Johnson Service Manual 5100 Series

o JPB-5100o JPS-5100

o JAR-6000

o JPC-5100

o JPE-5100o JAR-5100

TABLE OF CONTENTS

n SECTION 1: WIRING DIAGRAMo CONTROL BOARD WIRING DIAGRAM (JPC/B-5100).............................1-1o CONTROL BOARD WIRING DIAGRAM (JPS-5100)................................1-2o CONTROL BOARD WIRING DIAGRAM (JPE-5100)................................1-3o CONSOLE BACKSIDE (EAR CLIP SENSOR)...........................................1-4o CONSOLE BACKSIDE (HAND PULSE)...................................................1-5o WIRING DIAGRAM (JPC/B-5100).............................................................1-6o WIRING DIAGRAM (JPS-5100)................................................................1-7o WIRING DIAGRAM (JAR-5100)................................................................1-8o WIRING DIAGRAM (JAE-5100)................................................................1-9

n SECTION 2: TROUBLESHLOOTINGSJPC/B/S/E-5100o No display on the console or the display is dim..........................................2-1o No RPM is displayed during the exercise (JPC/B/S).................................2-2o All or some of the keys have no function......................................................2-3o Feel the resistance increase/decrease or fell no resistance(JPC/B/S)........2-4o Feel the resistance increase/decrease or feel no resistance (JPE)..............2-5o Feel slipping while pedaling.......................................................................2-6o Knocking or creaking noise..........................................................................2-7o No pulse is displayed on the console (Ear clip sensor)...............................2-8o No pulse is displayed on the console (Chest belt type)...............................2-9o No pulse is displayed on the console (Hand pulse type)..............................2-10o Console diagnostics mode...........................................................................2-11

JAR-5100o No display is on the console while any function key is pressed...................2-12o No display is on the console while adjusting the seat but there is display while

any key is pressed............................................................................................2-13o Console will not function properly...............................................................2-14o Count value will not increase while adjusting the seat..........................2-15

JAR-6000o No display on the console..............................................................................2-16o SPM value wont increase while running the rower................................2-17o No pulse display on the console....................................................................2-18

TABLE OF CONTENTS

n SECTION 3: PARTS REPLACEMENTn GENERAL (JPC/B/S/E)

o CONSOLE.......................................................................................3-1o CONSOLE CABLE......................................................................3-2o CONTROL BOARD.....................................................................3-3o GENERATOR OR ELECTROMAGNET BRAKE SET..................3-4

n JPC/B-5100o CRANK............................................................................................3-5o PEDAL............................................................................................3-6o POLY-V BELT 400/380J6................................................................3-7o POLY-V BELT 500/440J8................................................................3-8o AXLE.......................................................................................3-9o FRONT PULLEY.......................................................................3-10o BALL BEARINGS...........................................................................3-11

n JPS-5100o POLY-V BELT 430J6.......................................................................3-12o POLY-V BELT 430J8.......................................................................3-13o CHAIN OR SPRING.....................................................................3-14o SENSOR............................................................................................3-15o FOOT PAD....................................................................................................3-16o BALL BEARINGS.............................................................................3-17

n JPE-5100o CRANK.............................................................................................3-18o PEDAL.............................................................................................3-19o POLY-V BELT 430J12......................................................................3-20o POLY-V BELT 430J6........................................................................3-21o PULLEY AXLE..............................................................................3-22o AXLE.........................................................................................3-23o ROLLER............................................................................................3-24o SENSOR............................................................................................3-25

n JAR-5100o CONSOLE.......................................................................................3-26o CONSOLE CABLE.......................................................................3-27o SENSOR............................................................................................3-28o SEAT.........................................................................................................3-29o DRIVE BELT 3V-530......................................................................3-30o NYLON ROPE.............................................................................3-31o TENSION SPRING SET.................................................................3-32

TABLE OF CONTENTS

n SECTION 4: PREVENTIVE MAINTENANCE CLEANING THE GROOVES.......................................................4-1 RE-LUBRICATING THE CHAIN & GEAR (for JPS)................4-2 CLEANING THE RAIL AND ROOLER(JPE5100)......................4-3

n SECTION 5: SERVICE FORMo FIELD FAILURE REPORT.........................................................5-1o PARTS ORDER FORM................................................................5-2o WARRANTY CLAIM FORM........................................................5-3

Revision: 1.0 Date: 2001/06/01

SECTION 1WIRING DIAGRAM


JPC/B-5100 CONTROL BOARD WIRING DIAGRAM

A1 : 3-pin terminal to the generator

A2 : 2-pin terminal to the electromagnet

A3 : 4-pin terminal to the console

1-1 Revision: 1.0 Date: 2001/06/01

JPS-5100 CONTROL BOARD WIRING DIAGRAM

A1 : 3-pin terminal to the generator

A2 : 2-pin terminal to the electromagnet

A3 : 2-pin terminal to the output of the adapter


1-2 Revision: 1.0 Date: 2001/06/01

JPE-5100 CONTROL BOARD WIRING DIAGRAM

A1 : 3-pin terminal to the electromagnet brake set

A2 : 2-pin terminal to the adapter


A4: grounding wire to frame

A4 A1

A2

A3

1-3 Revision: 1.0 Date: 2001/06/01

CONSOLE BACKSIDE (EAR CLIP SENSOR)

A : console cable -> MCB A4

B : ear clip cable

C : console power switch

1-4 Revision: 1.0 Date: 2001/06/01

CONSOLE BACKSIDE (HAND PULSE)

A : console cable -> MCB A4

B : hand pulse cable (right)

C : hand pulse cable (left)

D : console power switch

1-5 Revision: 1.0 Date: 2001/06/01

JPC/B-5100 WIRING DIAGRAM

1-6 Revision: 1.0 Date: 2001/06/01

JPS-5100 WIRING DIAGRAM

1-7 Revision: 1.0 Date: 2001/06/01

JAR-5100 WIRING DIAGRAM

1-8 Revision: 1.0 Date: 2001/06/01

JPE-5100 WIRING DIAGRAM

1-9 Revision: 1.0 Date: 2001/06/01

SECTION 2TROUBLESHOOTINGS

Pedal speed has to be over 30 rpm fortroubleshooting at anytime for JPC/B-5100.


