1

2006 Johnson T8000Pro(TM96) SERVICE MANUAL

2

TABLE OF CONTENTSSECTION 1: MAINTENANCE PROCEDURE …………………….……31. MAINTENANCE CHECK LIST………………………...........................4 2. TENSIONING THE BELT PROCEDURE…………………………..…..5-6 3. DECK RE-WAXING PROCEDURE……………………………….……74. CLEAN THE GROOVES PROCEDURE…………….............................8 5. Replace Right / Left side rail module procedure…………………………9SECTION 2: WIRING DIAGRAM INSTRUCTION……………....…….101. T8000PRO MCB WIRING …………………..……………………….....112. T8000PRO MCB WIRING DEFINITION OF PIN…………..……...…..12-143. T8000PRO CONSOLE WIRING…………………………………….…..154. T8000PRO CONSOLE WIRING DEFINITION OF PIN…………..........16-205. T8000PRO ELECTRICAL BLOCK DIAGRAM FOR 220V..……….....21SECTION 3: CONSOLE FUNCTIONAL FLOW DIAGRAM..................221. OPERATION T8000PRO MANUAL…………………………………....232. OPERATION T8000PRO MANUAL- Engineer mode………………..…24-26SECTION 4: INCLINE POWER BOARD LED INSTRUCTIONS..........271. T8000PRO Incline power board LED PLACE AND DEFINITION….….28SECTION 5: TROUBLESHOOTINGS……………..……………………...29 1. No display on console ………………………………………………….....302. Running speed is not stable ……………………………….……………...313. Treadmill starts to run by itself ………………………………….…..……324. All or some of the keys on console do not work ………………..……..…325. Noises generated under motor cover ………………………………….….336. T8000PRO maintenance lamp of blue …………….…..……………..…..347. Error Messages on the Console …...…………………………………..…..358. Error message 1 troubleshooting (1)……………………………………....359. Error message 1 troubleshooting (2)………………………..…………..…3610. Error message 2 troubleshooting……………………………..………....…3711. Error message 3,6 troubleshooting ………………………….…………….3812. Error message Inverter error troubleshooting …………………………..…3913. How to make sure whether the machine hand pulse can not work……..….40-41

3

SECTION 1MAINTENANCE PROCEDURE

4

MAINTENANCE CHECK LIST

CleanMotor

Clean (Vacuum)

Control Board

InspectRunning Belt

Inspect & Re-waxingDeck Re-waxing

InspectCleanV Belt

InspectRunning belt Tension

TestEmergency Button

InspectCleanRear Roller

InspectCleanFront Roller

InspectCleanHandrail & Handlebar

InspectCleanDisplay Console

InspectPower Cord

InspectCleanFrame

InspectConsole Mounting Bolts

AnnualBiannualQuarterlyMonthlyWeeklyDailyItem

Johnson T8000PRO(TM96) TREADMILL

PREVENTIVE MAINTENANCE SCHEDULE

5

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.

Frequency: Every 3 months

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.

7

DECK RE-WAXING PROCEDURE

Frequency: Every 3 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 .

8

CLEAN THE GROOVES PROCEDURE

Frequency: Every 3 months

Procedure:

1.Remove the drive belt and check the grooves in belt 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 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

9

Replace Right / Left side rail module procedure

If side rail LED will be not light, please replace Right / Left foot rail set, because replace side rail module is very difficult.

Caution:

Step.1 Take off the right / left end cap

Step.2 Remove the damage side rail

Step.3 Assembly the side rail and end cap

Step.4 Connect side rail wire to right rail wire (UP).

Step.5 Press “START” key, to run the machine confirm the side rail LED is good.

10

SECTION 2WIRING DIAGRAM INSTRUCTION

11

T8000PRO MCB WIRING

CNT5CNT7

CNT8

CNT1 AC1

� AC1------ on/off switch (power)

� AC2------ on/off switch (power)

� CNT8----Console cable

� CNT7----Speed sensor

� CNT6----Inverter cable

� CNT5----Inverter power cable(220V)

� CNT1----Elevation cable

� CNT4---- Inverter power cable(110V)

CNT6AC2

CNT4

12

T8000PRO MCB WIRING DEFINITION OF PIN

CNT1: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

CNT1

3

4

5

6

13

CNT8 : Console cable

14

CNT6:Inverter cable

15

T8000PRO CONSOLE WIRING

� J1-------Left key board

� J2-------Right key board

� J3-------Display board

� J5-------Quick LED

� J8-------HR1/TZ

� J9-------HR2

� J6-------IR connect cable

� J4-------Safe key

� J10-----Console cable

� J17------LCD connect cabled

� J13------LED1 display blue/red

� J14------HR-LED1

� J15------HR-LED2

J6J10 J4 J2

J13J17c-safe cardio J14J15

J9 J8 J5 J3 J1

16

J2 : Right key cable

17

J1 : Left key cable

18

J3 : Display board cable

19

J9 : HR2 cable

20

J8 : HR1/TZ cable

21

T8000PRO(TM96) Electrical block diagram

22

SECTION 3CONSOLE FUNCTIONAL FLOW DIAGRAM

23

T8000Pro(TM96) 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 “SELECT" key enter.

