JOHNSON T8000. Treadmill. Service Manual

Transcription

1 JOHNSON T8000 Treadmill Service Manual Make by JearyCheng, KevinChang Aug

2 TABLE OF CONTENTS SECTION 1: LIMITED WARRANTY..1-1 SECTION 2: EXPLODED DIAGRAM.2-1 SECTION 3: WIRING DIAGRAM 3-1 SECTION 4: TROUBLE SHLOOTING SECTION 5: PARTS REPLACEMENT 5-1 SECTION 6: PREVENTIVE MAINTENANCE APPENDIX : RECOMMENDED TOOLS Make by JearyCheng, KevinChang Aug

3 LIMITED WARRANTY SECTION 1 Comments and Questions Scope of Warranty Intended Use Warranty Period Defects Replacement Safety Stock of Warranty Parts Warranty Procedure Technical Support

4 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. Commenttss and Quessttiionss We welcome comments and questions regarding our products. Please contact us at Customer Service Johnson Health Technology Company P.O.BOX Taichung, Taiwan, R.O.C Telephone: Facsimile: service@johnsonfitness.com Scope off Warrantty 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. IInttended Usse 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. 1-2

5 Warrantty Periiod 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. Deffecttss Repllacementt 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. Saffetty Sttock off Warrantty Parttss 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, 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. Warrantty 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

6 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). Defective Mechanical Components/Accessories: To receive a credit or the free replacement parts for the defective mechanical component under warranty, simply fill out a warranty claim form attached with the photo, graph or other media that could show us the outlook of the failure. Send all the information to JHT for approval. Defect Return: After finishing the above processes with each kind of component, the distributors are then required to contact JHT for a returned authorization and shipping arrangement (This may not be required for the mechanical defects). Once it is authorized by JHT, the distributor should pack the parts in the most appropriate way and send the package by the way as advised by JHT. Issuing Credit: It is within JHT s discretion to issue a credit or send parts with no charge to the distributors after the returned parts have been verified to be really defective. If the parts returned has been verified to be non defective and is good enough to be used, it will be sent back to the distributor. The distributor will be responsible for all the shipping cost incurred. No credits will be issued on the defective returns that can be proved to fail due to misuse, neglect or abuse. Techniicall ssupportt 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. 1-4

7 SECTION 1 WIRING DIAGRAM INSTRUCTION

8 WIRING DIAGRAM (MCB-220V) T8000 T1-----Motor wire (black) T2-----Motor wire (red) T CE (N3 of Capacitor) Non CE (D1 of on/off switch) T4-----CE (N4 of Capacitor) Non CE (D3 of on/off switch) T pin console cable T pin console cable T Elevation cable T8-----Speed sensor cable

9 SECTION 2 CONSOLE ENGINEERING MODE GUIDE

10 Engineering mode (T8000) 1.Hold both incline and speed + at the same time about 3sec to get into the engineering mode. The display will show ENGINEERING MODE Hold UP&FAST Key 3's PO : LOW SPEED LEARN MODE UP to previous Parameter P1 : HIGH SPEED LEARN MODE P2 : MIDDLE SPEED LEARN MODE P4 : LOW ELEVATION LEARN MODE P5 : HIGE ELEVATION LEARN MODE P6 : UNIT P7 : LIMIT TIME P8 : USER TIME P9 : SET WEIGHT P10 : MACHINE P11 : TOTAL TIME P12 : TOTAL DIST P13 : VERSINO DOW FAST SLOW STAR SELE NUMBER KEY ENTE RESE DOWN & SLOW 3'S HOLD STOP 3'S Press safe key to rear Parameter Parameter increase Parameter decrease Safe the Parameter Decide the Parameter Key in the Parameter import the Parameter cancel the Parameter reset the accumulate i d di RESET P14 : LANGUAGE

11 Model Unit Min Speed Max speed T8000 KPH 0.8K 20.0K MPH 0.5M 12.0M Address Description Default Value Min Value Max Value P0 low speed learn mode 77 P1 hige speed learn mode 600 P2 middle speed learn mode 300 P4 low elevation learn mode 55 P5 hige elevation learn mode 200 P6 unit KPH P7 limit time 90:00 10:00 90:00 P8 user time 20:00 10:00 90:00 P9 set weight KPH:80/MPH:150 KPH:22/MPH:50 KPH:180/MPH:400 P10 machine T8000 P11 total time P12 total dist P13 version P14 language English Notice! Press ENTER/SELCET will store displayed value Press Elevation UP/DOWN will increase/decrease address Px Press Speed UP/DOWN will increase/decrease displayed value. PRODUCE TEST : You can go ahend to do the hardware function test right after entering this engineer mode. AUTO CHECK : The console will do the auto calibration including speed and incline.

