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1

JOHNSON

Issue date

Edition

01

Doc No.

SM-TM-TEM-001

Revision

date

Edition time 01

Page

41

Johnson Industries (Shanghai) Co.,Ltd

Document:

612T&622T Service Manual

Approval

Review

Editor

Eric

Kali/Lucy

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2
3
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Summary of Contents for 612T

Page 1: ...1 JOHNSON Issue date Edition 01 Doc No SM TM TEM 001 Revision date Edition time 01 Page 41 Johnson Industries Shanghai Co Ltd Document 612T 622T Service Manual Approval Review Editor Eric Kali Lucy ...

Page 2: ...2 Product Browse ...

Page 3: ...3 ...

Page 4: ... 4 Program Information 15 CHAPTER 4 ENGINEERING MODE 4 1 Engineering Mode 17 4 2 Engineering Mode Overview 18 CHAPTER 5 TROUBLESHOTING 5 1 Electrical Diagram 19 5 2 MCB Wiring Instructions 20 5 2 1 Troubleshooting No Power To The Console 21 5 2 2 Troubleshooting No Function For Safety Key 22 5 2 3 Troubleshooting No Response For Machine Console Motor 23 5 2 4 Troubleshooting Incline Motor Issues 2...

Page 5: ... 32 6 4 Running Deck Replacement 33 6 5 Front Roller Replacement 34 6 6 Running Belt Replacement 35 6 7 Motor Control Board MCB Replacement 36 6 8 Motor Replacement 37 6 9 Drive Belt Replacement 38 6 10 Console Replacement 39 6 11 Incline Motor Replacement Only For 622T 40 6 12 Heart Rate Board Replacement Only For 622T 41 ...

Page 6: ...CHAPTER 2 Serial Number Location 6 1 1 SERIAL NUMBER LOCATION 612T ...

Page 7: ...CHAPTER 2 Serial Number Location 7 622T ...

Page 8: ...lt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned If any labels are damaged or illegible contact Customer Technical Support for replacements EVERY WEEK WEEKLY Clean underneath the treadmill following these steps Turn off the treadmill with the ON OFF switch then unplug the power cord at the walloutlet Fold the treadmill into the upright ...

Page 9: ...tions Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet Loosen both the rear roller bolts for best results place two removable marks on both sides of the frame and note roller position Once the belt is loosened take the bottle of lubricant and apply it to the entire top surface of the running deck Tighten both rear roller bolts matching up the marks for pr...

Page 10: ...ted at the factory before it was shipped At times the belt can move off center during shipment Before operating the treadmill make sure the belt is centered and remains centered to maintain smooth operation If the running belt is too far to the right side With the treadmill running at 1 mph turn the left adjustment bolt counter clockwise turn at a time using the supplied Allen wrench Check the bel...

Page 11: ...econds to reset the treadmill C Start Simply press to begin exercising starts your program and also changes the display D SPEED ARROW KEYS Used to adjust speed in small increments E SAFETY KEY POSITION Enables treadmill when safety key is engaged F QUICK PROGRAM SPEED KEYS Press key to select program Once in a program press key to select speed G THUMB SENSOR Monitors heart rate H WATER BOTTLE CD M...

Page 12: ...ion E QUICK ADJUST INCLINE SPEED KEYS Used to reach desired incline and or speed more quickly Select after pressing PRESS TO SET INCLINE or PRESS TO SET SPEED KEY F PRESS TO SET INCLINE KEY Used to confirm chosen incline Press before selecting INCLINE G INCLINE ARROW KEYS Used to adjust incline in small increments H PRESS TO SET SPEED KEY Used to confirm speed change Press before selecting SPEED I...

Page 13: ...the four quick speed keys easy 5 km h moderate 8 km h hard 12 km h or sprint 16 km h The treadmill will adjust accordingly 622T Press the press to set speed or press to set incline key and then press a number 0 9 This confirms that this is the speed or incline you want and the treadmill will adjust accordingly CLEAR CURRENT SE LECTION To clear the current program selection or screen hold the stop ...