No display on the console or the display is dim (JPC/B/S/E)

Possible causes:1. Console is damaged or

the console cable is notconnected properly.

2. Poor connection to allthe terminals on thecontrol board.

3. Control board isdamaged.

4. Generator isdamaged.(for JPC/B/S)

Fix:1. First, Check if the adapter is connected properly for

both input & output ends (for JPS/JPE). Remove theconsole, then check if the console cable is connected

properly. Unplug the console cable and use a multi-meter to check if the voltage on the 1st and 4th pinof the console cable is greater than 5(4.5) VDC.u If it is, replace the console and check again.

2. Open the side covers of the bike and check if all thewire harnesses are connected properly to the terminalsof the control board.

3. Unplug the console cable from the control board andcheck if the voltage on the 1st and 5th(4th forJPS/JPE) pin of control board is greater than 5(4.5forJPS)VDC

u If it is, replace consolecable with a new one.

u If it is not, next step.

4. Unplug the generator cablefrom the control board andcheck if the voltage isvariable.

u If it is, replace the control board with a new one.u If it is not, replace the generator with a new one.

2-1 Revision: 1.0 Date: 2001/06/01

No RPM is displayed during the exercise (JPC/B/S/E)

Possible causes:1. Console cable is

damaged or the consolecable is not connectedproperly.

2. Console is damaged.

u (3 for JPC/B)3. Control board is

damaged

u (4,5&6 for JPC/B)4. Speed sensor is

misaligned(for JPS/E)

5. Poor connection of thesensor.

6. Sensor is damaged(forJPS/E)

Fix:1. Remove the console and check if the terminal of

console cable is connected properly to the console.u If it is not connected well. Connect the terminal properly. If cable is damaged, replace it with a new one.

2. Console is damaged, replace it with a new one.

3. Open the side covers of the fitness then replaces thecontrol board with a new one.

4. Check if the sensor is misaligned. If it is, place thesensor in the correct position.

5. Open the side covers of the stepper and check if theconnection of the sensor is connected properly.u If it is not connected well. Connect the terminal properly.

u If cable is damaged, replace this with a new one

6. Sensor is damaged, replace it with a new one

2-2 Revision: 1.0 Date: 2001/06/01

All or some of the function keys do not respond (JPC/B/S/E)

Possible causes:1. Keypad connecting

plug has been not fit-in properly.

2. Keypad is damaged.

3. Upper board isdamaged.

Fix:1. Remove the console cover, and then check if

keypad cable is connected properly to the upperboard.u If it has not been connected well, reconnect it

to the terminal and check again..2. Keypad or upper board is damaged.u Replace the console.

2-3 Revision: 1.0 Date: 2001/06/01

Feel the resistance increase/decrease suddenly or feel no

resistance (JPC/B/S)

Possible causes:1. Console is damaged

or the console cableis not connectedproperly

2. Console cable isdamaged.


4. Generator isdamaged.

5. Alignment of thesensor (for JPS)

6. Sensor is damaged (for JPS)

7. Gap between theelectromagnet and thecopper disc of thegenerator is too wide.

Fix:1. Remove the console and check if the console

cable has been connected properly.

2. Console cable is damaged, replace it with a newone.

3. Remove the side covers of the fitness and checkif the terminal of the control board has beenconnected properly. Control board is damaged,replace it with a new one.

4. Generator is damaged, replace with a new one

5. Check if the sensor is positioned correctly.

u Re-align the sensor to the correct position

6. Sensor is damaged, replace it with a new one

7. (1)Loosen the assembly screws of electromagnet(2) With a c-vice press the electromagnet tonarrow the gap then check again.

.

2-4 Revision: 1.0 Date: 2001/06/01

Feel the resistance increase/decrease suddenly or fell no

resistance (JPE5100)

Possible causes:7. Console is damaged

or the console cableis not connectedproperly

8. Console cable isdamaged.


10. Electromagnet brakeset is damaged.

11. Gap between theelectromagnet andthe copper disc ofthe generator is toowide

Fix:8. Remove the console and check if the console

cable has been connected properly.

9. Console cable is damaged, replace it with a newone.

10. Remove the side covers of the fitness and checkif the terminal of the control board has beenconnected properly. Control board is damaged,replace it with a new one.

11. Electromagnet brake set is damaged, replace itwith a new one

12. (1)Loosen the assembly screws of electromagnet(2) With a c-vice press the electromagnet tonarrow the gap then check again.

.

2-5 Revision: 1.0 Date: 2001/06/01

Feel slipping while pedaling (JPC/B/S/E)

Possible causes:1 Belt tension is not

enough

2 Poly v Belt isdamaged

Fix:1 Re-adjust the belt tension.

