Johnson JPC-5100, JPB-5100, JPS-5100, JAR-5100, JAR-6100 Service Manual

o

JPB-5100

o

JPS-5100

o

JAR-6000

o

JPC-5100

o

JPE-5100

o

JAR-5100

TABLE OF CONTENTS

n SECTION 1: WIRING DIAGRAM

o CONTROL BOARD WIRING DIAGRAM (JPC/B-5100).............................1-1

o CONTROL BOARD WIRING DIAGRAM (JPS-5100)................................1-2

o CONTROL BOARD WIRING DIAGRAM (JPE-5100)................................1-3

o CONSOLE BACKSIDE (EAR CLIP SENSOR)...........................................1-4

o CONSOLE BACKSIDE (HAND PULSE)...................................................1-5

o WIRING DIAGRAM (JPC/B-5100).............................................................1-6

o WIRING DIAGRAM (JPS-5100)................................................................1-7

o WIRING DIAGRAM (JAR-5100)................................................................1-8

o WIRING DIAGRAM (JAE-5100)................................................................1-9

n SECTION 2: TROUBLESHLOOTINGS

JPC/B/S/E-5100

o No display on the console or the display is dim..........................................2-1

o No RPM is displayed during the exercise (JPC/B/S).................................2-2

o All or some of the keys have no function......................................................2-3

o Feel the resistance increase/decrease or fell no resistance(JPC/B/S)........2-4

o Feel the resistance increase/decrease or feel no resistance (JPE)..............2-5

o Feel slipping while pedaling.......................................................................2-6

o Knocking or creaking noise..........................................................................2-7

o No pulse is displayed on the console (Ear clip sensor)...............................2-8

o No pulse is displayed on the console (Chest belt type)...............................2-9

o No pulse is displayed on the console (Hand pulse type)..............................2-10

o Console diagnostics mode...........................................................................2-11

JAR-5100

o No display is on the console while any function key is pressed...................2-12

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

any key is pressed............................................................................................2-13

o Console will not function properly...............................................................2-14

o “Count” value will not increase while adjusting the seat..........................2-15

JAR-6000

o No display on the console..............................................................................2-16

o “SPM” value won’t increase while running the rower................................2-17

o No pulse display on the console....................................................................2-18

TABLE OF CONTENTS

n SECTION 3: PARTS REPLACEMENT

n GENERAL (JPC/B/S/E)

o CONSOLE.......................................................................................3-1

o CONSOLE CABLE......................................................................3-2

o CONTROL BOARD.....................................................................3-3

o GENERATOR OR ELECTROMAGNET BRAKE SET..................3-4

n JPC/B-5100

o CRANK............................................................................................3-5

o PEDAL............................................................................................3-6

o POLY-V BELT 400/380J6................................................................3-7

o POLY-V BELT 500/440J8................................................................3-8

o AXLE.......................................................................................3-9

o FRONT PULLEY.......................................................................3-10

o BALL BEARINGS...........................................................................3-11

n JPS-5100

o POLY-V BELT 430J6.......................................................................3-12

o POLY-V BELT 430J8.......................................................................3-13

o CHAIN OR SPRING.....................................................................3-14

o SENSOR............................................................................................3-15

o FOOT PAD....................................................................................................3-16

o BALL BEARINGS.............................................................................3-17

n JPE-5100

o CRANK.............................................................................................3-18

o PEDAL.............................................................................................3-19

o POLY-V BELT 430J12......................................................................3-20

o POLY-V BELT 430J6........................................................................3-21

o PULLEY AXLE..............................................................................3-22

o AXLE.........................................................................................3-23

o ROLLER............................................................................................3-24

o SENSOR............................................................................................3-25

n JAR-5100

o CONSOLE.......................................................................................3-26

o CONSOLE CABLE.......................................................................3-27

o SENSOR............................................................................................3-28

o SEAT.........................................................................................................3-29

o DRIVE BELT 3V-530......................................................................3-30

o NYLON ROPE.............................................................................3-31

o 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 FORM

o FIELD FAILURE REPORT.........................................................5-1

o PARTS ORDER FORM................................................................5-2

o WARRANTY CLAIM FORM........................................................5-3

Revision: 1.0 Date: 2001/06/01

SECTION 1

WIRING DIAGRAM

Revision: 1.0 Date: 2001/06/01

JPC/B-5100 CONTROL BOARD WIRING DIAGRAM

Ø A1 : 3-pin terminal to the generator Ø A2 : 2-pin terminal to the electromagnet Ø A3 : 4-pin terminal to the console

