this slipping tension
14. cket Figure A amp B B A 49 CHAPTER 7 Part Replacement Guide 7 8 Motor Control Board MCB Replacement 1 Turn off power and disconnect the cord from the machine 2 Remove the front shroud as outlined in Section 7 1 3 Cut any wire ties that are secured to the MCB panel Figure A B 4 Disconnect wires from the MCB six total connections Figure C 5 Remove Four MCB mounting screws using a Phillips head screwdriver Figures D 6 Reverse Steps 1 5 to install a new MCB 7 Auto Calibration must ALWAYS be run after replacing the MCB see Section 3 2 A D B C 50 CHAPTER 7 Part Replacement Guide 7 9 Motor Replacement 1 Turn off power and disconnect the cord from the machine 2 Remove the front shroud as outlined in Section 7 1 3 Release the drive belt tensioner as outlined in Section 7 5 4 Disconnect the motor power cable from the MCB Figure A 5 Using an 8 mm Allen wrench remove the four motor mounting screws Figure B 6 Lift the motor away from the treadmill 7 Reverse Steps 1 6 to install a new motor 8 When reinstalling the motor make sure the vibration pad is in place 9 Be careful the diversion when motor remove and reinstall Figure C A B C 51 CHAPTER 7 Part Replacement Guide 7 10 Drive Belt Replacement 1 Remove the front shroud as outlined in Section 7 1 2 Release the drive belt tension wheel set from drive belt as outlined in Secti
15. eat the wires on the new Heart Rate Board and test the grips after the console is reinstalled A A B OK
16. er mode setting Engineer mode setting 28 Enter the function place ENTER reset to sources RESET clean accumulate time and distance Hold UP amp FAST key for 3 s Set the parameter NUMBER KEY To Store up the parameter START Decrease this show parameter of speed and elevation SLOW Add this show parameter of speed and elevation FAST To scroll through the list of setting DOWN To scroll through the list of setting UP function key name KEY BEHALF FUNCTION KEY BEHALF FUNCTION 29 Measurement unit used for calorie calculations distance and speed N A N A Metric UNITS P14 Software Version of MCB not editable N A N A N A MCB SOFT VER P13 Software Version of UCB not editable N A N A N A UCB SOFT VER P12 Sets the language shown on the console N A N A English LANGUAGE P11 Controls the maximum time the treadmill can be paused during a workout 180 sec 30 sec 60 sec PAUSE TIME P10 Controls the starting speed for all programs does not affect minimum speeds 3 0 KPH 1 8 MPH 0 8 KPH 0 5 MPH 0 8 KPH 0 5 MPH START SPEED P9 Total distance on treadmill not editable TO RESET Press and hold INCLINE DOWN and SPEED DOWN for 3 5 seconds N A N A N A ACCUMULATED TIME P8 Total distance on treadmill not editable TO RESET Press and hold INCLINE DOWN and SPEED DOWN for 3 5 seconds N A N A N A ACCUMULATED DISTANCE P7 Controls the maxim
17. ller from the running belt 7 Reverse Steps 1 6 to install a new roller A B C 46 CHAPTER 7 Part Replacement Guide 7 5 Deck Removal 1 Remove the front shroud as outlined in Section 7 1 2 Remove the side rail as outlined in Section 7 3 3 Remove the eight deck screws using a 5 mm Allen wrench Figure A 4 Loose the tension of running belt 5 Remove the deck from the running belt 6 Be careful not to pinch fingers during removal installation of deck board 47 CHAPTER 7 Part Replacement Guide 7 6 Running Belt Removal 1 Remove the front shrouds as outlined in Section 7 1 2 Remove the rear roller as outlined in Section 7 2 3 Remove the side rail as outlined in Section 7 3 4 Remove the front roller as outlined in Section 7 4 5 Remove the deck as outlined in Section 7 5 6 Remove the running belt and replace with a new belt 7 Reverse Steps 1 6 to install a new running belt 48 CHAPTER 7 Part Replacement Guide 7 7 Deck Cushion Replacement 1 Remove the front shrouds as outlined in Section 7 1 2 Remove the rear roller as outlined in Section 7 2 3 Remove the side rail as outlined in Section 7 3 side rail as outlined in Section 7 3 4 Remove the deck as outlined in Section 7 5 5 Remove the running belt as outlined in Section 7 6 6 Remove the front roller as outlined in Section 7 4 7 Holding the bolt with a 5 mm Allen wrench loosen the nut with a 13 mm so