2 Replace poly v belt with a new one.

Adjust it

2-6 Revision: 1.0 Date: 2001/06/01

Knocking or creaking noise (JPC/B/S/E)

Possible causes:

1 Pedal is on crank armtoo loose

2 Crank or axle is wearout

3 Belt tension is tooloose or poly v belt istoo dirty

4 Rail or roller is toodirty

Fix:1 Re-tighten it.

2 Replace it with a new one

3 Re-adjust the belt tension and clean the poly v belt

4 Clean the rail and roller.

2-7 Revision: 1.0 Date: 2001/06/01

No pulse display on the console (Ear clip sensor) (JPC/B/S/E)

Possible causes:

1. Physical differencebetween individuals.

2. Ear clip sensor isdamaged.


Fix:

1. Open and close the clip of the ear clip sensorseveral times with your fingers, then check again.1.1 If there is no pulse, massage your earlobe

several times and then re-clip the sensor tocheck again.

1.2 No response because of individual physicaldifference.

2. Ear clip sensor is damaged. Replace it with a new one.

3. Console is damaged. Replace it with a new one.

: The general operation guide of Ear Clipsensor.

1. People with darker skin may have a weak response.

2. People with bad blood circulation may have no response.

3. Before using the ear clip sensor, massage earlobe several

times to circulate the blood.

4. The ear clip must be placed in the middle of earlobe.

5. Place the ear clip sensor properly on the earlobe to prevent

shaking during the exercise.

2-8 Revision: 1.0 Date: 2001/06/01

No pulse display on console (Chest belt type) (JPC/B/S/E)

Possible causes:

1. Chest belt is notplaced properly.

2. Chest belt isdamaged.


Procedure:

1. Place the chest belt inthe correct position.

2. Replace the chest belt with a new one.

3. Replace the console with a new one.

The correct operation of a Chest Belt.1. Moisten the electrodes that are located on

both ends of the belt.2. The belt functions will most effective

when placed close to the heart and to theskin.

2-9 Revision: 1.0 Date: 2001/06/01

No pulse display on the console (Hand pulse type)

(JPC/B/S/E)

Possible causes:

1. Connection of handpulse cable.

2. Hand pulse cable isdamaged.


Procedure:1. Remove the console to check if the terminal of hand

pulse cable has been connected to PCB well.

OR

2. Replace the hand pulse cable with a new one.

OR

3. Replace the console with a new one

2-10 Revision: 1.0 Date: 2001/06/01

Console Diagnostics Mode(JPC/B/S/E)STEP 1

STEP 2

STEP 3

STEP 4

1. Sit (stand) on your bike (stepper), Press and holddown the "RESET key then (for stepper turnthe power on) start pedaling to reach a pedalspeed of approximately 30rpm.OR Press andhold down the "RESET key then plug theadapter (JPE).

2. Dot Matrix Display will be scanned slowly startingfrom LEDs of the bottom row to the top; eachsegment of the 7-segments will be scannedsimultaneously

u If one of LEDS is not lit, replace the PCB.

1. Press the ENTER key.2. Dot Matrix Display will be scanned slowly starting

from LEDs at the leftmost column to the right.3. Each 7-segments display will be scanned one by

one.u If one of LEDS is not lit, replace the PCB.

1. Press the ENTER key.2. Dot Matrix and 7-segments will display lighted upu If one of LEDS is not lit, replace the PCB.

1. Press the ENTER key.2. Dot Matrix Display will show RPM.3. RPM window will show current RPM4. TIME window will show total accumulated

minutes and seconds.5. AGE window will show total accumulated hour.6. Hold down the RESET key first then press

PAUSE key to clear the record.u If RPM is not shown, please refer to section 4-2 for

troubleshooting.

2-11 Revision: 1.0 Date: 2001/06/01

Console Diagnostics Mode (JPC/B/S/E)

SETP 5

STEP 6

STEP 7

STEP 8

1. Press the ENTER key.2. In the Dot Matrix Display there will be two hearts

on it, which will light up completely in turn3. STEPS/MINS windows will show the current

heart rate while you are wearing a HAND PULSESENSOR or POLAR CHEST BELT.

u If the heart rate is not shown or not stable in thedisplay, please refer to page 2-8 ~ page 2-10

1. Press the ENTER key.2. Dot Matrix Display will show D/A.3. Press +/- key to increase or decrease resistance.u If there is no resistance, please refer to page 2-4~

page 2-5.

1. Press the ENTER key.2. Dot Matrix Display will show KEY on it.3. Ready for you to enter any key of all 18 keys other

than RESET now to verify the function of thekey..

4. The RPM window will show you a referencenumber accordingly while pressing a number orfunction key.

5. TIME window will show you the programmingyear of the software.

6. WORK LEVEL windows will show you theprogramming month and day.

7. PULSE window will show you the softwareversion.

u If any of the keys does not work, please refer topage 2-3

1. Press the ENTER key. This completes theprocedure.

2-11 Revision: 1.0 Date: 2001/06/01

No display on the console while any function key is pressed (JAR-5100)

Possible causes:1. Battery is not energy

enough


Fix:1. Remove thebattery cover fromthe console, thencheck if the batterys voltage is greaterthan 1.3 VDC.u If it is not,replace the batteryand check again.

2. Replace theconsole with a newone

u .

2-12 Revision: 1.0 Date: 2001/06/01

No display is on the console while adjusting the seat, but there

is display while any key is pressed (JAR-5100)

Possible causes:1. Improper adjustment of

the seat.