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

JPS-5100 CONTROL BOARD WIRING DIAGRAM

Ø A1 : 3-pin terminal to the generator Ø A2 : 2-pin terminal to the electromagnet Ø A3 : 2-pin terminal to the output of the adapter Ø A4 : 4-pin terminal to the console

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

JPE-5100 CONTROL BOARD WIRING DIAGRAM

Ø A1 : 3-pin terminal to the electromagnet brake set Ø A2 : 2-pin terminal to the adapter Ø A3 : 3-pin terminal to the console Ø A4: grounding wire to frame

A4 A1

A2

A3

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

CONSOLE BACKSIDE (EAR CLIP SENSOR)

Ø A : console cable -> MCB A4 Ø B : ear clip cable Ø C : console power switch

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

CONSOLE BACKSIDE (HAND PULSE)

Ø A : console cable -> MCB A4 Ø B : hand pulse cable (right) Ø C : hand pulse cable (left) Ø 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 2

TROUBLESHOOTINGS

Pedal speed has to be over 30 rpm for troubleshooting at anytime for

JPC/B-5100.

Revision: 1.0 Date: 2001/06/01

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 not connected properly.

2. Poor connection to all

the terminals on the control board.

3. Control board is

damaged.

4. Generator is

damaged.(for JPC/B/S)

Fix:

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

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

properly. Unplug the console cable and use a multimeter to check if the voltage on the 1’st and 4’th pin of 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 the

wire harnesses are connected properly to the terminals of the control board.

3. Unplug the console cable from the control board and

check if the voltage on the 1’st and 5’th(4’th for

JPS/JPE) pin of control board is greater than 5(4.5for JPS)VDC

u If it is, replace console

cable with a new one.

u If it is not, next step.

4. Unplug the generator cable

from the control board and check if the voltage is variable.

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 console cable is not connected properly.

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 the

sensor.

6. Sensor is damaged(for

JPS/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.

Ø Connect the terminal properly. Ø 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 the

control board with a new one.

4. Check if the sensor is misaligned. If it is, place the

sensor in the correct position.

5. Open the side covers of the stepper and check if the

connection of the sensor is connected properly.

u If it is not connected well.

Ø 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 fitin properly.

2. Keypad is damaged.

3. Upper board is

damaged.

Fix:

1. Remove the console cover, and then check if

keypad cable is connected properly to the upper board.

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 cable is not connected properly

2. Console cable is

damaged.

3. Control board is

damaged.

4. Generator is

damaged.

5. Alignment of the

sensor (for JPS)

6. Sensor is damaged

(for JPS)

7. Gap between the electromagnet and the copper disc of the generator 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 new

one.

3. Remove the side covers of the fitness and check

if the terminal of the control board has been connected 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 to narrow 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 cable is not connected properly

8. Console cable is

damaged.

9. Control board is

damaged.

10. Electromagnet brake

set is damaged.

11. Gap between the

electromagnet and the copper disc of the generator is too wide

Fix:

8. Remove the console and check if the console

cable has been connected properly.

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

one.

10. Remove the side covers of the fitness and check

if the terminal of the control board has been connected properly. Control board is damaged, replace it with a new one.

11. Electromagnet brake set is damaged, replace it

with a new one

12. (1)Loosen the assembly screws of electromagnet

(2) With a c-vice press the electromagnet to narrow 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 is

damaged

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 arm

too loose

2 Crank or axle is wear

out

3 Belt tension is too

loose or poly v belt is too dirty

4 Rail or roller is too

dirty

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 difference

between individuals.

2. Ear clip sensor is

damaged.

3. Console is damaged.

Fix:

1. Open and close the clip of the ear clip sensor

several 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 to check again.

1.2 No response because of individual physical

difference. <See Remark 1>

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

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

<Remark1>: The general operation guide of Ear Clip sensor.

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 not

placed properly.

2. Chest belt is

damaged.

3. Console is damaged.

Procedure:

1. Place the chest belt in

the correct position.

2. Replace the chest belt with a new one.

3. Replace the console with a new one.

<Remark 1> 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 the skin.

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 hand

pulse cable.

2. Hand pulse cable is

damaged.

3. Console is damaged.

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 hold

down the "RESET” key then (for stepper turn

the power on) start pedaling to reach a pedal

speed of approximately 30rpm.OR Press and

hold down the "RESET” key then plug the adapter (JPE).

