E7000 Service Manual
Contents
1. 4 6 No pulse is displayed on the console Handle pulse type 4 7 Console diagnostics Mode 4 8 4 1 n SS JOHNSON BERE No display on the console or the display is dim Possible causes Fix 1 Console is damaged or 1 First Check if the adapter is connected properly for the console cable is not both input amp output ends Remove the console then connected properly check if the console cable is connected properly 2 Poor connection to all the terminals on the control board 3 Control board is damaged Unplug the console cable and use a multi meter to check if the voltage on the 1 st and 4 th pin of the console cable 15 greater than 5V DC If it is replace the console and check again 4 Generator is damaged 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 1 st and 4 th pin of control board is greater than 5V DC If it is replace console cable with a new one If it is not next step 4 Unplug the generator cable from the control board and check if the voltage 1s variable fitis replace the control board with a new one If it is not replace the generator with a new one 4 2 APN JOHNSON No RPM is displayed during the exercise2. Possible causes Fix 1 Console cable is 1 Remove the console and check 1f the terminal of damaged or the console console cable is connected properly to the console cable is not connected If it is not connected well properly Connect the terminal properly gt Ifcable is damaged replace it with a new one 2 Console is damaged 2 Console is damaged replace it with a new one 3 Speed sensor is misaligned 3 Open the side covers of the fitness then replaces the control board with a new one 4 Poor connection of the sensor 4 Check if the sensor is misaligned If it is place the sensor in the correct position 5 Sensor is damaged 5 Open the side covers of stepper and check if the connection of the sensor is connected properly If it is not connected well Connect the terminal properly Ifcable is damaged replace this with a new one 6 Sensor is damaged replace it with a new one 4 3 um E 2d ale E i s QU uu Pd d n a 98 we d a feel slipping while pedaling Possible causes Fix Belt tension is not 1 Re adjust the belt tension enough 2 Replace poly belt with a new one Poly v Belt is damaged 4 4 JOHNSON Knocking or creaking noise Possible causes Fix Re tighten it 1 Pedal is on crank arm too loose 2 Replace it with a new one 2 Crank or axle is wear out 3 Re adjust the belt te
3. defective returns that can be proved to fail due to misuse neglect or abuse Technical support 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 to JHT 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 LY JOHNSON SECTION 2 EXPLODED DIAGRAM CONTENTS E EXPLODED DIAGRAM 2 1 JOHNSON 2 2 APN JOHNSON SECTION 3 WIRING DIAGRAM CONTENTS B CONTROL BOARD WIRING 3 2 E 7000 CONTROL BOARD WIRING DIAGRAM gt Al 3 pin terminal to the electromagnet brake set A2 2 pinterminal to the adapter gt 3 pin terminal to the console A4 grounding wire to frame 3 2 APN JOHNSON SECTION 4 TROUBLE SHOOTING Pedal speed has to be over 30 rpm CONTENTS 7 No display on the console or the display is dim sseesesessesseesssecesssssseooccee 4 2 7 RPM is displayed during the exercise 4 3 Feel slipping while 4 Knocking or creaking rie De 4 5 No pulse is displayed on the console Chest belt type
4. keep an inventory of spare parts especially for those of which are recommended by JHT 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 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 1 3 APN JOHNSON 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 T
5. E7000 Service Manual SECTION SECTION SECTION SECTION SECTION SECTION 6 LA JOHNSON TABLE OF CONTENTS LIMITED WARRANTY 1 1 EXPLODED DIAG RA es ex or Uma eS 2 1 WIRING DIAGRAM UU EC VM 3 1 TROUBLE SHLOOTING eee eee eene enun 4 1 PARIS REPLACEMENT 5 1 PREVENTIVE 6 1 APPENDIX RECOMMENDED TOOLS LAY JOHNSON SECTION 1 LIMITED WARRANTY Comments and QueStiONS scccccccccccccccceccccsseccccceccceel 2 YUU 1 2 D E 1 2 Marranty seu Re Detects 2 1 3 Safety Stock of Warranty Parts e eee 1 3 Warranty 1 3 Technical Suppor 1 4 n 2 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 Facsimi
6. ate cover 2 Clean the rail and roller 6 3 mn E i P SU m Hn d a ms APPENDIX RECOMMENDED TOOLS A OPEN END WRENCH 17mm B OPEN END WRENCH 14mm C RATCHET BOX WRENCH 11mm D PHILIPS SCREWDRIVER E SLOTTED SCREWDRIVER F CRANK EXTRACTOR MULTIMETER HEX KEYS 1 5 2 2 5 3 4 5 5 5 6 8 10 mm JOHNSON 1 WOODEN HAMMER 2 BEARING PULLER 3 C CLIP PLIERS 4 C CLIP PLIERS
