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2006 Johnson T8000E(TM97)

SERVICE MANUAL

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TABLE OF CONTENTS

SECTION 1: MAINTENANCE PROCEDURE …………………..….…31. MAINTENANCE CHECK LIST……………………….........................4 2. TENSIONING THE BELT PROCEDURE…………………..………...5-6 3. DECK RE-WAXING PROCEDURE……………………………..……7-8 4. CLEAN THE GROOVES PROCEDURE……………...........................9 5. USE THE CARBON STICK TO CLEAN THE DC MOTOR………...10-11

SECTION 2: WIRING DIAGRAM INSTRUCTION…………….……...121. T8000E(TM97) MCB WIRING 220V…………..…………………..…..132. T8000E(TM97) MCB WIRING DEFINITION OF PIN 220V………...14-153. T8000E(TM97) ELECTRICAL BLOCK DIAGRAM FOR 220V..….…16

SECTION 3: CONSOLE ENGINEER MODE………………..………..171. OPERATION T8000E(TM97) Engineer mode..…………..………….18-21..SECTION 4: MCB LED INSTRUCTIONS…………………..…..… ….221. MCB LED place and definition for 220V……………………….…….23

SECTION 5: TROUBLESHOOTINGS……………………………….…24 1. No display on console………………………………………..………...252. Running speed is not stable…………………………………………….263. Noises generated under motor cover………………...…………..….….274. Error Messages on the Console…………………………………….…..285. Error message 1 troubleshooting (1)…...……………………………....286. Error message 1 troubleshooting (2)…...……………………………....297. Error message 3,6 troubleshooting……………………............………..308. Error message 4 troubleshooting………………………...…….……….319. T8000E(TM97) maintenance lamp…………..…………………………32

SECTION 6: What is the difference between 2006 TM95 & 2006 TM97…33-35

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SECTION 1MAINTENANCE PROCEDURE

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MAINTENANCE CHECK LIST

CleanMotor

Clean (Vacuum)Control Box

InspectRunning Belt

Inspect & Re-

waxingDeck Re-waxing

InspectCleanV Belt

InspectRunning belt Tension

TestEmergency Button

InspectCleanRear Roller

InspectCleanFront Roller

InspectCleanHandrail & Handlebar

InspectCleanDisplay Console

InspectPower Cord

ReplaceInspect Carbon Brush

InspectCleanFrame

InspectConsole Mounting Bolts

AnnualBiannualQuarterlyMonthlyWeeklyDailyItem

2006 Johnson T8000E TREADMILL

PREVENTIVE MAINTENANCE SCHEDULE

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TENSIONING THE BELT PROCEDURE

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: Perfect Tension of Running Belt: 0.9~1.1 lbs0.9~1.1 lbs

Frequency: Every 1 months

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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.

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DECK RE-WAXING PROCEDUREFrequency: Every 1 month

Parts name: Silicon oil setParts number: SZTM74SOSPrice (USD): 0.6Use 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.)

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 .

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Use the clamp-on meter (DC current-meter):

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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 :

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CLEAN THE GROOVES PROCEDUREFrequency: Every 3 months

Procedure:

1.Remove the drive belt and check the grooves in belt for dirt or dust and clean it.

3Check the grooves in roller pulley for dirt or dust and clean it.

If dirty grooves in the drive belt, motor and roller pulley, there will be noises while running.

Caution:

2.Check the grooves in motor pulley for dirt or dust and clean it

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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- 0421 Box – 10 pcsPrice : USD 28.5

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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.

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SECTION 2WIRING DIAGRAM INSTRUCTION

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T8000E (TM97) MCB WIRING(220V)

J1P2

P3

J2

MTR2

L2 L1

�

�

�

�

�

�

�

�

MTR1

P4 P1

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T8000E(TM97) MCB WIRING DEFINITION OF PIN(220V)

P2:Elevation cable(6pin/AMP-350762-4)

Incline motor does turn on powerCOM6

Incline motor does move to downDOWN5

Incline motor does move to upUP4

Incline place signal test groundELVR_GND3

Incline place signalELVR_POT2

Incline place signal test power ELVR_+5V1

DefinitionNamePin

1

2

JP1

3

4

5

6

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P3: 8-pin console cable

DefinitionNamePin

Console groundSGND8

Incline place signalELVR_POT7

Incline place signal test groundELVR_GND6

Incline place signal test powerELVR_+55

Console provide for incline motor UP signalUP4

Console provide for incline motor DOWN signalDOWN3

Speed sensor provide signalRPM2

Console for MCB of the PWM signal PWM1

1 8

J3

P4: 6-pin console cable

J1

DefinitionNamePin

Console groundSGND4,5,6

Console power+121,2,3

1 6

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T8000E(TM97) Electrical block diagram for 220VLo

utL-

Ret

urn

R-R

etur

nR

out

GN

D

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SECTION 3CONSOLE ENGINEER MODE

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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.

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The list manager’s custom setting

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21

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SECTION 4

MCB LED INSTRUCTIONS

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T8000E(TM97) MCB LED PLACE AND DEFINITION FOR 220V

� +18------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 feedbackby 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.

MTR_SHRT

MOTOR

MTR_AC

I_LIMIT+18PWMSPD_SENSR

V_CON

DOWN

UP

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SECTION 5

TROUBLESHOOTINGS

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No display on console

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: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

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Running speed is not stable

Possible causes:

1. AC power voltage is too low.

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.

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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 drive belt.

4. The motor is damaged.

Fix: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.

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Error Messages on the Console engineer mode-ERROR LOG

Incline motor not to movement

E3

RPM Detect the mistake (Only occur on Auto Check)

E4

Incline motor the signal not answer

E6

Treadmill will not start E1

Definition Error

Error message 1 troubleshooting (1)

[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

[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

Magnet

Speed sensor

Check the connector MCB and Speed sensor cable

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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.

2. 8-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

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[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.

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).

Error message 3,6 troubleshooting

MCB LED UP and DOWN LED whether have light.

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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]

Magnet

Speed sensor

Check the connector MCB and Speed sensor cable

1.

2.

3.

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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 belt2.3 Remove the motor cover and clean the dust inside2.4 Clean the frame2.5 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

Maintenance lamp

Johnson T8000E(TM97) maintenance lamp

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SECTION 6What is the difference between

2006 T8000(TM95) & 2006 T8000E(TM97)

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T8000E(TM97) Console is 15’TFT TV

T8000 (TM95)Console is 7’LCD

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T8000 Upgrade Control overlay

Item number : N12

Parts number :

MC0601250F(IE)

002934-F(SAP)

Item number : AY1

Parts number :

MC0601251F(IE)

002935-F(SAP)

Item number : N12

Parts number :

MC0601989B(IE)

066427-B(SAP)

Item number : AY1

Parts number :

MC0601990A(IE)

066428-A(SAP)

T8000E Control overlay