2. Console cable has notbeen connected well tothe connector or broken.


4. Magnet is missing or notpositioned well.

5. Sensor is damaged orloosely attached.

Fix:1. Slide the seat to far end of the rail and slide it

back and forth several times to check if there isdisplay on the console

2. Remove the console and check if the terminal ofconsole cable is connected properly. Reconnect the cable. If the cable is damaged, replace it with a

new one.


4. Re-position the magnet.

5. Replace it with a new one or re-attach it.

2-13 Revision: 1.0 Date: 2001/06/01

Console function will not function properly (JAR-5100)

Possible causes:1. Batteries do not have

enough voltage.

2. Console is out oforder

Fix:1. Remove the batterycover from the console,then check if thebatterys voltage isgreater than 1.3 voltage.u If it is notenough, replace thebattery and check again.

2. Replace the console with a new one.

2-14 Revision: 1.0 Date: 2001/06/01

Count value wont increase while the seat is being adjusted(JAR-5100)

Possible causes:1. Improper operation of

the seat adjustment.

2. Console cable isbroken or not in goodcontact with theconnector.


4. Magnet has fallen out.

5. Sensor is looselyattached or broken.

Fix:1. Slide the seat to far end of rail and slide it back

and forth several times to check if there is displayon the console

2. Remove the console and check if the console cablehas been connected properly. Reconnect the cable. Or replace it with a new one.


4. Check if the magnet is positioned well.

5. Replace the sensor or re-attach it.

2-15 Revision: 1.0 Date: 2001/06/01

No display on the console (JAR-6000)

Possible causes:1. Battery is not energy

enough


Fix:1. Remove thebattery cover fromthe console, thencheck if the batterys voltage is greaterthan 1.3 VDC.u If it is not,replace the batteryand check again.

2. Replace theconsole with a newone

2-16 Revision: 1.0 Date: 2001/06/01

SPM value wont increase while running the rower (JAR-6000)

Possible causes:1. Console RPM cable is

broken or not in goodcontact with theconnector.


3. Speed sensor isloosely attached orbroken.

Fix:

1. Remove the console and check if the console RPMcable has been connected properly. Reconnect the cable. Or replace it with a new one.


3. Replace the speed sensor or re-attach it.

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2-17 Revision: 1.0 Date: 2001/06/01

No pulse display on the console (JAR-6000)

Possible causes:1. Console HR cable is

broken or not in goodcontact with theconnector.

2. HR receiver is out oforder

3. Chest belt is notplaced properly.


Fix:

1. Remove the console and check if the console HRcable has been connected properly. Reconnect the cable. Or replace it with a new one.

2. HR receiver is damaged, replace it with a new one.

3. Place the chest beltin the correct position.


The correct operation of a Chest Belt.1. Moisten the electrodes that are located on

both ends of the belt.The belt functions will most effective when placedclose to the heart and to the skin.

2-18 Revision: 1.0 Date: 2001/06/01

SECTION 3PARTS REPLACEMENT PROCEDURE


CONSOLE REPLACEMENT PROCEDURE (5100series)

Tools required:

u Philipsscrewdriver

Procedure:

1. Loosen the screws (arrow) from the console using thescrewdriver.

2. Disconnect the consolecables from the consoleconnectors.

3. Replace the consolewith a new one and

reconnect the console cable to the connector.

4. Tighten the screws that hold the console to the bracket.

3-1 Revision: 1.0 Date: 2001/06/01

CONSOLE CABLE REPLACEMENT PROCEDURE (5100series)

Tools required:


u Adjustablewrench

u hex key(8mm)

u crank extractor

u coin

Procedure:

1. Loosen the screws thathold the console to theconsole holding bracket.

2. Unplug the consolecable from the consoleconnectors.

3. Remove the upper cover,screw

4. Remove the screw (A)and take bracket out (forJPE). Remove the crank andside cover(for JPC/B/S).

5. Disconnect the console cable from the connectors, andthen tie the old cable to the new one with a rigid string.

6. Pull the old cable from the top end until the new cablethreads all the way through the support.

7. Reconnect the console cables to both the console andcontrol board.

8. Tighten the screws that hold the console to the consolebracket.

9. Install the parts.

A

3-2 Revision: 1.0 Date: 2001/06/01

CONTROL BOARD REPLACEMENT PROCEDURE (5100 series)

Tools required:


u Crank extractor

u Coin

u Adjustablewrench

Procedure:

1. Remove the rear(see fig. 1) or side cover,then the crank (forJPC/B/S)

2. Disconnect all thecables from the controlboard.

3. Replace it with a newone.

4. Reconnect all the cables.

5. Reverse step 1-3 to install the side cover.

Fig.1

Control board

3-3 Revision: 1.0 Date: 2001/06/01

GENERATOR OR ELECTROMAGNET BRAKE SET

REPLACEMENT PROCEDURE (5100series)

Tools required:

u Philips screwdriver

u Hex key (5mm)

u Ratchet Box Wrench(11mm)

Procedure:

1. Remove all covers.

2. Remove the POLY-VBELT (A) and disconnectthe cable from the controlboard.

3. Loosen the tensionscrews and screw (B) fromthe generator(electromagnet brake set.)

4. Replace it with a new one.

5. Secure the tension screw and the screws holding thegenerator (electromagnet brake set) to the frame (nottoo tight at this time so that the tension adjustment canbe made).