Page 14: ...ROGRAM 1 Press a PROGRAM key to select a program 2 Use the ARROW keys to select time 3 Press START to begin 3 3 2 622T GETTING STARTED 1 Check to make sure no objects are placed on the belt that will hinder the movement of the treadmill 2 Plug in the power cord and turn the treadmill ON 3 Stand on the side rails of the treadmill 4 Attach the safety key clip to part of your clothing 5 Insert the sa...

Page 15: ...CHAPTER 3 Console Instruction 15 3 4 PROGRAM INFORMATION ...

Page 16: ...CHAPTER 3 Console Instruction 16 ...

Page 17: ...CHAPTER 4 Engineering Mode 17 4 1 ENGINEERING MODE ...

Page 18: ...CHAPTER 4 Engineering Mode 18 4 2 ENGINEERING MODE OVERVIEW ...

Page 19: ...CHAPTER 5 Troubleshooting 19 5 1 1 612T Electrical Diagram 5 1 1 622T Electrical Diagram ...

Page 20: ...ubleshooting 20 5 2 TROUBLESHOOTING MCB WIRING INSTRUCTIONS MCB wiring instructions CN1 AC motorcable socket CN2 ACpower cable socket CN3 Elevation motor cable socket CN4 Console set cable socket CN5 Transfer board ...

Page 21: ...ower to the console Measure the pins in the yellow circle in the picture below If approximately 12 VDC is measured at these pins replace the console cable C Check that the MCB is receiving 120 VAC Measure the black and white wires which connect to the MCB If there is approximately 120 VAC 15 VAC on these wires replace the MCB As previously mentioned this MCB has no indicator LED to indicate the MC...

Page 22: ...ow still shows safety key off 2 SOLUTION a Check if the safety key totally inserted in the console If no take off and insert again b Check if the safety key oxidized or not which will affect the conduction If yes please change a new one c If the safety key is function check the safety key sensor wires in console Suggest to re connect the wires or to change new wires ...

Page 23: ...hanged the console is ok If not replace the PCB c Turn off the power switch and open the motor upper cover Remove the red black wires of motor from the MCB and use a multi meter to measure the resistance of drive motor If the resistance is bigger than 10 Ω the drive motor is defective Replace the drive motor If the resistance is lower than 10 Ω the drive motor is ok Then Check the connection of th...

Page 24: ...o ENG 1 Hardware Test Press the key ENTER first and then the key START Press the key INCLINE If can hear beeps from two relays at the MCB the MCB is ok Then check the connection of the elevation motor at the MCB first try to unplug and re plug these two pins If can not resolve the issue replace the elevation motor If there is no beeps from these two relays MCB is defective and replace the MCB ...

Page 25: ...and tensioned correctly Remove and clean the rollers if needed Replace the rollers or running belt as needed b This sound is likely a moving component Remove the motor cover and check the drive belt for alignment and make sure it is not slipping or is frayed cut in any way Replace the drive belt ifneeded Make sure the optic disk on the motor is not rubbing the speed sensor Turn the motor by hand t...

Page 26: ...f needed Check to see if the air shock is making this noise lubricate or replace if needed f This sound is likely due to the air shock Lubricate or replace the air shock as needed g This sound is likely from the incline motor Check that the incline motor connection points include Teflon washers Lubricate the incline motor worm screw and connection points with grease Replace the incline motor ...

Page 27: ...ing from the amp board to the console Replace the speaker or amp boards and wiring Replace the speakers If the speaker board amp board wiring and speakers do not solve the issue replace the console b There is a bad connection between the headphones and the console Verify the connection of the music player to the dock or audio adaptor cable Verify the audio adaptor cable connection at the console R...

Page 28: ...iring is bad Check the speaker wire connections Switch the speaker connections from one speaker to the other to see if sound switches sides If the sound does not switch sides replace the speaker board If the sound does switch sides replace the speaker and speaker wires f Grounding issue Try a different set of headphones Check the grounding of the console ...

Page 29: ...he chest strap is damaged d The HR grips are damaged e Heart rate board damaged f The UCB is damaged 2 SOLUTION a Re center the chest strap below the user s pectoral muscle and check again b Replace the battery in the chest strap c Replace the chest strap d If there is no HR present replace the HR grips e If there is a HR present but it is much higher than normal replace the HR board f If replacin...

