R7000 Service Manual
Contents
1. AGE window will show total accumulated hour 6 Hold down the RESET key first then press PAUSE key to clear the record If RPM is not shown please refer to section 4 2 for troubleshooting Pe YS CA 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 If the 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 enter 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 Ifany of the keys does not work please refer to section 4 3 1 Press the ENTER key This completes the STEP 8 proce2. Open end wrench 14 amp 17 mm Procedure frame Loosen the screws from the side covers with the screwdriver then remove crank using pulley refer to section 5 2 1 Loosen the screws from the side cover with the screwdriver then remove footpad guard and side cover Loosen the POLY V belts 500 440J8 amp 400 380J6 and the fit in screw of idler spring The spring replacement is dangerous Take special cautions during the operation so you will not damage both you and other parts Using the hex key 4mm to loosen screws holding the bearing housing to the 4 With the C Clip Pliers remove the C clip and then using the Bearing Puller remove the Bearing Housing Ifthe Ball Bearing failed replace it 9 9 99 99 4 JOHNSON BEARING REPLACEMENT PROCEDURE Tools required Procedure 5 Remove the C clip c with the C Clip Pliers Philips screwdriver Hex key 4mm and then remove the pulley Assembly by Bearing puller using the Bearing Puller If the Ball Bearing failed replace pulley assembly C Clip pliers Wooden hammer 6 Remove the C clip D with the C Clip Pliers and then remove the idler Assembly by using the Bearing Puller then strike bearing out from the housing of idler assembly Replace bearing with a new one Open end wrench 14817 mm Crank extractor 7 Reverse step 1 7 to install the parts JOHNSON SECTION 6 MAINTENAN
3. 5 Gap between the 5 Check if the sensor is positioned correctly electromagnet and the copper disc of the Re align the sensor to the correct position generator is too wide 6 Sensoris damaged replace it with a new one 7 l Loosen the assembly screws of electromagnet 2 With a c vice press the electromagnet to narrow the gap then check again e JOHNSON Feel slipping while pedaling Possible causes Fix Belt tension is not 1 Re adjust the belt tension enough 2 Replace poly v belt with a new one 2 Poly v Belt is damaged JOHNSON Knocking or creaking noise Possible causes 1 Pedal is on crank arm too loose 2 Crank or axle is wear out 3 Belt tension 1s too loose or poly v belt is too dirty 4 Rail or roller is too dirty Fix 1 Re tighten it 2 Replace it with a new one 3 Re adjust the belt tension and clean the poly v belt 4 Clean the rail and roller JOHNSON No pulse display on console Chest belt type Possible causes Procedure 1 Chest belt is not 1 Place the chest belt in placed properly the correct position lt Remark 1 gt 2 Chest belt is damaged 2 Replace the chest belt with a new one 3 Console is damaged 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 hear
4. CE PROCEDURE CONTENTS n CLEANING THE GROOVES Fi JOHNSON CLEANING THE GROOVES Frequency Every 3 Procedure to 4 months Remove the Poly V belts and check the grooves of the belt for dirt or dust and clean If there is any dust in the it if any grooves of the Poly V belts and pulleys noises will be generated during operation Check the grooves in the pulley for dirt or dust and clean it if any Check the grooves in the roller pulley for dirt or dust and clean it if any AN JOHNSON APPENDIX RECOMMENDED TOOLS A OPEN END WRENCH 17mm B OPEN END WRENCH 14mm C 11mm D E SLOTTED SCREWDRIVER F G MULTIMETER RATCHET BOX WRENCH PHILIPS SCREWDRIVER CRANK EXTRACTOR HEX KEYS 1 5 2 2 5 3 4 5 5 5 6 8 10 mm diia JOHNSON 1 WOODEN HAMMER 2 BEARING PULLER 3 C CLIP PLIERS 4 C CLIP PLIERS APPENDIX
5. JOHNSON R7000 Service Manual UNS Revision 1 0 Date 2004 7 25 PS JOHNSON TABLE OF CONTENTS SECTION 1 LIMITED WARRANTY SECTION 2 EXPLODED DIAGRAM SECTION 3 WIRING DIAGRAM SECTION 4 TROUBLE SHLOOTING SECTION 5 PARTS REPLACEMENT SECTION 6 PREVENTIVE MAINTENANCE APPENDIX RECOMMENDED TOOLS AS JOHNSON SECTION 1 LIMITED WARRANTY Comments and Questions Scope of Warranty Intended Use Warranty Time Period Defects Replacement Safety Stock of Warranty Parts Defects Return Procedure Technical Support AT 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 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 warr
6. REPLACEMENT PROCEDURE Tools required Procedure 1 Remove all covers Philips screwdriver 2 Remove the POLY V BELT and Hex key 5mm disconnect the cable from the control board Ratchet Box Wrench 11mm 3 Loosen the tension screws and screw from the generator electromagnet brake set 4 Replace it with a new one 5 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 6 Install the POLY V BELT on the front and rear pulley 7 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 8 Reconnect the generator electromagnet brake set cable to the control board and then install the side covers and the parts e iS JOHNSON SECTION 5 2 Contents CRANK PEDAL POLY V BELT 400 380J6 POLY V BELT 500 440J8 AXLE FRONT PULLEY BALL BEARINGS JOHNSON CRANK REPLACEMENT PROCEDURE Tools required Crank extractor Procedure Coin 1 Loosen the crank Open end cover with a coin and wrench remove it 14 amp 17mm 2 With the crank extractor and open end wrench loosen the screw attaching the crank to the axle 3 Using the crank extractor and open end wrench to extract the crank then replace it with a new one 4 Re
