2006 Johnson T8000E(TM97) SERVICE MANUAL

Transcription

1 2006 Johnson T8000E(TM97) SERVICE MANUAL 1

2 TABLE OF CONTENTS SECTION 1: MAINTENANCE PROCEDURE MAINTENANCE CHECK LIST TENSIONING THE BELT PROCEDURE DECK RE-WAXING PROCEDURE CLEAN THE GROOVES PROCEDURE USE THE CARBON STICK TO CLEAN THE DC MOTOR SECTION 2: WIRING DIAGRAM INSTRUCTION T8000E(TM97) MCB WIRING 220V T8000E(TM97) MCB WIRING DEFINITION OF PIN 220V T8000E(TM97) ELECTRICAL BLOCK DIAGRAM FOR 220V SECTION 3: CONSOLE ENGINEER MODE OPERATION T8000E(TM97) Engineer mode SECTION 4: MCB LED INSTRUCTIONS MCB LED place and definition for 220V..23 SECTION 5: TROUBLESHOOTINGS No display on console Running speed is not stable Noises generated under motor cover Error Messages on the Console Error message 1 troubleshooting (1) Error message 1 troubleshooting (2) Error message 3,6 troubleshooting Error message 4 troubleshooting T8000E(TM97) maintenance lamp.. 32 SECTION 6: What is the difference between 2006 TM95 & 2006 TM

3 SECTION 1 MAINTENANCE PROCEDURE 3

4 MAINTENANCE CHECK LIST PREVENTIVE MAINTENANCE SCHEDULE 2006 Johnson T8000E TREADMILL Item Daily Weekly Monthly Quarterly Biannual Annual Console Mounting Bolts Inspect Frame Clean Inspect Carbon Brush Inspect Replace Power Cord Inspect Display Console Clean Inspect Handrail & Handlebar Clean Inspect Front Roller Clean Inspect Rear Roller Clean Inspect Emergency Button Test Running belt Tension Inspect V Belt Clean Inspect Deck Re-waxing Inspect & Rewaxing Running Belt Inspect Control Box Clean (Vacuum) Motor Clean 4

5 TENSIONING THE BELT PROCEDURE Frequency: Every 1 months 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 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: 0.9~1.1 lbs 5

6 Drive Belt: If you have tensioned the running belt and are still experiencing a slipping, adjust the tension screw. Then try the treadmill again to check for slipping. 6

7 DECK RE-WAXING PROCEDURE Frequency: Every 1 month Caution: If deck is not to periodical add the waxing, between the deck and running belt will produce great friction make the deck and running belt to burn up and cut down the motor life. Parts name: Silicon oil set Parts number: SZTM74SOS Price (USD): 0.6 Use time : 1 Procedure: 1. Loosen the tension bolts at both ends. 2. Pull the belt with your left hand and apply the silicon in the deck with your right hand. (The volume of silicon applied is about 40ml) 3. Tighten the tension bolts. 4. Start the treadmill. Step on the treadmill belt to walk the silicon in. Adjust the belt tension if necessary. 5. With the clamp-on meter, measure the current draw of the motor. (Clamp on either the red or the black wire.) The current should be less than 15Amps for 110V model. (less than 7.5Amps for 220V model.) 7

8 Use the clamp-on meter (DC current-meter): With the clamp-on meter, measure the current draw of the motor. (Clamp on either the red or the black wire.) The current should be less than 15Amps for 110V model. (less than 7.5Amps for 220V model.) current limit : 8

9 CLEAN THE GROOVES PROCEDURE Frequency: Every 3 months Caution: If dirty grooves in the drive belt, motor and roller pulley, there will be noises while running. Procedure: 1.Remove the drive belt and check the grooves in belt for dirt or dust and clean it. 2.Check the grooves in motor pulley for dirt or dust and clean it 3Check the grooves in roller pulley for dirt or dust and clean it. 9

10 Use the carbon stick to clean the DC motor Frequency: Every 3 month Caution: If the treadmill with DC motor makes noise or running speed isn t stable. You can use the carbon stick to clean the motor Parts number : MTOOL Box 10 pcs Price : USD

11 Carbon stick use Step : Step 1. Take off the motor cover. Step 2. Take off the motor carbon brush cover. Step 3. Press Start key to run in the middle speed. Step 4. Put the carbon stick to clean the motor dust inside. 11

12 SECTION 2 WIRING DIAGRAM INSTRUCTION 12

13 T8000E (TM97) MCB WIRING(220V) MTR2 P2 J1 MTR1 J2 P4 P1 P3 L2 L1 13

14 T8000E(TM97) MCB WIRING DEFINITION OF PIN(220V) P2:Elevation cable(6pin/amp ) JP1 Pin Name ELVR_+5V ELVR_POT ELVR_GND UP DOWN COM Definition Incline place signal test power Incline place signal Incline place signal test ground Incline motor does move to up Incline motor does move to down Incline motor does turn on power 14

15 P3: 8-pin console cable 1 8 J3 Pin Name PWM RPM DOWN UP ELVR_+5 ELVR_GND ELVR_POT SGND Definition Console for MCB of the PWM signal Speed sensor provide signal Console provide for incline motor DOWN signal Console provide for incline motor UP signal Incline place signal test power Incline place signal test ground Incline place signal Console ground P4: 6-pin console cable 1 6 J1 Pin Name Definition 1,2,3 +12 Console power 4,5,6 SGND Console ground 15

16 T8000E(TM97) Electrical block diagram for 220V Lout L-Return R-Return Rout GND 16

17 SECTION 3 CONSOLE ENGINEER MODE 17

18 T8000E OPERATION MANUAL- Engineer mode How to enter into the engineering mode? 1. Press & 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. 18

