Johnson T8000 User manual

1

2006 Johnson T8000(TM95)

SERVICE MANUAL

2

TABLE OF CONTENTS

SECTION 1: MAINTENANCE PROCEDURE ………………..….…3

1. 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…………….…...12

1. T8000(TM95) MCB WIRING 220V…………..………………….…..13

2. T8000(TM95) MCB WIRING 110V………………………………….14

3. T8000(TM95) MCB WIRING DEFINITION OF PIN 220V……....15-16

4. T8000(TM95) MCB WIRING DEFINITION OF PIN 110V…….....17-18

5. T8000(TM95) CONSOLE WIRING…………………………………..19

6. T8000(TM95) CONSOLE WIRING DEFINITION OF PIN………..20-22

7. T8000(TM95) ELECTRICAL BLOCK DIAGRAM FOR 220V..……23

SECTION 3: CONSOLE ENGINEER MODE………………..………..24

1. OPERATION MX-T3x Engineer mode..…………………………….25-28

..

SECTION 4: MCB LED INSTRUCTIONS…………………..…..… ….29

1. MCB LED place and definition for 220V……………………….…….30

2. MCB LED place and definition for 110V……………………..………31

SECTION 5: TROUBLESHOOTINGS……………………………….…32

1. No display on console………………………………………..………...33

2. Running speed is not stable…………………………………………….34

3. Treadmill starts to run by itself………………………………..……….35

4. All or some of the keys on console do not work………………….……35

5. Noises generated under motor cover………………...…………..….….36

6. Error Messages on the Console…………………………………….…..37

7. Error message 1 troubleshooting (1)…...……………………………....37

8. Error message 1 troubleshooting (2)…...……………………………....38

9. Error message 3,6 troubleshooting……………………............………..39

10. Error message 4 troubleshooting………………………...…….……….40

11. How to make sure whether the machine hand pulse can not work…....41-42

12. T8000(TM95) maintenance lamp…………..…………………………..43

SECTION 6: What is the difference between 2005 TM68 & 2006 TM95…44-62

3

SECTION 1

MAINTENANCE PROCEDURE

4

MAINTENANCE CHECK LIST

CleanMotor

Clean

(Vacuum)

Control Box

InspectRunning Belt

Inspect &

Re-

waxing

Deck Re-waxing

InspectCleanV Belt

InspectRunning belt Tension

TestEmergency Button

InspectCleanRear Roller

InspectCleanFront Roller

InspectCleanHandrail & Handlebar

InspectCleanDisplay Console

InspectPower Cord

ReplaceInspect Carbon Brush

InspectCleanFrame

Inspect

Console Mounting

Bolts

AnnualBiannualQuarterlyMonthlyWeeklyDailyItem

2006 Johnson T8000 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.

Perfect Tension of Running Belt:

Perfect Tension of Running Belt: 0.9~1.1 lbs

0.9~1.1 lbs

Frequency: Every 1 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 1 month

Parts name: Silicon oil set

Parts number: SZTM74SOS

Price (USD): 0.6

Use 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

Use the

clamp-on meter (DC current-meter)

:







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 :

9

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.

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

10

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- 042

1 Box – 10 pcs

Price : USD 28.5

11

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.

12

SECTION 2

WIRING DIAGRAM INSTRUCTION

13

T8000 (TM95) MCB WIRING(220V)

J1

P2

P3

J2

MTR2

L2 L1



MTR1

P4 P1

14

T8000 (TM95) MCB WIRING(110V)

P2

MTR2

NEUTRAL LINE



MTR1

P3

JP3

15

T8000(TM95) 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

16

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

16

17

T8000(TM95) MCB WIRING DEFINITION OF PIN(110V)

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

18

P3: 20-pin console cable

No UseN/A19

DefinitionNamePin

No UseN/A20

No UseN/A18

No UseN/A17

No UseN/A16

Drive motor signalMOTOR15

Console provide for incline motor DOWN signalDOWN14

Console provide for incline motor UP signalUP13

Console power+1212

Console power+1211

Console power+1210

Console for MCB of the PWM signalPWM9

Console groundGND8

Console groundGND7

Speed sensor provide signalRPM6

Incline place signal test power(+5V)VCC5

Incline place signalELE4

Console groundGND3

No UseN/A2

Console groundGND1

1

2

20

19

P3

19



T8000(TM95) CONSOLE WIRING

J13 J6J12



J8 J7 J10 J3J5

C-SAFE

J14

20

T8000(TM95) CONSOLE WIRING DEFINITION OF PIN

J6:20-pin console cable

No UseN/A19

DefinitionNamePin

No UseN/A20

No UseN/A18

No UseN/A17

No UseN/A16

Drive motor signalMOTOR15

Console provide for incline motor DOWN signalDOWN14

Console provide for incline motor UP signalUP13

Console power+1212

Console power+1211

Console power+1210

Console for MCB of the PWM signalPWM9

Console groundGND8

Console groundGND7

Speed sensor provide signalRPM6

Incline place signal test power(+5V)VCC5

Incline place signalN/A4

Console groundN/A3

No UseN/A2

Console groundGND1

1

2

20

19

J6

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