12 SECTION 3 MCB LED INSTRUCTIONS

13 Note: Use a multi-meter to test the power socket. 220v mode: 210v 250v Note: For MCB (Lower-board) Note: For PCB (Upper-board) MCB LED Indication 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. MTR_AC Light- When lit, this indicates that 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. +18V Light- When lit, this indicates the presence of the unregulated 18 volt direct current supply necessary for the operation of the MCB circuitry. If dim the supply voltage may be marginal and if out, not present or inadequate. If this light is not lit, the MCB will not operate even if the PCB is operating properly. If the AC light is lit and the +11V and +18V light are not, check fuse F1. If the +11V light is lit and the +18V light is not lit, return the board to JHT. V_CON Light- When lit, this indicates the presence of the regulated 11 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 is not lit, the console will not operate. If the AC and +18V light are lit and the +11V light is not, check for shorted cabling or a defective upper console. If the AC light is lit and the +11V and +18V lights are not, check fuse F1.

14 MCB LED Indication MOTOR Note: over 10 Amps when lit Note: a control command from the PCB to the MCB Light- When lit, indicates the High Power Direct Current supply for the motor (B+) is online. This light will remain lit for a period of time after power has been removed from the MCB. While the MTR light remains lit, anyone handling the MCB should use caution since there is still a hazardous potential present. When the MTR light is off, B+ is not present and the motor controller will not operate. If the MTR and I-limit lights are off, verify motor connections and proper motor operation. If the MTR light is off and the I-limit light is on, the MCB shut off due to an extended current limit condition. In this case, resetting the PCB or cycling power will eliminate the problem. However, the treadmill should be thoroughly examined for wear or damaged components which might have lead to the extended current limit condition. If this problem persists, return the board to JHT. I-limit Light- When lit, indicates the current to the motor has reached the peak current trip point of 10 Amps. The MCB will limit the current when the current limit point has been reached. If the current limit continues for roughly 5 seconds, the MCB shuts down and the I-Limit light will remain on. To reset the I-Limit, turn the treadmill off at the power switch wait about 30 seconds then turn the power back on. PWM Light- Indicates the control PWM 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.

15 MCB LED Indication Note: the incline is being commanded up Note: the incline is being commanded down UP Light- Indicates the PCB is commanding the incline motor 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 motor and its connection to the board; check fuse F4. If this problem persists replace MCB. DOWN Light- Indicates the PCB is commanding the incline motor 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 motor and its connection to the board; check fuse F4. If this problem persists replace MCB. Note: The speed sensor present from the MCB to the PCB SPD_SENSR Light- Indicates the MCB from the speed senson is present. It will blink at the speed sensor reaction to magnet when the PCB can check the speed sensor and MOTOR whether to damage. If the MOTOR to run SPD_SENSR light is not lit, Please check the speed sensor whether bad or speed sensor wire not to touch the P1of the MCB.

16 MCB LED Indication Note: MOTOR short circuit of the MCB bad MTR_SHRT Light- Indicates the MOTOR short circuit, If the running belt not running at the MTR_SHRT LED light, express the MOTOR short circuit of the MCB bad.

17 MCB LED-AIDED TROUBLESHOOTING CHART NO. PROBLEM/RESULT CORRECTIVE ACTION 1 No operation of MCB or PCB 2 No operation of MCB or PCB Check fuse F1 Verify connections, power switch, circuit breaker and fuse 3 PCB will not power up Replace MCB or 6-pin console cable 4 PCB will power up but the MCB will not operate 5 Will not operate the motor 6 Will not operate the motor 7 MCB in current limit mode 8 Will not operate the motor Verify adequate line voltage. If line voltage is adequate, MCB is damaged and needs to be returned to manufacturer. Verify connections to motor and the motor itself. If the motor and its connections are good, the MCB should be replace. Return MCB to manufacture with information on location. Power level, how it was used when failure occurred etc. The motor can be verified by disconnection the motor; connecting a volt-ohm meter(set to VCD) to the motor leads; and spinning the tread and observing a voltage. If no voltage, Bad motor. A 5-second current limit time-out has occurred. Resets console or cycle power to correct. Check treadmill for excessive wear or mechanical defects. If problem persists, return 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. 9 Incline all the way move up Please replacement the MCB Verify connections to the P3 & incline motor. If 10 Incline does not move the connections look good, check F4. 11 Incline all the way move down Please replacement the MCB