6. Install the POLY V BELT on the front and rear pulley.

7. Use the wrench (11mm) to adjust the belt tension byadjusting the tension screw until you can only presswith your thumb the POLY V BELT down about1~1.5cm, then tighten all the screws.

8. Reconnect the generator (electromagnet brake set)cable to the control board and then install the sidecovers and the parts.

B

3-4 Revision: 1.0 Date: 2001/06/01

CRANK REPLACEMENT PROCEDURE (JPC/B)

Tools required:

u Crank extractor

u Coin

u Open-endwrench(14&17mm)

Procedure:

1 Loosen the crankcover with a coin andremove it.

2 With the crankextractor and open-endwrench loosen the screwattaching the crank to theaxle.

3 Using the crank extractor and open-end wrench to extractthe crank then replace it with a new one.

4 Reverse step 1-3 to install the parts

3-5 Revision: 1.0 Date: 2001/06/01

PEDAL REPLACEMENT PROCEDURE (JPC/B)

Tools required:

u Open-endwrench(15 mm)

Procedure:

1 Using the open-end wrench loosen the screws attachingthe pedal to the crank.

2 Replace the pedal with a new one.

3-6 Revision: 1.0 Date: 2001/06/01

POLY V BELT 400/380J6 REPLACEMENT PROCEDURE (JPC/B)

Tools required:


u Hex key (4mm)

u Crank extractor

u Coin

u Open-endwrench(14&17 mm)

Procedure:

1. Remove thecrank cover andscrew, then removethe crank. (Refer topage 3-5).Loosen the screwsfrom the side coverwith the screwdriver,then remove thefootpad, guard and

side cover.

2. Loosen the400(380 for JPB-5100) J6 and500(440 for JPB-5100) J8 belts.

3. Loosen the screws from the front pulley by using the hexkey (4mm), then remove the front pulley

4. Replace the 400(380) J6 belt with a new one.

5. Tighten the screws from the front pulley by using the hexkey (4mm).

6. Install 400(380) J6 and 500(440) J8 belts onto the frontand rear pulleys.

7. Install the side covers and the parts.

3-7 Revision: 1.0 Date: 2001/06/01

POLY V BELT 500/440 J8 REPLACEMENT PROCEDURE (JPC/B)

Tools required:


u Hex key (4mm)

u Open endwrench(14mm)

u Crank extractor

u Coin

u Open-endwrench(14&17 mm)

Procedure:

1. Remove the crank coverand screw, then remove thecrank. (Refer to page 3-5)Loosen the screwsfrom the side cover with thescrewdriver, then removefootpad, guard and sidecover.

2. Loosen the screws fromthe front pulley by using thehex key (4mm) and the fit-inscrew of idler spring byusing screwdriver (Thespring replacement isdangerous. Take specialcautions during the operationso you will not damage bothyou and other parts), thenremove the front pulley.

3. Remove the 500(440 for JPB-5100) J8 belts from thepulley and replace with the new 500(440)J8 belt

4. Reverse step 1-3 to install the parts.

3-8 Revision: 1.0 Date: 2001/06/01

AXLE REPLACEMENT PROCEDURE (JPC/B)

Tools required:


u Hex key(4mm)

u C-Clip Pliers

u Woodenhammer

u Coin

u Crankextractor

u Hex key(4mm)

u Open-endwrench

(14&17 mm)

Procedure:

1. Remove the crank coverand screw, then remove thecrank. (Refer to page 3-5).Loosen the screws from theside cover with thescrewdriver, then remove thefootpad, guard and side covers.

2. Loosen the belts(500/440J8&400/380J6) fromthe axle

3. With the C-Clip Pliersremove the C-clip.

4. With the wooden hammer tap the axle out

5. Replace the axle with a new one, then install the c-clip byusing c-clip pliers.

6. Reverse the step 1-3 to install the parts.

3-9 Revision: 1.0 Date: 2001/06/01

PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT

PROCEDURE (JPC/B)

Tools required:


u C-clip pliers

u Crank extractor

u Coin

u Hex key (4mm)

u Open-endwrench

(14&17 mm)

Procedure:

1. Remove the crank coverand screw, then remove thecrank. (Refer to page 3-5)Loosen the screwsfrom the side cover with thescrewdriver, then removefootpad, guard and side

cover.2. Loosen the screw (A) and remove it (for the axle-pulley

assembly of the new design).

3. Remove the spring attaching the idler pulley to the framefirst, then loosen the screws attaching the bearing housingto the axle-pulley assembly using the hex key (4mm)(The spring replacement is dangerous. Take specialcautions during the operation so you will not damageboth you and other parts, then remove the front pulley)

4. Remove the c-clip (B) by using the c-clip pliers and usingthe Bearing Puller remove the Bearing Housing

3-10 Revision: 1.0 Date: 2001/06/01

PEDAL AXLE-PULLEY ASSEMBLY REPLACEMENT

PROCEDURE (JPC/B)

Tools required:


u C-clip pliers

u Crank extractor

u Coin

u Hex key (4mm)

u Open-endwrench

(14&17 mm)

Procedure:

5. Remove the c-clip (C) by using the c-clip pliers andremove the metal pulley from the generator using theBearing Puller.

6. Remove the c-clip (D) by using the c-clip pliers andremove the idler using the Bearing Puller.

7. Remove the c-clip (B) by using the c-clip pliers andremove the Bearing Housing using the Bearing Puller.

8. Replace the axle-pulley assembly with a new one.


3-10 Revision: 1.0 Date: 2001/06/01

BEARING REPLACEMENT PROCEDURE (JPC/B)

Tools required:


u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wood-hammer

u Crank extractor

u Coin

u Open-endwrench

(14&17 mm)

Procedure:

1. Loosen the screws fromthe side covers with thescrewdriver then removecrank using pulley (refer topage 3-5). Loosen thescrews from the side coverwith the screwdriver, then

remove footpad, guard andside cover.

2. Loosen the POLY-V belts500/440J8 & 400/380J6 andthe fit-in screw of idler spring(The spring replacement isdangerous. Take specialcautions during the operationso you will not damage bothyou and other parts)

3. Using the hex key (4mm)to loosen screws holding thebearing housing to the frame.

4. With the C-Clip Pliers remove the C-clip and then usingthe Bearing Puller remove the Bearing Housing.

u If the Ball Bearing failed, replace it.

3-11 Revision: 1.0 Date: 2001/06/01

BEARING REPLACEMENT PROCEDURE (JPC/B)

Tools required:


u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Woodenhammer

u Open-endwrench

(14&17 mm)u Crank extractor

Procedure:

5. Remove the C-clip (c) withthe C-Clip Pliers and thenremove the pulley Assembly byusing the Bearing Puller.u If the Ball Bearing failed,replace pulley assembly.

6. Remove the C-clip (D) withthe C-Clip Pliers and thenremove the idler Assembly byusing the Bearing Puller thenstrike bearing out from thehousing of idler assembly.Replace bearing with a newone.


3-11 Revision: 1.0 Date: 2001/06/01

POLY V BELT 430J6 REPLACEMENT PROCEDURE (JPS)

Tools required:


u Hex key (4mm)

Procedure:

1. Loosen the screwsfrom the side cover withthe screwdriver.

2. Loosen the 430J6 and

430J8 belts.

3. Loosen the screwsfrom the front pulley byusing hex key (4mm).

4. Replace the 430J6belt with a new one.

5. Tighten the screws from the front pulley by using the hexkey (4mm).

6. Install the 430J6 and 430J8 belts onto the front and rearpulleys.

7. Install the side cover.

3-12 Revision: 1.0 Date: 2001/06/01


Tools required:


u Hex key (4mm)


Procedure:

1. Loosen the screws of theside cover with the screwdriver.

2. Remove the 430J6 and430J8 belts from the pulley.

3. Loosen the screws from thefront pulley by using the hexkey (4mm), then remove thefront pulley.

4. Loosen the screws from thechain tension springs at the boththe left and right sides (Thespring replacement is dangerous.Take special cautions during theoperation so you will notdamage both you and otherparts). 5. Loosen the screws holding

the bearing housing to theframe by using the open-endedwrench and then remove thepulley with the axle.

6. Replace with the new belt(430J8) and at the same timeinstall the front wheel with theaxle.

3-13 Revision: 1.0 Date: 2001/06/01


Tools required:


u Hex key (4mm)

u Open endwrench (14mm)

Procedure:

7. Tighten the screws holding the both-end bearing housingsto the frame.

8. Tighten the screws in both the chain tension springs.

9. Tighten the screws that hold the bearing housing to theframe.

10. Install the 430J8 & 430J6 belts onto the front and rearpulleys.

11. Install the side covers.

3-13 Revision: 1.0 Date: 2001/06/01

CHAIN & SPRING REPLACEMENT PROCEDURE (JPS)

Tools required:


u Hex key (4mm)

u C-Clip Pliers

Procedure:

1. Loosen the screws from the sidecovers with the screwdriver.

2. Loosen the screws from bothsprings by using the hex key(4mm).

3. Replace the spring with a newone.

4. Remove the chain latch toseparate the spring from the chainby using the C-Clip Pliers, then

take out the spring (The springreplacement is dangerous. Takespecial cautions during theoperation so you will not damageboth you and other parts.)

5. Remove the other chain latchto separate the chain from the gear,and then take out the chain.

6. Replace the chain with a newone.

7. Install the chain latch.

8. Tighten the screws in both springs.

9. Install the side covers.

3-14 Revision: 1.0 Date: 2001/06/01

SENSOR REPLACEMENT PROCEDURE (JPS)

Tools required:


Procedure:

1. Loosen the screws fromthe side cover with thescrewdriver.

2. Disconnect the sensorcable from the control board.

3. Loosen the screwsholding the sensor to theframe.

4. Replace the sensor with a new one.

5. Tighten the screws holding the sensor to the frame.

6. Reconnect the sensor cable to the control board.

7. Install the side cover.

3-15 Revision: 1.0 Date: 2001/06/01

FOOTPAD REPLACEMENT PROCEDURE (JPS)

Tools required:

u None

Procedure:

1. Pull out the worn footpad slowly from one of the cornersof the pad backside with one of your hands.

2. Replace the pad with a new one.

3-16 Revision: 1.0 Date: 2001/06/01

BEARING REPLACEMENT PROCEDURE (JPS)

Tools required:


u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wood-hammer

Procedure:

1. With the screwdriver toremove the side covers of thesteeper.

2. Loosen the POLY-V belt430J8 & 430J6.

3. Using the hex key (4mm)to loosen screws holding thebearing housing to the frame.

4. Remove the spring hookedat the idler pulley bracket.

(Take cautions not to damagethe Generator.)

5. With the C-Clip Pliersremove the C-clip and thenusing the Bearing Pullerremove the Bearing Housing.u If the Ball Bearing failed,replace it.