Page 30: ...rews holding the motor cover to the frame Figures A B 2 The cover is secured to the frame with velcro so you will have to pull up with some force FIGURE A FIGURE B 3 Figure C shows the motor area with the motor cover removed FIGURE C 4 Reverse Steps 1 3 to install a new motor cover ...

Page 31: ...CHAPTER 6 PartReplacementGuide 31 6 2 REAR ROLLER REPLACEMENT 1 Remove the rear end caps Figure A 2 Remove both roller adjustment screws Figure B FIGURE A FIGURE B 3 Remove the roller Figure C FIGURE C ...

Page 32: ...e back of the treadmill Figures B FIGURE A FIGURE B 4 Reverse Steps 1 2 to install a new side rail NOTE After reinstalling the side rail make sure the rear end cap is on first before tightening the screws for proper gap spacing Be careful not to over tighten the screws or they will poke through the top of the side rail ...

Page 33: ...n Section 6 3 3 Remove the end cap 4 Remove the running deck screws Figure A FIGURE A FIGURE B 5 Remove the running deck from the running belt Figure B 6 Reverse Steps 1 4 to install a new running deck NOTE The running deck is waxed on both sides so the opposite side surface may be usable New deck surfaces must ALWAYS be matched to a new running belt ...

Page 34: ... 1 2 Loosen both of the rear roller screws to remove tension from the running belt Figure A FIGURE A FIGURE B 4 Remove the spring from the drive belt tensioner The tensioner should now pivot away from the drive belt Figure B 5 Remove the drive belt from the front roller and remove the roller from the running belt ...

Page 35: ... in Section 6 2 3 Remove the running deck as outlined in Section 6 4 4 Remove the front roller as outlined in Section 6 5 5 Remove the running belt Figures A FIGURE A 6 Reverse Steps 1 5 to install a new running belt NOTE New running belts should ALWAYS be installed on a new deck surface deck should either be flipped or replaced to gain a new surface ...

Page 36: ...machine 2 Remove the motor cover as outlined in Section 6 1 3 Disconnect the wire connectors at the MCB 4 Remove the 2 screws holding each side of the MCB to the frame Figures A FIGURE A FIGURE B 5 Remove the MCB Figure B 6 Reverse Steps 1 5 to install a new MCB Make sure that all wires removed during Step 3 are re connected ...

Page 37: ... spring from the drive belt tensioner 4 Remove the drive belt tensioner 6 Disconnect the motor cable ground wire from the grounding post 7 Disconnect the motor cable from the MCB 8 Remove the 4 screws holding the motor to the frame Figure A FIGURE A 9 Remove the motor from the treadmill 10 Reverse Steps 1 9 to install a new motor NOTE Be sure that the motor isolator pad is in place prior to mounti...

Page 38: ...The tensioner should now pivot away from the drive belt 5 With the tension on the drive belt relieved it can be walked off of the motor pulley 6 Loosen the rear roller screws to relieve tension on the running belt 7 Remove the two 8 mm screws from front roller 8 Lift the roller and remove the old drive belt 9 Reverse Steps 1 8 to install a new drive belt NOTE After installing a new belt check it f...

Page 39: ...nd disconnect the power cord 2 Remove the 4 screws holding the console from the console mast Figure A FIGURE A FIGURE B 3 Remove the 5 screws holding the back of console Figure B 4 Disconnect the wires connections from the console 5 Remove the console 6 Reverse Steps 1 5 to install a new console ...

Page 40: ...ort it so that the front wheels are off the floor or the unit may be tipped on its side 4 Remove the screws from the elevation rack Figure A FIGURE A FIGURE B 5 Disconnect the incline motor from the top mounting bracket Figure B 6 Reverse Steps 1 5 to install a new incline motor NOTE When installing a new incline motor make sure to replace the white nylon washers at the top and bottom connection p...

Page 41: ... to the treadmill and remove the power cord 2 Remove the console as outlined in Section 6 12 3 Loose the screws which fix the heart rate sensor Figure A FIGURE A FIGURE B 4 Disconnect the wires connections that go to the heart rate board Figure B 5 Reverse Steps 1 3 to install a new heart rate board ...

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