7. d reconnect the console cable to the connector 4 Tighten the screws that hold the console to the bracket 5 2 E E 2 E 4 Qm ue n Pd d n m me bt CONSOLE CABLE REPLACEMENT PROCEDURE Tools required Philips screwdriver Adjustable wrench hex key 8mm crank extractor coin Procedure 1 Loosen the screws that hold the console to the console holding bracket 2 Unplug the console cable from the console connectors Remove the upper cover screw Remove the screw A and take bracket out for JPE Remove the crank and side cover for JPC B S Disconnect the console cable from the connectors and then tie the old cable to the new one with a rigid string Pull the old cable from the top end until the new cable threads all the way through the support Reconnect the console cables to both the console and control board Tighten the screws that hold the console to the console bracket Install the parts 5 3 C E um hu a P a E DUO i E E E up ea CONTROL BOARD REPLACEMENT PROCEDURE Tools required Procedure Philips 1 Remove the rear screwdriver see fig 1 or side m 7o cover then the crank Crank extractor Ee a E for JPC B S Coin 2 Disconnect all the cables from the Adjustable control board w
8. he distributor may choose by himself the disposition of the failed motors under warranty You can either send the motors to your local motor manufacturer 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 ona routine basis monthly is preferred 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
9. le 886 4 25683456 E mail service johnsonfitness com Scope of Warranty 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 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 APN JOHNSON 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 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
10. nd handrail links Remove all of the covers Remove the nut A then pull the crank and pedal set out Remove the c clip B then with wooden hammer tap the crank out Replace the crank with a new one Reverse step 1 4 to install the parts mn i i P S E B a a PEDAL REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver Tear down the rubber footpad and clean it Two faced masking tape 2 Remove screw A then replace pedal with a new one 3 Attach the rubber footpad 5 7 in JOHNSON POLY V BELT 430J6 REPLACEMENT PROCEDURE Tools required Procedure 1 Remove all covers Except the Philips right cover screwdriver 2 Loosen the 430J6 belts then hex key replace it with a new one 6 mm Hexagonal socket wrench 13mm 5 8 in JOHNSON POLY V BELT 430 J12 REPLACEMENT PROCEDURE Tools required Procedure Remove all of the covers except the left cover Philips screwdriver 2 Remove the pedal arm and crank Loosen the screws then Hex key 6mm A remove poly v belt and replace it with a new one Hexagonal socket wrench 19 amp 13mm Puller Reverse step 1 3 to install the parts Adjustable wrench 5 9 JOHNSON PULLEY AXLE REPLACEMENT PROCEDURE Tools required Procedure Remove all of the covers Philips and poly v belts screwdriver 2 Remove the
11. neously STEP 2 If one of LEDS is not lit replace the PCB 1 Press the ENTER key 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 STEP 3 one Ifone 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 STEP 4 Press the ENTER key Dot Matrix Display will show RPM RPM window will show current RPM TIME window will show total accumulated minutes and seconds AGE window will show total accumulated hour 6 Hold down the RESET key first then press PAUSE key to clear the record 4 8 JOHNSON Console Diagnostics Mode 1 Press the ENTER key SETP 5 2 In the Dot Matrix Display there will be two hearts on it which will light up completely in turn 3 STEPS MINS windows will show the current heart rate while you are wearing a HAND PULSE SENSOR or POLAR CHEST BELT Ifthe heart rate is not shown or not stable in the display please refer to section 4 8 section 4 10 1 Press the ENTER key STEP 6 2 Dot Matrix Display will show D A 3 Press key to increase or decrease resistance If there is no resistance please refer to section 4 4 section 4 5 1 Press the ENTER key STEP 7 2 Dot Matrix Display will show KEY on it 3 Ready for you to en