Engineer mode setting

24

The list manager’s custom setting

25

26

27

SECTION 4

Incline power boardLED INSTRUCTIONS

28

+12(B)

+12(A)

SPEED

PWM

UP

DOWN

+18V

FAIL

AC RUN

Indicates the presence of the unregulated 18 volt for MCB+18V

Indicates if inverter is commanding speed.RUN

Indicates if the AC Buss is Energized (Voltage Present).AC

Indicates if the upper console is commanding Elevation DOWN. DOWN

Indicates if the upper console is commanding Elevation UP. UP

Inverter is damageFAIL

Indicates if Console is commanding speed. PWM

Indicates the motor is moving via the encoder's feedback by blinking.

SPEED

Indicates is incline power board have provide the +12V power for PUMP.

+12(B)

Indicates is incline power board have provide the +12V power for console.

+12(A)

DescriptionLED

29

SECTION 5

TROUBLESHOOTINGS

30

No display on console

Possible causes:

1. Breaker is damaged.

2. ON/OFF switch is damaged.

3. Incline power board is damaged

4. 20-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 AC1 & AC2 on the MCB.

(Please refer the” MCB WIRING” ……page 10)3. Verify the MCB whether supply the +12VDC for console.

(Please refer the” MCB WIRING” ……page 15)4. Replace 20-pin console cable .5. Replace PCB

31

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. Inverter 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 Inverter.

3. Replace new Motor.

32

Treadmill starts to run by itself

Possible causes:

1. The console cable is broken.

2. PCB is out of order.

3. Inverter is out of order.

Fix:1. Replace the console cable with a new one.

2. Replace the PCB.

3. Replace the Inverter .

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.

33

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 cleanif necessary. Clean also the motor pulley and the roller pulley grooves and check if the noise has disappeared.

4. The motor bearing is damaged.

34

1. When the distance accumulate to 4000KM 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 UP" & "Speed FAST" for 3 seconds to turn off the light

Maintenance lamp

T8000PRO maintenance lamp of blue

35

Error Messages on the Console

Panel control board the MCU not answer E2

Incline motor the signal not answerE6

Inverter problemInverter error

Incline motor not to movement E3

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 LED displaywill show “Error 1”

[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

36

Error message 1 troubleshooting(2)

[Symptom 2 of treadmill will not start ]Press start and after 10 sec. the LED display will show “Error 1”

[Cause]

1. 20-pin console cable is damaged.

2. PCB is damaged.

3. Motor is damaged.

[Solution]1. Open MCB cover, connect all cable to Inverter again turn on the power, verify

the LED indicator of PWM is to glitter.

(If that PWM is not glitter, replace console cable)

2. If PWM LED also do not glitter, replace PCB.

3. Verify wire connection Motor wire and inverter cable on the Inverter, then plug in the power cord and turn on the power switch.

(Then press “START“ button, if motor do not to run, replace the motor.)

PWM

37

Error message 2 troubleshooting

[Symptom]

Press “Start” key then the console display show ”Error 2”

[Cause]

Panel control board cause by static destroy, make the panel control board inside parts MCU damage.

[Solution]1.Turn on power again, if console still show “Error 2”,replace PCB.2. Please check the console ground wire whether connect to PCB.(Please refer the below photo and check the machine ground between the

console and incline power board whether connect.)

Check the machine ground whether have connect.

Console back screw Incline power board ground

38

[Symptom]Press start then the console display show “Error 3 or 6“

[Cause]

1. The 20-pin console cable is damaged.

2. Incline motor is damaged.

3. PCB is damaged.

4. Incline power board is damaged.

5. The incline setting is not correct.

[Solution]1.Enter the “Engineer mode” to P19:MANUFACTURING TEST this ADDRESS

place, Holding the “Up & Fast” key for 3’S, press speed key to select M4:LOW ELEVATION console display will show incline motor parameter (Please refer the below photo), if display not show right parameter, please check the between Incline power board and incline motor whether connect is OK, if it is OK, please replace new console cable to test again.

2. If display still show “Error 3 or 6“, please replace the incline motor.

3. If display still show “Error 3 or 6“, please replace the PCB.

4. If display still show “Error 3 or 6“, please replace the incline power board.

5. Enter Engineering Mode to Auto-calibration place to renew the Auto-calibration elevation parameter (Please refer the page 25) .

Error message 3,6 troubleshooting

Incline motor right now place parameter

Incline motor Default Value place parameter

39

Error message 4 troubleshooting

[Symptom]Running the “Auto check “ can’t finish.

[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.

40

How to make sure whether the machine hand pulse can not work

1. Please make sure then user hold the hand pulse whether windows show picture.

Remark: Heart rate figure show up on the screen about in 15~20 sec.

2. If the heart rate figure still dosen't show up on the screen, Please inspect according to the step as below.

Step 1: Please make use of tools to confirm line have conduct.

41

Step 2: Please check the connection.

Check whether the heart rate cable is touching hand pulst metal (both of left hand and right hand).

Besides the other side of the heart rate cable should be connected with HR board.

Step 3: If you can't find any problem with above step, and the heart rate figure still can't showup, Please replace the heart rate board.