7. anty 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 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 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 o
8. cessories 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 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 wi
9. ctor 2 Loosen the screw A and remove it for the axle pulley assembly of the new design Coin 3 Remove the spring attaching the idler pulley to the frame first then loosen the screws attaching the Hex key 4mm bearing housing to the axle pulley assembly using the hex key 4mm The spring replacement is dangerous Take special cautions during the Open end wrench operation so you will not damage both you and 14 amp 17 mm other parts then remove the front pulley 4 Remove the c clip B by using the c clip pliers and using the Bearing Puller remove the Bearing Housing JOHNSON PEDAL AXLE PULLEY ASSEMBLY REPLACEMENT Tools required Philips screwdriv C clip pliers Crank extractor Coin Hex key 4mm Open end wrench 14 amp 17 mm PROCEDURE Procedure 5 Remove the c clip C by using the c clip pliers and remove the metal pulley from the generator using the Bearing Puller 6 Remove the c clip D by using the c clip pliers and remove the idler using the Bearing Puller 7 Remove the c clip B by using the c clip pliers and remove the Bearing Housing using the Bearing Puller 8 Replace the axle pulley assembly with a new one 9 Reverse step 1 9 to install the parts JOHNSON BEARING REPLACEMENT PROCEDURE Tools required 9 9 9 9 9 4 Philips screwdriver Hex key 4mm Bearing puller C Clip pliers Wood hammer Crank extractor Coin
10. dure JOHNSON SECTION 5 Spare Parts Replacement Contents GENERAL 5 1 R7000 lt A JOHNSON SECTION 5 1 GENERAL Contents CONSOLE CONSOLE CABLE CONTROL BOARD GENERATOR OR ELECTROMAGNET BRAKE SET e gt JOHNSON CONSOLE REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver 1 Loosen the screws arrow from the console using the screwdriver 2 Disconnect the console cables from the console connectors mE 3 Replace the console with a new one and reconnect the console cable to the connector 4 Tighten the screws that hold the console to the bracket e JOHNSON CONSOLE CABLE REPLACEMENT PROCEDURE Tools required Philips screwdriver Adjustable wrench hex key 8mm crank extractor coin Procedure l Loosen the screws that hold the console to the console holding bracket Unplug the console cable from the console connectors Remove the upper cover screw Remove the crank and side cover 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 A CE JOHNSON GENERATOR OR ELECTROMAGNET BRAKE SET
11. f 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 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 on a routine basis monthly is preferred YA JOHNSON Defective Mechanical Components Ac
12. hex key 4mm and Open end the fit in screw of idler wrench spring by using 14 amp 17 mm screwdriver The spring replacement is dangerous Take special cautions during the operation so you will not damage both you and other parts then remove the front pulley 3 Remove the 500 440 for JPB 5100 J8 belts from the pulley and replace with the new 500 440 J8 belt 4 Reverse step 1 3 to install the parts JOHNSON AXLE REPLACEMENT PROCEDURE Tools required Philips screwdriver Hex key 4mm C Clip Pliers Wooden hammer Coin Crank extractor Hex key 4mm Open end wrenc 14 amp 17 mm remove the C clip Procedure Remove the crank cover and screw then remove the crank Loosen the screws from the side cover with the screwdriver then remove the footpad guard and side covers Loosen the belts 500 440J8 amp 400 380J6 from the axle With the C Clip Pliers With the wooden hammer tap the axle out Replace the axle with a new one then install the c clip by using c clip pliers Reverse the step 1 3 to install the parts JOHNSON PEDAL AXLE PULLEY ASSEMBLY REPLACEMENT PROCEDURE Tools required Procedure Philips screwdriver 1 Remove the crank cover and screw then remove the crank Loosen the screws from the side cover with C clip pliers the screwdriver then remove footpad guard and side cover Crank extra
13. perly 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 is greater than 5 VDC if it is replace the console and check again 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 the 1 st and 5 th pin of control board is greater than 5 VDC fit is replace console cable with a new one f it is not next step 4 Unplug the generator cable from the control board and check if the voltage is variable fit is replace the control board with a new one if it is not replace the generator with a new one uw AT JOHNSON No RPM is displayed during the exercise l Possible causes Console cable is damaged or the console cable is not connected properly Console is damaged Control board is damaged Speed sensor is misaligned for JPS E Poor connection of the sensor Sensor is damaged for JPS E Fix 1 Remove the console and check if the terminal of console cable is connected properly to the console If it is not connected well gt Connect the terminal properly gt If cable is damaged replace it with a new one Console is damaged replace it with a new one Open the side covers of the fitness then replaces the control board