18 SECTION 4 TROUBLESHOOTINGS

19 Possible causes: 1. Breaker is damaged. 2. ON/OFF switch is damaged. 3. MCB is damaged pin console cable is damaged. 5. PCB is damaged. No display on console Fix: 1. ( refer to MCB LED layout & indication SECTION 6) Verify if LED 220vAC(AC) is lit. If this LED is lit, go to step 2. If LED 220vAC(AC) is not lit, verify the following: A B 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.) 2. The switch is turned to the "ON" position. ( If the switch light isn't lit, replace the switch.) Verify wire connection AC1 & AC2 on the MCB. ( refer to wiring diagram.page 4-3 ) Verify the ON/OFF switch, breaker & socket wires are connected. 3. Verify if LED +V_CON & +18v is lit. If one is not lit, replace MCB. 4. Replace console cable. 5. Replace PCB.

20 Possible causes: Running speed is not stable 1. AC power voltage is too low. 2. Tension of poly belt or running belt is too loose. 3. Poor adjustment of MCB. 4. MCB is damaged. 5. Motor is damaged. Fix: 1. Check the power voltage by using voltage-meter to see if it is within 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. 3. Remove the motor cover and run the machine at low speed, then adjust the R42 of MCB the variable resistance. If it hasn't been improved, replace new MCB. 4. Replace new motor.

21 Possible causes: Treadmill starts to run by itself 1. The console 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.

22 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 poly belt. 4. The motor is damaged. Fix: noise has disappeared. 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 and become quiet then check if the 2. Replace the front roller with a new one to see if the noise disappear. 3. Remove poly-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. (Refer to "motor bearings replacement procedure" page 8-22 ~ 8-23) Replace the motor.

23 Possible causes: 1. MCB is damaged pin console cable is damaged. 3. PCB is damaged. 4. Motor is damaged. Treadmill will not start Fix: Open motor cover, verify wire connection MTR1 and MTR2 on the MCB then plug in the power cord and turn on the power switch. Then press START key. 1. Verify the LED indicator of MOTOR is lit. (If that LED MOTOR is not lit, replace MCB.) 2. Verify if LED PWM is lit. (if it is not lit, replace 8-pin console cable.) 3. If LED PWM is still not lit, replace PCB. 4. Replace Motor.

24 Possible causes: Incline function does not work 1. The 8-pin console cable is damaged. 2. Incline motor is damaged. 3. PCB is damaged. 4. MCB is damaged. 5. The incline setting is not correct. Fix: Enter to the Engineering Mode to recalibrate the elevation values Then press "FAST" and "SLOW" key to see if the incline motor will be activated. 1. OR Use a new 8-pin console cable to connect PCB and MCB. Then press "FAST" and "SLOW" key to see if the incline motor will be activated. 2. OR Replace the incline motor. 3. OR Replace PCB. 4. OR Replace MCB. 5. Enter Engineering Mode to reset the elevation parameter.

25 Speed or Incline Changes by Itself Possible causes: 1. Keypad is damaged. 2. PCB is damaged. Fix: 1. Remove the keypad and verify it is stuck. If it is, replace with a new keypad. 2. If speed or incline changes by itself, replace the PCB with a new one and refer to "Engineering Mode Guide" to re-program all the parameters.

26 Error Messages on the Console When the Error Messages on the Console the lamp will be lighted in red Error-message E1 E3/E6 Problem / Result The speed sensor can t sense the speed. Press start and after 10 sec. the LED display will show 1.The incline motor was broken or the cable was lost. 2.The 8 pin signal cable was lost. Maintenance lamp

27 Error Message " E1" Possible cause: 1. speed sensor cable damaged. 2. MCB is damaged. 3. Check the magnet on the front roller. 4. Fix: 1. Check the connector condition of the speed sensor cable. 2. Check the speed sensor wire not to touch the P1 of the MCB. 3. Check the magnet whether on the front roller. Possible cause: Error Message " E3" and E6 1. The incline motor was broken or the cable was lost. 2. The 8 pin signal cable was lost.. Fix: 1. Check the incline motor cable or the 8 pin cable. 2. Replace the incline motor.