12. nsion and clean the poly v belt 3 Belt tension is too loose or poly v belt 1s 4 Clean the rail and roller too dirty 4 or roller is too dirty 4 5 JOHNSON No pulse display on console Chest belt type Possible causes Procedure 1 Chest belt is not placed properly 1 Place the chest belt in the correct position 2 Chest belt is lt Remark 1 gt damaged 2 Replace the chest belt 3 Console is damaged with a new one 3 Replace the console with a new one lt Remark 1 gt 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 4 6 JOHNSON No pulse display on the console Hand pulse type Possible causes 1 Connection of hand pulse cable 2 Hand pulse cable 15 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 JOHNSON Console Diagnostics Mode STEP 1 1 Sit on your bike Press and hold down the key then start pedaling to reach a pedal speed of approximately 30rpm Dot Matrix Display will be scanned slowly starting from LEDs of the bottom row to the top each segment of the 7 segments will be scanned simulta
13. rench 3 Replace it with a new one 4 Reconnect all the cables 5 Reverse step 1 3 to install the side cover 5 4 in JOHNSON GENERATOR OR ELECTROMAGNET BRAKE SET REPLACEMENT PROCEDURE Tools required Philips screwdriver Hex key 5mm Ratchet Box Wrench 11mm Procedure Remove all covers Remove the POLY V BELT and disconnect the cable from the control board 3 Loosen the tension screws and screw from the generator electromagnet brake set 4 Replace it with a new one 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 Install the POLY V BELT on the front and rear pulley Usethe 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 tighten all the screws Reconnect the generator electromagnet brake set cable to the control board and then install the side covers and the parts 5 5 QU oF bu i FU Pu CRANK REPLACEMENT PROCEDURE Tools required Puller Wooden hammer Hexagonal socket wrench 19 amp 13mm Philips screwdriver Hex key 6mm C clip pliers Adjustable wrench Procedure 5 6 Remove the joint screw between handlebar a
14. rew 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 5 12 JOHNSON SENSOR REPLACEMENT PROCEDURE Tools required Procedure 1 Remove the rear cover Philips screwdriver 2 Disconnect the sensor cable from the control board Hex key 5mm 3 Loosen the screws that hold the sensor to the frame Ratchet Box Wrenc 11mm 4 Replace the sensor with a new one b 5 Reverse step 1 3 to install the parts X Sensor 5 13 JOHNSON SECTION 6 MAINTENANCE PROCEDURE CONTENTS H CLEANING THE GROOVY 6 2 CLEANING THE RAIL AND ROOLER 6 3 6 1 en JOHNSON CLEANING THE GROOVES Frequency Every 3 to 4 months Procedure Remove Poly V belts and check the grooves of the belt for dirt If there is any dust in the or dust and clean grooves of the Poly V belts it 1f any and pulleys noises will be generated during operation 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 1f any 6 2 E i 8 P SU m B a JP ms CLEANING THE RAIL AND ROLLER Frequency Every 1 2 months For club Every 6 months For home Procedure 1 Remove the roller pl
15. screw A and Hexkey washer 6mm 3 Pull pulley out then C Clip Pliers knock axle set out with the Wooden wooden hammer hammer 4 Remove the nut C then tap the axle out Adjustable ap the axle ou wrench 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 5 10 in JOHNSON AXLE ASSEMBLY REPLACEMENT PROCEDURE Tools required Philips screwdriver C clip pliers puller Hex key 6mm Hexagonal socket wrench 19 amp 13mm Adjustable wrench Procedure 1 Remove all of the covers 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 Stepl pull crank out Step2 remove the c clip Step3 tap axle assy out Step4 remove the nut then tap axle out Step5 replace the axle with a new one Step6 reverse all of the steps to install the parts 5 11 E E E Ed 8 gt P sd a a ROLLER REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver 1 Remove the all of cover 2 Move pedal arm back Hex key 4mm then pick up it 3 Loosen the sc
16. ter 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 the programming year of the software 6 WORK LEVEL windows will show you the programming month and day 7 PULSE window will show you the software version If any of the keys does not work please refer to section 4 3 1 Press the ENTER key This completes the STEP 8 procedure 4 9 JOHNSON SECTION 5 Spare Parts Replacement C ONSODDE 929990999 999992999 9090 00 9520990920005 0809982929055000209 000 59 9050 5050 00 50008307 5 2 0 9 0 6 9 1 0 5 3 CONIROL ORD e 5 4 GENERATOR OR ELECTROMAGNET BRAKE 5 5 SIN V an 5 6 1 5 7 BEET 3016 E R 5 8 POLV UE 5 9 PULLES S 4 By 5 10 err 5 12 Ju Cos 5 13 5 7 E i Pu d Pad ai CONSOLE REPLACEMENT PROCEDURE Tools required Procedure Philips 1 Loosen the screws arrow from the console using the screwdriver screwdriver 2 Disconnect the console cables from the console connectors 2 Replace the console Ero o with a new one an
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