2. Dot Matrix Display will be scanned slowly starting

from LEDs of the bottom row to the top; each segment of the 7-segments will be scanned simultaneously

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 up

u 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 RPM

4. “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 turn

3. “STEPS/MINS” windows will show the current

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

u If the heart rate is not shown or not stable in the

display, 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 the key..

4. The RPM window will show you a reference

number accordingly while pressing a number or function key.

5. “TIME ” window will show you the programming

year of the software.

6. “WORK LEVEL” windows will show you the

programming month and day.

7. “PULSE “ window will show you the software

version.

u If any of the keys does not work, please refer to

page 2-3

1. Press the ENTER key. This completes the

procedure.

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

2. Console is damaged.

Fix:

1. Remove the battery cover from the console, then check if the battery ‘s voltage is greater than 1.3 VDC. u If it is not, replace the battery and check again.

2. Replace the console with a new one

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 not

been connected well to the connector or broken.

3. Console is damaged.

4. Magnet is missing or not

positioned well.

5. Sensor is damaged or

loosely attached.

Fix:

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

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

2. Remove the console and check if the terminal of

console cable is connected properly.

Ø Reconnect the cable. Ø If the cable is damaged, replace it with a

new one.

3. Console 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 of

order

Fix:

1. Remove the battery cover from the console, then check if the battery ’s voltage is greater than 1.3 voltage. u If it is not enough, replace the battery and check again.

2. Replace the console with a new one.

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

“Count” value won’t increase while the seat is being adjusted

(JAR-5100)

Possible causes:

1. Improper operation of

the seat adjustment.

2. Console cable is

broken or not in good contact with the connector.

3. Console is out of

order

4. Magnet has fallen out.

5. Sensor is loosely

attached 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 display on the console

2. Remove the console and check if the console cable

has been connected properly.

Ø Reconnect the cable.

Ø Or replace it with a new one.

3. Console is damaged, 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

2. Console is damaged.

Fix:

1. Remove the battery cover from the console, then check if the battery ‘s voltage is greater than 1.3 VDC. u If it is not, replace the battery and check again.

2. Replace the console with a new one

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

“SPM” value won’t increase while running the rower (JAR-6000)

Possible causes:

1. Console RPM cable is

broken or not in good contact with the connector.

2. Console is out of

order

3. Speed sensor is

loosely attached or broken.

Fix:

1. Remove the console and check if the console RPM

cable has been connected properly.

Ø Reconnect the cable.

Ø Or replace it with a new one.

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

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

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e

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 good contact with the connector.

2. HR receiver is out of

order

3. Chest belt is not

placed properly.

4. Console is out of

order

Fix:

1. Remove the console and check if the console HR

cable has been connected properly.

Ø Reconnect the cable.

Ø Or replace it with a new one.

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

3. Place the chest belt in the correct position.

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

<Remark 1> 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 placed close to the heart and to the skin.

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

SECTION 3

PARTS REPLACEMENT PROCEDURE

Revision: 1.0 Date: 2001/06/01

CONSOLE REPLACEMENT PROCEDURE (5100series)

Tools required:

u Philips

screwdriver

Procedure:

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

screwdriver.

2. Disconnect the console cables from the console connectors.

3. Replace the console with 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 Philips

screwdriver

u Adjustable

wrench

u hex key(8mm)

u crank extractor

u coin

Procedure:

1. Loosen the screws that hold the console to the console holding bracket.

2. Unplug the console cable from the console connectors.

3. Remove the upper cover, screw

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

5. Disconnect the console cable from the connectors, and

then tie the old cable to the new one with a rigid string.

6. Pull the old cable from the top end until the new cable

threads all the way through the support.

7. Reconnect the console cables to both the console and

control board.

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

bracket.

9. Install the parts.

A

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

CONTROL BOARD REPLACEMENT PROCEDURE (5100 series)

Tools required:

u Philips

screwdriver

u Crank extractor

u Coin

u Adjustable

wrench

Procedure:

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

2. Disconnect all the cables from the control board.

3. Replace it with a new one.

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-V BELT (A) and disconnect the cable from the control board.

3. Loosen the tension screws and screw (B) from the generator (electromagnet brake set.)

4. Replace it with a new one.

5. Secure the tension screw and the screws holding the

generator (electromagnet brake set) to the frame (not too tight at this time so that the tension adjustment can be made).

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

7. Use the wrench (11mm) to adjust the belt tension by

adjusting the tension screw until you can only press with your thumb the POLY V BELT down about 1~1.5cm, then tighten all the screws.

8. Reconnect the generator (electromagnet brake set)

cable to the control board and then install the side covers 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-end

wrench (14&17mm)

Procedure:

1 Loosen the crank cover with a coin and remove it.

2 With the crank extractor and open-end wrench loosen the screw attaching the crank to the axle.

3 Using the crank extractor and open-end wrench to extract

the 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-end

wrench(15 mm)

Procedure:

1 Using the open-end wrench loosen the screws attaching

the 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 Philips

screwdriver

u Hex key (4mm)

u Crank extractor

u Coin

u Open-end

wrench

(14&17 mm)

Procedure:

1. Remove the crank cover and screw, then remove the crank. (Refer to

page 3-5).

Loosen the screws from the side cover with the screwdriver, then remove the footpad, guard and

side cover.

2. Loosen the 400(380 for JPB-

5100) J6 and 500(440 for JPB-

5100) J8 belts.

3. Loosen the screws from the front pulley by using the hex

key (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 hex

key (4mm).

6. Install 400(380) J6 and 500(440) J8 belts onto the front

and 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 Philips

screwdriver

u Hex key (4mm)

u Open end

wrench (14mm )

u Crank extractor

u Coin

u Open-end

wrench (14&17 mm)

Procedure:

1. Remove the crank cover and screw, then remove the crank. (Refer to page 3-5) Loosen the screws from the side cover with the screwdriver, then remove footpad, guard and side cover.

2. Loosen the screws from the front pulley by using the hex key (4mm) and the fit-in screw of idler spring by using screwdriver (The

spring replacement is dangerous. Take special cautions during the operation so you will not damage both you and other parts), then

remove the front pulley.

3. Remove the 500(440 for JPB-5100) J8 belts from the

pulley 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 Philips

screwdriver

u Hex key

(4mm)

u C-Clip Pliers

u Wooden

hammer

u Coin

u Crank

extractor

u Hex key

(4mm)

u Open-end

wrench

(14&17 mm)

Procedure:

1. Remove the crank cover and screw, then remove the crank. (Refer to page 3-5). Loosen the screws from the side cover with the screwdriver, then remove the footpad, guard and side covers.

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

3. With the C-Clip Pliers remove 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 by

using 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 Philips

screwdriver

u C-clip pliers

u Crank extractor

u Coin

u Hex key (4mm)

u Open-end

wrench

(14&17 mm)

Procedure:

1. Remove the crank cover and screw, then remove the crank. (Refer to page 3-5) Loosen the screws from the side cover with the screwdriver, then remove footpad, 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 frame

first, then loosen the screws attaching the bearing housing to the axle-pulley assembly using the hex key (4mm)

(The spring replacement is dangerous. Take special cautions during the operation

so you will not damage

both you and other parts, then remove the front pulley)

4. Remove the c-clip (B) by using the c-clip pliers and using

the 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 Philips

screwdriver

u C-clip pliers

u Crank extractor

u Coin

u Hex key (4mm)

u Open-end

wrench

(14&17 mm)

Procedure:

5. Remove the c-clip (C) by using the c-clip pliers and

remove the metal pulley from the generator using the Bearing Puller.

6. Remove the c-clip (D) by using the c-clip pliers and

remove the idler using the Bearing Puller.

7. Remove the c-clip (B) by using the c-clip pliers and

remove the Bearing Housing using the Bearing Puller.

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

9. Reverse step 1-9 to install the parts.

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

BEARING REPLACEMENT PROCEDURE (JPC/B)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wood-hammer

u Crank extractor

u Coin

u Open-end

wrench

(14&17 mm)

Procedure:

1. Loosen the screws from the side covers with the screwdriver then remove crank using pulley (refer to

page 3-5). Loosen the

screws from the side cover with the screwdriver, then

remove footpad, guard and side cover.

2. Loosen the POLY-V belts 500/440J8 & 400/380J6 and the fit-in screw of idler spring (The spring replacement is

dangerous. Take special cautions during the operation so you will not damage both you and other parts)

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

4. With the C-Clip Pliers remove the C-clip and then using

the 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 Philips

screwdriver

u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wooden

hammer

u Open-end

wrench

(14&17 mm) u Crank extractor

Procedure:

5. Remove the C-clip (c) with the C-Clip Pliers and then remove the pulley Assembly by using the Bearing Puller. u If the Ball Bearing failed, replace pulley assembly.