28 T8000 maintenance lamp Maintenance lamp 1. When the distance accumulate to 2000KM the lamp will be lighted in blue. 2. There has to do some maintenance 2.1 Test the running belt if loose or not? 2.2 Lubricate the running belt 2.3 Remove the motor cover and clean the dust inside 2.4 Clean the frame 2.5 Check the running belt is in the center or not. 3. There can hold "Elevation Down" & "Speed Slow" for 3 seconds to turn off the light

29 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: 1. 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 transmitter, please dry transmitter after use. 3. OR Transmitter is damaged. Replace the Transmitter. 4. OR Heart-rate-control board is damaged. Replace the HR-control board. 5. OR PCB is damaged. Replace the PCB.

30 SECTION 7 PARTS REPLACEMENT PROCEDURE

31 MCB REPLACEMENT Tools required: Philips screwdriver Procedure: 1. remove the motor cover 2. Unplug all the cables and wires connecting to the MCB. 3. With the screwdriver remove the MCB. 4. Replace the MCB and tighten the screws holding the MCB to the frame. 5. Reconnect all the cables and wires to the MCB by referring to the wiring diagram. 6. Enter the engineering mode, recalibrate the speed of the treadmill. 7. Install the motor cover. 7-1

32 PCB REPLACEMENT Tools required: Philips screwdriver Procedure: 1. Loose the screws of the console lower cover. 2. Loose the screws of the console display.

33 3. Disconnect the plug of PCB from console then with the screwdriver remove the PCB. 4. Replace the PCB with a new one. 5. Reverse step 1-4 to install all parts. 7-2

34 Tools required: KEYPAD REPLACEMENT Screwdriver Procedure: 1. remove screws from the console upper cover. 2. Disconnect the plug of the keypad from the PCB. 3. Remove the overlay and the tape residue on the console thoroughly 4. Replace the keypad and plug the new keypad with the PCB. 5. Install the console upper cover and tighten the screws. 6. Tear off about 2 cm-wide of the protective paper on the backside of the overlay, align the overlay to the top of the console, press the overlay firmly on the portion with no paper on the backside then tear the remaining paper slowly. Press the overlay down to the console simultaneously. 7-3

35 RUNNING BELT/DECK/ROLLER REPLACEMENT Tools required: Philips screwdriver T-handle key (6 mm, 5 mm) Procedure: 1. Remove the end capes of the side rail and pull out the two side rails. 2. Remove the motor cover. 3. Turn the flywheel counterclockwise by using your left hand and pull the drive belt out from the pulley of the front roller by using your right hand. 4. Remove the bolts of the front and rear rollers (If replacing the roller, go to step 13) 5. Loosen the 8 bolts holding the deck to the frame then remove the deck with the running belt. (If replacing the running deck, go to step 11) 6. Remove the fix plate with screwdriver. 7. Replace the deck and tighten the fix plate, then install a new running belt. (Go to step 14) 7-4

36 RUNNING BELT/DECK/ROLLER REPLACEMENT Tools required: Philips screwdriver T-handle key (6mm,5mm) Procedure: 8. Turn the flywheel counterclockwise by using your left hand and pull the drive belt out from the pulley of the front roller by using your right hand. 9. Loosen the screws from the front and rear rollers, remove the front roller and rear roller. (If replacing the roller, go to step 13) 10. Loosen the 8 screws holding the deck to the frame then remove the deck with the running belt.(if replacing the running deck, go to step 11) 11. Remove the fix plate with screwdriver. Replace the deck and tighten the fix plate, then install a new running belt. (Go to step 14) 11. Replace the deck and center the running belt. 12. Tighten the deck screws and assemble the rear roller first, then assemble the front roller. ( Go to step 16) 13. Replace the front roller and rear roller. (Go to step 15) 14. Tighten the deck screws. 15. Assemble the rear roller first, and then assemble the front roller. 16. Turn the flywheel clockwise with your left hand and place the drive belt onto grooves of the front roller pulley with your right hand. 17. Install the front and rear rollers and adjust the belt tension screw such that you can only press with your thumb the belt down 1cm ~ 1.5cm. 7-5

37 18. Install the front / rear rollers. Adjust the running belt tension screw to center the running belt at high speed. 19. Try to step on the belt at low speed to check if the belt slips. 20. Install the side rails and secure the end plates and all the covers. 7-6