19 The list manager s custom setting 19

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22 SECTION 4 MCB LED INSTRUCTIONS 22

23 T8000E(TM97) MCB LED PLACE AND DEFINITION FOR 220V UP DOWN MTR_SHRT MOTOR MTR_AC V_CON SPD_SENSR PWM +18 I_LIMIT MCB Power indicator light V_CON Indicates if Console Voltage Supply is present. PWM------Console PWM signal light UP----- Indicates if the upper console is commanding Elevation UP DOWN---- Indicates if the upper console is commanding Elevation DOWN. SPD_SENSR--- Indicates the motor is moving via the encoder's feedback by blinking. I_LIMIT---- Over the 16A current limit time-out for 3 s has occurred. MTR_AC----MOTOR power indicator light. MOTOR---- MOTOR running light. MTR_SHRT---- MCB damage. 23

24 SECTION 5 TROUBLESHOOTINGS 24

25 Possible causes: 1. Breaker is damaged. 2. ON/OFF switch is damaged. 3. MCB is damaged 4. 6-pin console cable is damaged 5. PCB is damaged Fix: No display on console 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 L1 & L2 on the MCB. (Please refer the MCB WIRING page 13) 3. Verify the MCB whether supply the +12VDC for console. (Please refer the MCB LED V_CON have light page 23) 4. Replace low console cable or up console cable. 5. Replace TV 25

26 Possible causes: 1. AC power voltage is too low. Running speed is not stable 2. Tension of drive belt or running belt is too loose. 3. MCB is damaged. 4. Motor is damaged. Fix: 1. 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. Page5-6). 2. Replace new MCB. 3. Replace new Motor. 26

27 Possible causes: Fix: Noises generated under motor cover 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. 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 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. (Please refer the Use the carbon stick to clean the DC motor page 10-11) Replace the motor. 27

28 Error Messages on the Console engineer mode-error LOG Error E1 E3 E4 E6 Definition Treadmill will not start Incline motor not to movement RPM Detect the mistake (Only occur on Auto Check) Incline motor the signal not answer Error message 1 troubleshooting (1) Check the connector MCB and Speed sensor cable [Symptom 1 of treadmill will have start ] Press start and after 10 sec. the maintenance lamp will light RED, when the ERROR Log- ERROR 1 will show the 01. [Cause] The speed sensor can t sense the speed Speed sensor Magnet [Solution] 1. Check the connector condition of the speed sensor cable. 2. Replace the speed sensor. 3. Check the magnet on the front roller if it s too far away from the speed sensor 28

29 Error message 1 troubleshooting(2) [Symptom 2 of treadmill will not start ] Press start and after 10 sec. the maintenance lamp will light RED, when the ERROR Log- ERROR 1 will show the 01. [Cause] 1. MCB is damaged pin console cable is damaged. 3. PCB is damaged. 4. Motor is damaged. [Solution] 1. Open motor cover, verify wire connection BL [Motor wire (black)] and RED [Motor wire (red)] on the MCB then plug in the power cord and turn on the power switch. Then press START button. 2. Open MCB cover, connect all cable to MCB again turn on the power, verify the LED indicator of +18 LED is to glitter. (If that +18 LED is not glitter, replace MCB) 3. Press Start key, verify the LED indicator of PWM LED is to lit. (If that PWM LED is not lit, replace console cable. If PWM LED is still not lit, replace PCB. ) 4. Replace Motor. PWM 29

30 [Symptom] Press start then maintenance lamp will light RED, when the ERROR Log- ERROR 3 or 6 will show the 01. [Cause] 1. The 8-pin console cable is damaged. 2. Incline motor is damaged. 3. TV is damaged. 4. MCB is damaged. Error message 3,6 troubleshooting 5. The incline setting is not correct. [Solution] 1. Please check the incline motor cable whether to inset MCB. 2. Check the console signal whether transmission to MCB, you can refer to MCB LED UP and DOWN. If LED not light please check the console cable and console. If LED have light please replace the incline motor 3. If ERROR Log- ERROR 3 or 6 still show the 01, please replace the incline motor. 4. If ERROR Log- ERROR 3 or 6 still show the 01, please replace the TV. 5. If ERROR Log- ERROR 3 or 6 still show the 01, please replace the MCB. 6. Enter Engineering Mode to renew the Auto-calibration( Engineer mode P15). MCB LED UP and DOWN LED whether have light. 30

31 Error message 4 troubleshooting [Symptom] Running the Auto check can t finish, then maintenance lamp will light RED, when the ERROR Log- ERROR 4 will show the 01. [Cause] 1. Check the connector condition of the speed sensor cable. 2. Replace the speed sensor. 3. Check the magnet on the front roller if it s too far away from the speed sensor [Solution] 1. Check the connector MCB and Speed sensor cable 2. Speed sensor 3. Magnet 31

32 Johnson T8000E(TM97) maintenance lamp Maintenance lamp 1. When the distance accumulate to 5000KM 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 and SPEED Key for 3 seconds to turn off the light 32

33 SECTION 6 What is the difference between 2006 T8000(TM95) & 2006 T8000E(TM97) 33

34 T8000E(TM97) Console is 15 TFT TV T8000 (TM95)Console is 7 LCD 34

35 T8000 Upgrade Control overlay Item number : N12 Parts number : MC F(IE) F(SAP) Item number : AY1 Parts number : MC F(IE) F(SAP) T8000E Control overlay Item number : N12 Parts number : MC B(IE) B(SAP) Item number : AY1 Parts number : MC A(IE) A(SAP) 35