6. Remove the C-clip (D) with the C-Clip Pliers and then remove the idler Assembly by using the Bearing Puller then strike bearing out from the housing of idler assembly. Replace bearing with a new one.

7. Reverse step 1-7 to install the parts.

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

POLY V BELT 430J6 REPLACEMENT PROCEDURE (JPS)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

Procedure:

1. Loosen the screws from the side cover with the screwdriver.

2. Loosen the 430J6 and

430J8 belts.

3. Loosen the screws from the front pulley by using hex key (4mm).

4. Replace the 430J6 belt with a new one.

5. Tighten the screws from the front pulley by using the hex

key (4mm).

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

pulleys.

7. Install the side cover.

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

POLY V BELT 430J8 REPLACEMENT PROCEDURE (JPS)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u Open end

wrench (14mm )

Procedure:

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

2. Remove the 430J6 and 430J8 belts from the pulley.

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

4. Loosen the screws from the chain tension springs at the both the left and right sides (The

spring replacement is dangerous. Take special cautions during the operation

so you will not

damage both you and other parts).

5. Loosen the screws holding

the bearing housing to the frame by using the open-ended wrench and then remove the pulley with the axle.

6. Replace with the new belt (430J8) and at the same time install the front wheel with the axle.

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

POLY V BELT 430J8 REPLACEMENT PROCEDURE (JPS)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u Open end

wrench (14mm)

Procedure:

7. Tighten the screws holding the both-end bearing housings

to the frame.

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

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

frame.

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

pulleys.

11. Install the side covers.

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

CHAIN & SPRING REPLACEMENT PROCEDURE (JPS)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u C-Clip Pliers

Procedure:

1. Loosen the screws from the side covers with the screwdriver.

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

3. Replace the spring with a new one.

4. Remove the chain latch to separate the spring from the chain by using the C-Clip Pliers, then

take out the spring (The spring

replacement is dangerous. Take special cautions during the operation

so you will not damage

both you and other parts.)

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

6. Replace the chain with a new one.

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:

u Philips

screwdriver

Procedure:

1. Loosen the screws from the side cover with the screwdriver.

2. Disconnect the sensor cable from the control board.

3. Loosen the screws holding the sensor to the frame.

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 corners

of 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 Philips

screwdriver

u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wood-hammer

Procedure:

1. With the screwdriver to remove the side covers of the steeper.

2. Loosen the POLY-V belt 430J8 & 430J6.

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

4. Remove the spring hooked at the idler pulley bracket.

(Take cautions not to damage the Generator.)

5. With the C-Clip Pliers remove the C-clip and then using the Bearing Puller remove 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 Philips screwdriver

u Hex key (4mm)

u Bearing puller

u C-Clip pliers

u Wooden hammer

Procedure:

6. Remove the Cclip with the C-Clip Pliers and then remove the Idler Assembly by using the Bearing Puller. u If the Ball Bearing failed, replace it.

7. With the wooden hammer tap the idler pulley assembly back to the pulley-axle assembly.

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 Wooden

hammer

u Hexagonal

socket wrench (19&13mm)

u Philips

screwdriver

u Hex key (6mm)

u C-clip pliers

u Adjustable

wrench

1 Remove the joint screw between handlebar and handrail links. 2 Remove all of the covers.

3 Remove the nut(A) then pull the crank and pedal set out

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

5 Replace the crank with a new one

6 Reverse step 1-4 to install the parts

A

B

Tap here

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

PEDAL REPLACEMENT PROCEDURE (JPE5100)

Tools required: Procedure:

u Philips

screwdriver

u Two-faced

masking 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 Philips

screwdriver

u hex key

(6 mm)

u Hexagonal

socket wrench (13mm)

Procedure:

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

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

Install the side covers and the parts

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

POLY V BELT 430 J12 REPLACEMENT PROCEDURE (JPE5100)

Tools required:

u Philips

screwdriver

u Hex key (6mm)

u Hexagonal

socket wrench (19&13mm)

u Puller

u Adjustable

wrench

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 then remove poly v belt and replace it with a new one

4 Reverse step 1-3 to install the parts.

A

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

PULLEY AXLE REPLACEMENT PROCEDURE (JPE5100)

Tools required:

u Philips

screwdriver

u Hex key

(6mm)

u C-Clip Pliers

u Wooden

hammer

u Adjustable

wrench

Procedure:

1 Remove all of the covers and poly v belts.

2 Remove the screw (A) and washer

3 Pull pulley (B) out then knock axle set out with the

wooden hammer.