38 MOTOR REPLACEMENT Tools required: Philips screwdriver T-handle wrench (14mm) Ratchet Box Wrench (11mm) Procedure: 1. Remove top motor cover and bottom motor cover. 2. Remove cables connecting to the motor and the lower board, Meanwhile, remove the ground wire 3. Using your thumb to press the surface of belt and at the same time rotate the pulley in counter-clockwise till the poly belt being removed. 4. Remove the mount bolts on the bottom of motor bracket to take off bad motor. 5. Secure the motor mount bolts (not too tight at this time. So the motor can be adjusted in horizontal direction). 6. 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. Notice! Not allow alignment exists on both pulleys or the poly belt will fall down when running. 7. Adjust the belt-tension-adjusting screw until the tension is within 80 ~ 90lbs. 8. Tighten the motor mount bolts 9. Reconnect cables and the ground wire. 10. Turn on the power and enter the Engineering Mode to check if the extreme speeds are within the correct range. 11. Try to step on the belt at low speed to check if the belt slips. 12. Install the front cover and secure the screws. 7-7

39 Tools required: INCLINE MOTOR REPLACEMENT Philips screwdriver Wrench (14mm) Wrench ( 17mm) Procedure: 1. Remove screws of both top and bottom motor covers by using a screwdriver 2. Disconnect cables from the connectors of the incline motor and MCB and also disconnect the ground wire. 3. Fold up the treadmill and then loose a nut and a bolt on the top fixed plate by using the wrenches (14, 17). 4. Replace the incline motor with a new one. 5. Tighten a nut and a bolt on the incline motor at first. Then fixed another bolt on the Elevator Frame Set. 6. Reconnect cables and the grounding wire to the connectors 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 motor covers and secure the screws. 7-8

40 Tools required: CONSOLE CABLE REPLACEMENT Philips screwdriver Procedure: 1. Remove the console lower cover and the motor cover. 2. Disconnect the console cable from the PCB and MCB. 3. Tie the old cable to the new one with a rigid string. 4. Pull the old cable from the top end until the new cable pass all the way through the right console mast. Then let it go to the console base. 5. Connect the console cable to PCB and MCB. 6. Install the console cover and the motor cover. 7-9

41 MOTOR BEARINGS & CARBON BRUSH REPLACEMENT Tools required : Nutdriver (10mm, 11mm) Bearing puller Wooden-hammer Procedure: 1. Remove the carbon brush cover and spring. 2. Check if the surface of carbon brush is smooth. If the surface of carbon brush is pitted, rough, or with burn marks replace the carbon brush. (If replacing the carbon brush, go to step 10) 3. Prior to disassembling the end caps, you must make a mark on the end cap. 4. Use the nutdriver (10mm, 11mm) to remove bolts from the end caps. 5. Tap the shaft carefully with a wooden hammer to remove the end caps Revision: 1.0 Date:

42 MOTOR BEARINGS & CARBON BRUSH REPLACEMEN Tools required: Nutdriver (10mm, 11mm) Bearing puller Wooden-hammer Procedure: 6. Remove the bearings at both sides of the shaft by using bearing puller. 7. Install the new bearings to the shaft by using wooden-hammer. 8. Install the two end caps and use the nutdriver (10mm, 11mm) 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 hours at 3.0 kph Revision: 1.0 Date:

43 SECTION 8 SERVICE FORM Revision: 1.0 Date:

44 MCB LED Status Report Product Type :... Serial Number :... When power-up the treadmill the MCB LED status is : AC(*115V)Light 18V Light 11(*12)V Light LED On : LED On : LED On : LED Off : LED Off : LED Off : MTR Light I-Limit Light PMW Light LED On : LED On : LED blinking: LED Off : LED Off: LED Dim: LED Off : ILT1 Light (JET7000) ILT2 Light (JET7000) LED On : LED On : LED Off: LED Off : When you press the UP or DOWN key, the LED status is : Up Light Dn Light LED On : LED On : LED Off: 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 :... by :... Reported Approximate hours of use :... Company Name :... Revision: 1.0 Date:

45 Field Failure Report Name of Distributor : Report #... Warranty ( ) Yes ( ) No Product : Failure ( ) Intermittent ( ) Persistent Serial number:.. Failure Symptom : ( Pls refer to the service manual for the symptom of failure. )... Cause of Failure :... Parts Replaced* : Failure : Suggestions to prevent *When parts needed please fill out a Parts Order Form as detailed as possible. Date : Place : Prepared By : Company Stamp :... Revision: 1.0 Date:

46 Parts Order Distributor:..... Order # Delivery Terms: ( ) CIP... Delivery Address: ( ) FCA ( ) FOB Warranty ( ) Yes ( ) No Product Serial number Product Drawing # Part Number Part Name Qty Remark: Please refer to the spare part kit for all the information that are to be filled out above. Date Place Signature Company Stamp Revision: 1.0 Date:

47 no:... Warranty Claim Form Claim Dealer Name:... Page... of...pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS # QTY AUTHORIZED BY:... Revision: 1.0 Date: