Johnson JET 6000 Service Manual Download Page 49 | Manualshive

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GEAR MOTOR REPLACEMENT

(JET-7000 series)

Tools required:

ü

Philips
screwdriver

ü

T-handle Wrench
(14mm)

ü

Ratchet Box

Wrench (11mm)

Procedure:

5.

Install the chain onto main chain wheel and tighten the
fixed bolts of gear motor. Use Ratchet Box wrench
(11mm) to adjust the chain-tension-screw, which is located
at the back end of the gear, motor.

6.

Reconnect cables and ground wire by referring to the
wiring diagram. Remove the support under the frame.

7.

Turn on the power and enter the Engineering Mode to
check if the extreme incline is within the correct range.

8.

Install the front cover and secure the screws.

7-6 Revision: 1.0 Date: 2001-06-01

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Summary of Contents for JET 6000

Page 1: ......

Page 2: ...OWER VOLTAGE INSTRUCTIONS 2 1 n SECTION 3 WIRING DIAGRAM o WIRING DIAGRAM TERMINAL END CE 3 1 o WIRING DIAGRAM TERMINAL END 3 2 o WIRING DIAGRAM MCB 3 3 n SECTION 4 CONSOLE ENGINEERING MODE GUIDE o JE...

Page 3: ...6 8 o TREADMILL WILL INCLINE UP OR DOWN BY ITSELF 6 9 o TREADMILL VARIES THE SPEED BY ITSELF 6 10 o ERROR MESSAGE ON CONSOLE 6 11 n SECTION 7 PARTS REPLACEMENT o RUNNING BELT DECK ROLLER 7 1 o MOTOR 7...

Page 4: ...Revision 1 0 Date 2001 06 01 SECTION 1 MAINTENANCE PROCEDURE...

Page 5: ...nspect Running Belt Top Clean Vacuum Inspect 3 Carbon Brush Inspect Replace Power Cord Inspect Display Console Clean Inspect Handlebar Clean Inspect Handrail Handlebar Inspect Front Roller Clean Inspe...

Page 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 Drive Belt If...

Page 7: ...the deck screws and assemble the rear roller first then assemble the front roller 5 Replace the drive belt on the transmission pulley by turning the Flywheel clockwise by using left hand and use righ...

Page 8: ...ooves in belt for dirt or dust and clean it 2 Check the grooves in motor pulley for dirt or dust and clean it 3 Check the grooves in roller pulley for dirt or dust and clean it If dirty grooves in the...

Page 9: ...Revision 1 0 Date 2001 06 01 SECTION 2 IMPORTANT SAFETY INSTRUCTIONS...

Page 10: ...ectrical shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grou...

Page 11: ...Revision 1 0 Date 2001 06 01 SECTION 3 WIRING DIAGRAM INSTRUCTION...

Page 12: ...WIRING DIAGRAM TERMINAL END CE E1 B1 E2 Ground E3 D2 B2 D4 D1 I3 D3 I4 I5 Ground I1 A2 I2 A3 A1 C1 A4 C2 C3 AC1 of MCB C4 AC2 of MCB 3 1 Revision 1 0 Date 2001 06 01...

Page 13: ...WIRING DIAGRAM TERMINAL END E1 B1 E2 GROUND E3 D2 D4 B2 D1 AC1 of MCB D3 AC2 of MCB 3 2 Revision 1 0 Date 2001 06 01...

Page 14: ...P3 8 pin console cable P4 6 pin console cable UP Incline yellow except the JET7000E Down Incline white except the JET7000E ELEV COMMMON Incline black except the JET7000E AC1 CE C3 of Capacitor Non CE...

Page 15: ...Revision 1 0 Date 2001 06 01 SECTION 4 CONSOLE ENGINEERING MODE GUIDE...

Page 16: ...C2 C6 refer to table 1 parameter value memo C1 35 For ver0 3 35 British 51 metric C2 125 C3 66 C4 50 C5 4 C6 1 89 Only for ver 0 3 max time Table 1 3 Press POWER key to save 1 Press Slow Down and RESE...

Page 17: ...sh System only 4 Using the Fast or Slow keys to adjust the speed of the treadmill to 0 5mph 0 8kph Then press START STOP key and the display shows FAS 5 Using the Fast or Slow keys to adjust the speed...

Page 18: ...XX u The content in the TIME WINDOW indicates the accumulated running hours of the treadmill u The content in the HEART RATE DISTANCE CALORIES WINDOW indicate the accumulated running miles in British...

Page 19: ...n press SLOW key until the deck lowers to min incline Press SELECT key to store 7 Press UP key to reach P7 address press SELECT key Then press SLOW or FAST key to adjust the values to 99 Press the SEL...

Page 20: ...store Press STOP key for next parameter setting 6 Press FAST key to reach P8 address press SELECT key Then press SLOW or FAST key to input your weight Press the SELECT key to store Press STOP key for...

Page 21: ...Revision 1 0 Date 2001 06 01 SECTION 5 MCB LED INSTRUCTIONS...

Page 22: ...s 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 Light when lit this indicates...

Page 23: ...lit indicates the current to the motor has reached the peak current trip point of 25 3 Amps The MCB might be broken down if the over current situation persists for a while It is recommended that the t...

Page 24: ...this problem persists replace MCB Light Indicates the PCB is commanding the incline gear to move down If the User is commanding the incline to decrease and this light is not lit check cabling verify...

Page 25: ...OFF OFF OFF OFF 4 ON ON OFF OFF OFF OFF OFF OFF 5 ON ON OFF OFF OFF OFF OR BLINKING N A N A 6 ON ON ON OFF ON and OFF BLINKING N A N A 7 ON ON ON ON OFF COMES ON BRIEFLY THEN SHUTS OFF N A N A 8 ON O...

Page 26: ...le and the keypad If problem still persist replace the MCB 6 MCB in current limit mode The MCB is experiencing a discontinuous over current events Check for mechanical wear and or defective motor If o...

Page 27: ...Revision 1 0 Date 2001 06 01 SECTION 6 TROUBLESHOOTINGS...

Page 28: ...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 O...

Page 29: ...to see if it is within 120V 15 or 230V 15 u 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 acro...

Page 30: ...run by itself Possible causes 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 6 3 Revision...

Page 31: ...ork 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 Repla...

Page 32: ...t 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 Remov...

Page 33: ...nd A2 motor wire on the MCB then plug in the power cord and turn on the power switch Then press POWER START FAST buttons 1 Verify the LED indicator of MOTOR is lit If that LED MOTOR is not lit replace...

Page 34: ...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 u Actually as moistu...

Page 35: ...line motor will be activated u OR Use a new 8 pin console cable to connect PCB and MCB to see if the incline motor will be activated u OR Replace PCB u OR Replace MCB 2 Enter to Engineering Mode and v...

Page 36: ...dmill is poor Fix 1 Use a new 8 pin console cable to connect PCB to MCB Then turn the power on press POWER START UP DOWN keys to see if this fix the problem 2 Replace MCB 3 Replace PCB 4 Each componen...

Page 37: ...ad 2 If speed or incline still changes by itself replace the PCB and refer to Engineering Mode Guide to re program all the parameters 3 Each component shall be properly grounded to the frame and the f...

Page 38: ...e plug or replace the Incline Motor Jet6000 Re plug or replace the VR Jet7000 Re plug or replace the 8 pin console cable MCB or PCB is damaged Err6 No elevating after press the up or down key about 5...

Page 39: ...SECTION 7 PARTS REPLACEMENT PROCEDURE Revision 1 0 Date 2001 06 01...

Page 40: ...e key 8mm 5mm Procedure 1 Remove the screws from the front cover by using the screwdriver 2 Remove two rear covers from the end of the side rails 3 Pull out the two side rails 4 Elevate the machine to...

Page 41: ...ove the front roller drive belt and rear roller If replacing the roller go to step 13 8 Remove the 8 screws holding the deck to the frame then remove the deck with the running belt If replacing the ru...

Page 42: ...r roller first then assemble the front roller 16 Place the drive belt on the transmission pulley by turning the flywheel clockwise by using left hand and place the drive belt on to grooves of the fron...

Page 43: ...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 7 Adjust the belt tension adjus...

Page 44: ...heavily while removing the incline motor put a support with proper height under the front of frame 4 Remove the bolts and the nuts from the incline motor by using the wrenches 14 17 5 Replace the incl...

Page 45: ...sole cover 4 Disconnect the console cable from the PCB and MCB 5 Pull out the snap bushing first then tie the old cable to the new one with a rigid string 6 Pull the old cable from the top end until t...

Page 46: ...ush if smooth u 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 ma...

Page 47: ...wooden hammer 8 Put on the two end caps and use the nutdriver 5 16inch 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...

Page 48: ...using screwdriver to open the cover 2 Disconnect remove cables from the Gear motor and lower 3 To prevent the frame from falling down heavily while remove the incline motor please put the support wit...

Page 49: ...r Use Ratchet Box wrench 11mm to adjust the chain tension screw which is located at the back end of the gear motor 6 Reconnect cables and ground wire by referring to the wiring diagram Remove the supp...

Page 50: ...and remove it 2 Use the T handle key 5mm to remove screws of the left handle bar and remove it 3 With the screwdriver remove the screws from the console base plate 4 Disconnect the console cable from...

Page 51: ...ables 7 Install the new cable into the left stanchion protrusion 8 Install the stanchion protrusion onto the stanchion 9 Install the console base onto the stanchion and tighten it 10 Install the conso...

Page 52: ...Use the Nutdriver 6mm to loosen the screws holding the PCB to the base to remove the PCB 4 Replace with a new PCB and tighten the screws 5 Reconnect the cables with PCB by referring to wiring diagram...

Page 53: ...2 Disconnect the plug of keypad from the PCB 3 Remove the safety key and the overlay 4 Replace with a new keypad and connect it with PCB 5 Install the console base plate and tighten the screws 6 Place...

Page 54: ...from the MCB 4 Use the T handle key 5mm to loosen screws and remove the stanchion together with console base 5 To prevent the frame from fall down heavily while remove the elevation rack outer pinion...

Page 55: ...on rack on to the transportation wheel and attach C clip then attach the elevation rack onto the incline gear and install the covers 9 Remove the support 10 Install and tighten the left right stanchio...

Page 56: ...turn off power 2 Remove the front cover 3 To prevent the frame from falling down heavily while replacing the chain please put a support with proper height 9cm under the front of frame before replacem...

Page 57: ...eel in such the way that the minimum elevation control dog touches the minimum elevation limit switch 7 Install the chain latch 8 Adjust the chain tension then tighten the Gear motor mount screws by u...

Page 58: ...SECTION 8 SERVICE FORM Revision 1 0 Date 2001 06 01...

Page 59: ...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 ou...

Page 60: ...ct Serial number Failure Symptom Pls refer to the service manual for the symptom of failure Cause of Failure Parts Replaced Suggestions to prevent Failure When parts needed please fill out a Parts Ord...

Page 61: ...dress 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 Pla...

Page 62: ...Warranty Claim Form Claim no Dealer Name Page of Pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS QTY AUTHORIZED BY 8 4 Revision 1 0 Date 2001 06 01...

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