4 Remove the nut (C), then tap the axle out

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

6 Reverse the step 1-4 to

install the parts.

Note: To clean the bearing housing and apply adhesive on

the 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 Hexagonal

socket wrench (19&13mm)

u Adjustable

wrench

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, then

remove the poly v belt

4 Follow the procedures below to install the axle.

Step1: pull crank out Step2: remove the cclip. Step3: tap axle assy out Step4: remove the nut

then tap axle out Step5: replace the axle with a new one Step6: 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 Philips

screwdriver

u Hex key (4mm)

Procedure:

1. Remove the all of cover.

2. Move the pedal arm back then pick up it.

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

4. Reverse the steps to install the side cover.

A

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

SENSOR REPLACEMENT PROCEDURE (JPE5100)

Tools required: Procedure:

u Philips screwdriver

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 sensor with a new one.

5. Reverse the step 1-3 to 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 and

unplug the sensor cable terminal from the connector then remove 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 Philips

screwdriver

u Open-end

wrench (8&15mm)

Procedure:

1. Push the console forward and pull the console up, then

unplug the sensor wire terminal from the connector then remove the console

2. With the open-end wrench loosen the nut and with the

Philips screwdriver loosen the screws from the female connector.

3. Unplug the console wire from the rail

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

remove the rail.

5. Replace console wire with a new one.

6. Reverse step 1-2 to install the parts.

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

SENSOR REPLACEMENT PROCEDURE (JAR)

Tools required:

u Philips

screwdriver

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 then

remove it

3. Loosen the screws attaching the sensor to the rail then tie

a new sensor to bad sensor with a rigid string

4. Loosen the nut attaching the female connector to the rail

with the open-end wrench. Pull the old cable from the front end until the new cable threads all the way through the 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 Philips

screwdriver

u Open-end wrench

(13mm)

Procedure:

1. Remove the bolt from

the seat roller by using the open-end wrench (13mm) then remove the seat

2. Loosen the screws

holding the seat to the bracket.

3. Replace the seat with a

new one

4. Reverse step 1-2 to

install all the parts

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

DRIVE BELT 3V-530 REPLACEMENT PROCEDURE (JAR)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u Ratchet Box

Wrench (11mm)

Procedure:

1. Push the console forward and pull the console out, then unplug the sensor cable terminal from the female connector then remove the console and skid pad.

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

3. Remove tension springs set and loosen the screws attaching cable wheel axle to the frame, then remove the axle and belt

4. Loosen the screws from the shroud cover

5. Loosen the screws attaching the hub drive train assembly to the frame, then remove the axle and belt.

6. Install the belts onto the pulley of hub drive train assembly and rope axle.

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

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

NYLON ROPE REPLACEMENT PROCEDURE (JAR)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

u Open end

wrench (14mm )

Procedure:

1. Follow the tension spring set (refer to page 3-32) replacement procedure to remove the parts.

2. Loosen the

screws attaching the rope to the rope wheel.

3. Cut down the

rope and remove it

4. Replace it with a

new rope, first thread the rope through the guide hole of the rope wheel and tie a knot, put the bracket onto the knot, then tighten the screws.

5. Thread the other end of the rope through the square

hole of the bracket, and the wheel in the handle holder cover then tie the rope to the handle bar.

6. Turn forward the rope wheel until the handle touches

the handle holder.

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

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

TENSION SPRING SET REPLACEMENT PROCEDURE (JAR)

Tools required:

u Philips

screwdriver

u Hex key (4mm)

Procedure:

1. Remove the console and skid pad (Refer to page 3-26). Loosen the screws from the side covers with the screwdriver then remove side covers.

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

3. With the hex key loosen the screws from the tension spring 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 4

PREMENTIVE MAINTENANCE

Revision: 1.0 Date: 2001/06/01

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 PolyV belts and check the grooves of the belt for dirt or dust and clean it if any.

2 Check the

grooves in the pulley for dirt or dust and clean it if any.

3 Check the

grooves in the roller pulley for dirt or dust and 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 to

allow the lubricating oil to be fully mixed with the chains 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 5

SERVICE FORM

Revision: 1.0 Date: 2001/06/01

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