3-17 Revision: 1.0 Date: 2001/06/01

BEARING REPLACEMENT PROCEDURE (JPS)

Tools required:


u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wooden hammer

Procedure:

6. Remove the C-clip with the C-ClipPliers and thenremove the IdlerAssembly by usingthe Bearing Puller.u If the BallBearing failed,replace it.

7. With the woodenhammer tap the idlerpulley assembly backto the pulley-axleassembly.

8. Install all C-clips and ball bearings.

9. Install the side covers and tighten the screws.

3-17 Revision: 1.0 Date: 2001/06/01

CRANK REPLACEMENT PROCEDURE (JPE5100)

Tools required: Procedure:

u Puller

u Woodenhammer

u Hexagonalsocket wrench(19&13mm)


u Hex key (6mm)

u C-clip pliers

u Adjustablewrench

1 Remove the joint screw betweenhandlebar and handrail links.2 Remove all of the covers. 3 Remove the nut(A) then pull thecrank and pedal set out

4 Remove the c-clip (B) then withwooden hammer tap the crank out.

5 Replace the crank with a new one

6 Reverse step 1-4 to install theparts

A

B

Tap here

3-18 Revision: 1.0 Date: 2001/06/01

PEDAL REPLACEMENT PROCEDURE (JPE5100)



u Two-facedmasking tape

1 Tear down the rubber footpad and clean it

2 Remove screw (A) then replace pedal with a new one.

3 Attach the rubber footpad.

A

3-19 Revision: 1.0 Date: 2001/06/01

POLY V BELT 430J6 REPLACEMENT PROCEDURE (JPE5100)

Tools required:


u hex key(6 mm)

u Hexagonalsocket wrench(13mm)

Procedure:

1 Remove all covers. (Except the right cover).

8. Loosen the 430J6 belts thenreplace it with a new one.

Install the side covers and theparts

3-20 Revision: 1.0 Date: 2001/06/01

POLY V BELT 430 J12 REPLACEMENT PROCEDURE (JPE5100)

Tools required:


u Hex key (6mm)


u Puller

u Adjustablewrench

Procedure:

1 Remove all of the covers. (except the left cover).

2 Remove the pedal arm and crank (refer to page 3-18 & 3-19)

3 Loosen the screws thenremove poly v belt andreplace it with a new one

4 Reverse step 1-3 toinstall the parts.

A

3-21 Revision: 1.0 Date: 2001/06/01

PULLEY AXLE REPLACEMENT PROCEDURE (JPE5100)

Tools required:


u Hex key(6mm)

u C-Clip Pliers

u Woodenhammer

u Adjustablewrench

Procedure:

1 Remove all of the coversand poly v belts.

2 Remove the screw (A) andwasher

3 Pull pulley (B) out thenknock axle set out with the

wooden hammer.

4 Remove the nut (C), thentap the axle out

5 Replace the axle with anew one, then install the c-clipby using c-clip pliers.

6 Reverse the step 1-4 toinstall the parts.

Note: To clean the bearing housing and apply adhesive onthe outer race of bearing is necessary.

A

C

B

3-22 Revision: 1.0 Date: 2001/06/01

AXLE ASSEMBLY REPLACEMENT PROCEDURE (JPE5100)

Tools required:

u Philips

screwdriver

u C-clip pliers

u puller

u Hex key (6mm)


u Adjustablewrench

Procedure:

1 Remove all of the covers.

2 Loosen the nut (A) and remove it ,another side is same

3 Loosen the tension adjustment screw of idler pulley, thenremove the poly v belt

4 Follow theprocedures below toinstall the axle.

Step1: pull crank outStep2: remove the c-clip.Step3: tap axle assy outStep4: remove the nutthen tap axle out

Step5: replace the axle with a new oneStep6: reverse all of the steps to install the parts

A

3-23 Revision: 1.0 Date: 2001/06/01

ROLLER REPLACEMENT PROCEDURE (JPE5100)

Tools required:


u Hex key (4mm)

Procedure:

1. Remove the all of cover.

2. Move the pedal arm backthen pick up it.

3. Loosen the screw (A)holding the wheel to theframe with the hex key(4mm), and then replace itwith a new one.

4. Reverse the steps toinstall the side cover.

A

3-24 Revision: 1.0 Date: 2001/06/01

SENSOR REPLACEMENT PROCEDURE (JPE5100)



u Hex key (5mm)

u Ratchet Box Wrench(11mm)

1. Remove the rear cover.

2. Disconnect the sensor cable from the control board.

3. Loosen the screws that hold the sensor to the frame.

4. Replace the sensorwith a new one.

5. Reverse the step 1-3to install the parts.

Sensor

3-25 Revision: 1.0 Date: 2001/06/01

CONSOLE REPLACEMENT PROCEDURE (JAR)

Tools required:

u none

Procedure:

1. Push the console forward and pull the console out andunplug the sensor cable terminal from the connector thenremove the console.