18. on 7 4 3 Remove the front roller screws on both side Figure A 4 Lift the roller and remove the old drive belt 5 After installing a new belt check it for correct alignment to the motor pulley before setting the tension wheel set in place A A 52 CHAPTER 7 Part Replacement Guide 7 11 Incline Motor Replacement 1 Turn off power and disconnect the cord from the machine 2 Lift the treadmill and support it so that the front wheels are off the floor or the unit may be tipped on its side Figure A 3 Disconnect the incline motor power cable from the MCB Figure B 4 Disconnect the bolt from the incline motor Figure C 5 Lift the incline motor away from the treadmill 6 When installing the new incline motor make sure to replace the white washers at the top and bottom 7 Auto Calibration must ALWAYS be run after replacing the incline motor see Section 3 2 C C B A C C B 53 CHAPTER 7 Part Replacement Guide 7 12 Console control board Replacement 1 Turn off power and disconnect the cord from the machine 2 Remove the four 6 mm screws using a Phillips head screwdriver from underneath the console to open the upper console cover Figure A 3 Disconnect all of the wires from the console control board Figure B 4 Remove the seven fix screws of CCB using a Phillips head screwdriver Figure C 5 Reverse Steps 1 4 to install a new console control board 6 Auto Cali
19. r key 1 and 3 for 3 s enter MANUFACTURING TEST description ADDRESS RPM Parameter M3 High speed M2 Low speed M1 TEST M0 31 SECTION 5 T7000 Pro MCB LED INSTRUCTIONS 32 PWM Console PWM signal light when motor running the light should be flash COM Digital communication light Fault The machine is stopped cause any C class errors Up Down FF Elevation motor status light T7000 Pro MCB LED PLACE AND DEFINITION 33 SECTION 6 TROUBLESHOOTINGS 34 No display on console Possible causes 1 Breaker is damaged 2 ON OFF switch is damaged 3 MCB is damaged 4 Digital communication cable is damaged 5 PCB is damaged Fix 1 Inspect the circuit breaker 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 A B 2 The switch is turned to the ON position If the switch light isn t lit replace the switch 2 1 Verify wire connection N amp L on the MCB Please refer the MCB WIRING page 17 3 Verify the MCB whether supply the 12VDC for console 4 Replace digital communication cable 5 Replace PCB 35 Running speed is not stable Possible causes 1 AC power voltage is too low 2 Tension of drive belt or running belt is too loose 3 MCB is damaged 4 Motor is damaged Fix 1
20. um incline for all programs 4 8 12 15 15 MAXIMUM INCLINE P6 Controls the maximum speed for all programs 20 KPH 12 0 MPH 6 4 KPH 4 0 MPH 20 KPH 12 MPH MAXIMUM SPEED P5 Default age used in HR programs 99 10 30 DEFAULT AGE P4 Default weight used in calorie calculations and HR programs 159KG 350LB 34KG 75LB 68KG 150LB DEFAULT WEIGHT P3 Default start level in all programs 10 1 1 DEFAULT LEVEL P2 Default start time in all programs 99 10 20 DEFAULT TIME P1 Maximum workout duration 99 10 99 MAXIMUM TIME P0 DESCRIPTION MAXIMUM MINIMUM DEFAULT CUSTOM SETTING THE LIST OF MANAGER THE LIST OF MANAGER S CUSTOM SETTING S CUSTOM SETTING CONTINUE 30 This function is to calibrate the treadmill incline N A N A N A AUTO CHECK P16 Controls the distance accumulative to maintenance If default ON will can to select goal distance accumulative 4000 8000KM 2500 5000 Mile N A N A ON MAINTEN REMINDER P15 For factory use only N A N A N A MANUFATURING TEST P19 This function is to reset all parameter N A N A N A RESET ALL P18 This function is to record the error occur history N A N A N A ERROR LOG P17 DESCRIPTION MAXIMUM MINIMUM DEFAULT CUSTOM SETTING THE LIST OF MANAGER THE LIST OF MANAGER S CUSTOM SETTING S CUSTOM SETTING Remarks Remarks If you on P19 MANUFACTURING TEST this ADDRESS place you can hold the numbe
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