14. sh but before doing this it is preferred for you to send out the forms in advance LY JOHNSON SECTION 2 EXPLODED DIAGRAM CONTENTS B R7000 EXPLODED DIAGRAM AN JOHNSON R7000 EXPLODED DIAGRAM YA JOHNSON SECTION 3 WIRING DIAGRAM CONTENTS B CONTROL BOARD WIRING DIAGRAM B WIRING DIAGRAM AS JOHNSON CONTROL BOARD WIRING DIAGRAM gt Al 3 pin terminal to the generator gt A2 2 pin terminal to the electromagnet gt A3 4 pin terminal to the console JOHNSON WIRING DIAGRAM AT JOHNSON SECTION 4 TROUBLESHOOTING Pedal speed has to be over 30 rpm CONTENTS 77 No display on the console or the display is dim 77 No RPM is displayed during the exercise All or some of the function keys do not response 7 F eel the resistance increase decrease or fell no resistance Feel slipping while pedaling Knocking or creaking noise No pulse is displayed on console No pulse is displayed on the console hand pulse type Console diagnostics mode Y JOHNSON No display on the console or the display is dim Possible causes 1 Console is damaged or the console cable is not connected properly 2 Poor connection to all the terminals on the control board 3 Control board is damaged 4 Generator is damaged Fix 1 First Check if the adapter is connected properly for both input amp output ends Remove the console then check if the console cable is connected pro
15. t and to the skin JOHNSON No pulse display on the console Hand pulse type Possible causes Procedure 1 Remove the console to check if the terminal of hand 1 Connection of hand pulse cable has been connected to PCB well pulse cable 2 Hand pulse cable is OR damaged 3 Console is damaged 2 Replace the hand pulse cable with a new one OR 3 Replace the console with a new one JOHNSON Console Diagnostics Mode STEP 1 1 Sit stand on your bike stepper Press and hold down the RESET key then for stepper turn the power on start pedaling to reach a pedal speed of approximately 30rpm OR Press and hold down the RESET key then plug the STEP 2 adapter JPE 2 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 simultaneously If one of LEDS is not lit replace the PCB STEP 3 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 one If one of LEDS is not lit replace the PCB STEP 4 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 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
16. verse step 1 3 to install the parts JOHNSON PEDAL REPLACEMENT PROCEDURE Tools required Open end wrench 15 Procedure mm Using the open end wrench loosen the screws attaching the pedal to the crank 2 Replace the pedal with a new one JOHNSON POLY V BELT400 380J6 REPLACEMENT PROCEDURE Tools required Procedure 1 Remove the crank cover and screw then remove the Philips screw crank Loosen the screws from the side cover with driver the screwdriver then remove the footpad guard and side cover Hex key 4mm 2 Loosen the 400 J6 and 500 J8 belts Crank extractor Coin 3 Loosen the screws from the front pulley by using the hex key 4mm then remove the front pulley Open end wrench 14 amp 17 mm 4 Replace the 400 380 J6 belt with a new one 5 Tighten the screws from the front pulley by using the hex key 4mm 6 Install 400 380 J6 and 500 440 J8 belts onto the front and rear pulleys 7 Install the side covers and the parts JOHNSON POLY V BELT 500 440 J REPLACEMENT PROCEDURE Tools required FOOTPAD ern Procedure screwdriver 1 Remove the crank cover Hexkey and screw then remove 4mm the crank Refer to section 5 2 1 Loosen Open end the screws from the side wrench cover with the 14mm screwdriver then remove footpad guard and side cover Crank extractor 2 Loosen the screws from Coin the front pulley by using the
17. with a new one Check if the sensor is misaligned If it is place the sensor in the correct position Open the side covers of the stepper and check if the connection of the sensor is connected properly fitis not connected well gt Connect the terminal properly If cable is damaged replace this with a new one Sensor is damaged replace it with a new on pl JOHNSON All or some of the function keys do not respond Possible causes ix 1 Remove the console cover and then check if keypad cable is connected properly to the upper board If it has not been connected well reconnect it to the terminal and check again 1 Keypad connecting plug has been not fit in properly 2 Keypad is damaged Keypad or upper board is damaged 3 Upper board is Replace the console damaged JOHNSON Feel the resistance increase decrease suddenly or feel no resistance Possible causes 1 Console is damaged Fix or the console cable 1 Remove the console and check if the console is not connected cable has been connected properly properly 2 Console cable is damaged replace it with a new 2 Console cable is one damaged 3 Remove the side covers of the fitness and check 3 Control board is if the terminal of the control board has been damaged connected properly Control board is damaged replace it with a new one 4 Generator is damaged 4 Generator is damaged replace with a new one
Download Pdf Manuals
Related Search