2. Replace console with a new one.

3-26 Revision: 1.0 Date: 2001/06/01

CONSOLE WIRE REPLACEMENT PROCEDURE (JAR)

Tools required:


u Open-endwrench(8&15mm)

Procedure:

1. Push the console forward and pull the console up, thenunplug the sensor wire terminal from the connector thenremove the console

2. With the open-end wrench loosen the nut and with thePhilips screwdriver loosen the screws from the femaleconnector.

3. Unplug the console wire from the rail

4. Loosen the bolts attaching the bracket to the rail thenremove the rail.

5. Replace console wire with a new one.


3-27 Revision: 1.0 Date: 2001/06/01

SENSOR REPLACEMENT PROCEDURE (JAR)

Tools required:


u Open-end wrench

(8&15mm)

Procedure:

1. Unplug the console wire from the rail

2. Loosen the bolts attaching the bracket to the rail thenremove it

3. Loosen the screws attaching the sensor to the rail then tiea new sensor to bad sensor with a rigid string

4. Loosen the nut attaching the female connector to the railwith the open-end wrench. Pull the old cable from thefront end until the new cable threads all the way throughthe rail

5. Reverse step 1-5 to install the parts

3-28 Revision: 1.0 Date: 2001/06/01

SEAT REPLACEMENT PROCEDURE (JAR)

Tools required:


u Open-end wrench(13mm)

Procedure:

1. Remove the bolt fromthe seat roller byusing the open-endwrench (13mm) thenremove the seat

2. Loosen the screwsholding the seat to thebracket.

3. Replace the seat with anew one

4. Reverse step 1-2 toinstall all the parts

3-29 Revision: 1.0 Date: 2001/06/01

DRIVE BELT 3V-530 REPLACEMENT PROCEDURE (JAR)

Tools required:


u Hex key (4mm)

u Ratchet BoxWrench(11mm)

Procedure:

1. Push the console forwardand pull the console out, thenunplug the sensor cable terminalfrom the female connector thenremove the console and skidpad.

2. Loosen the screws from theside covers and remove it.

3. Remove tension springs setand loosen the screws attachingcable wheel axle to the frame,then remove the axle and belt

4. Loosen the screws from theshroud cover

5. Loosen the screws attachingthe hub drive train assembly tothe frame, then remove the axleand belt.

6. Install the belts onto thepulley of hub drive trainassembly and rope axle.


3-30 Revision: 1.0 Date: 2001/06/01

NYLON ROPE REPLACEMENT PROCEDURE (JAR)

Tools required:


u Hex key (4mm)


Procedure:

1. Follow the tensionspring set (refer to page 3-32)replacement procedure toremove the parts.

2. Loosen thescrews attaching therope to the ropewheel.

3. Cut down therope and remove it

4. Replace it with anew rope, first threadthe rope through theguide hole of the ropewheel and tie a knot,put the bracket ontothe knot, then tightenthe screws.

5. Thread the other end of the rope through the squarehole of the bracket, and the wheel in the handle holdercover then tie the rope to the handle bar.

6. Turn forward the rope wheel until the handle touchesthe handle holder.


3-31 Revision: 1.0 Date: 2001/06/01

TENSION SPRING SET REPLACEMENT PROCEDURE (JAR)

Tools required:


u Hex key (4mm)

Procedure:

1. Remove the console andskid pad (Refer to page 3-26).Loosen the screws from theside covers with thescrewdriver then removeside covers.

2. Loosen the belts(500/440J8&400/380J6)from the pulley

3. With the hex key loosenthe screws from the tensionspring set.

4. Replace it with a new one then turn the set CW about 2.5-3 turns

5. Reverse the step 1-3 to install the parts.

3-32 Revision: 1.0 Date: 2001/06/01

SECTION 4PREMENTIVE MAINTENANCE


CLEANING THE GROOVES

Frequency: Every 3

to 4 months.

If there is any dust in the

grooves of the Poly-V belts

and pulleys, noises will be

generated during operation..

Procedure:

1 Remove the Poly-V belts and check thegrooves of the beltfor dirt or dust andclean it if any.

2 Check thegrooves in the pulleyfor dirt or dust andclean it if any.

3 Check thegrooves in the rollerpulley for dirt or dustand clean it if any.

4-1 Revision: 1.0 Date: 2001/06/01

RE-LUBRICATING THE CHAIN & GEAR (JPS)

Frequency:

Every 3-4 months.

Procedure:

1. Remove the side covers of the stepper.

2. Add some lubricating oil to the chains.

3. Add some lubricating oil to the gears.

4. Start to step the machine, repeating several times toallow the lubricating oil to be fully mixed with thechains and gears.

4-2 Revision: 1.0 Date: 2001/06/01

CLEANING THE RAIL AND ROLLER (JPE5100)

Frequency: Procedure:

Every 1-2 months.(For club)

Every 6 months.(For home)

1. Remove the roller plate cover.

2. Clean the rail and roller.

Clean here

4-3 Revision: 1.0 Date: 2001/06/01

SECTION 5SERVICE FORM


Field Failure Report

Name of Distributor : Report # ......

Warranty ( ) Yes ( ) No Failure ( ) Intermittent ( ) Persistent

Product : 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 Order Form as detailed as possible.

Date : Place : Prepared By : Company Stamp :

. . .

5-1 Revision: 1.0 Date: 2001/06/01

Parts Order

Distributor: ........ .. Order #

Delivery Terms: ( ) CIP ..................... Delivery Address: ( ) 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 Place Signature Company Stamp

............................ ............................ .....................................

5-2 Revision: 1.0 Date: 2001/06/01

Warranty Claim Form Claim no: ........................

Dealer Name: .................................................. Page .......... of ...........Pages

MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS # QTY

AUTHORIZED BY: ..............................

5-3 Revision: 1.0 Date: 2001/06/01

IndexSection 1: Wiring DiagramSection 2: TroubleshootingsSection 3: Parts ReplacementSection 4: Preventive MaintenanceSection 5: Service Form

Johnson Service Manual 5100 Series

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Transcript of Johnson Service Manual 5100 Series