AFG 2.0AS Assembly and Owner`s manual

AFG Service Seminar
Horizon Fitness
Models
1.0AT, 2.0AT, 2.0AT,
4.0AT, 5.0AT, 13.0AT,
14.0At
Models
2.0AE, 3.0AE, 4.0AE,
14.0AE, 18.0AE
Models
2.0AR, 3.0AR, 4.0AR,
3.0AH, 4.0AH
Models
2.0AS
Table of Contents
>> Table of Contents
Section One
Section Two
Warranty
Service and Billing Information
Safety Instructions
3
4
-Treadmill
-Elliptical | Bike
-Gym
Recommended Tools
Parts Diagrams
6
8
10
12
-Treadmill
-Elliptical
-Bike
-Gym
13
14
15
16
Maintenance
-Treadmill
>> Lubrication
>> Tensioning & Alignment
-Elliptical
-Bike
-Gym
Proper Heart Rate Usage
| 2008 AFG Service Seminar [rev 1.3]
17
18
19
20
21
22
23
Horizon Fitness “5-Step” Diagnostic Process
Wiring Diagrams and Schematics
Resetting the Incline Motor
Adjusting the Magnetic Break
Voltage Checks
Engineering Mode
-Treadmill
-Elliptical | Bike
25
27
30
31
32
44
45
Section Three
Troubleshooting
-Treadmill
-Elliptical | Bike
-Gym
Known Issues
48
61
69
71
>> Limited Home-Use Warranty
Section One | Warranty Information
AFG extends the following exclusive, limited warranty, which shall apply to the use of the device in the home, for
residential, non-commercial purposes only. Any other use shall void this warranty. AFG hereby offers the following
limited warranties for the following components of the device, for the time period indicated:
Model
1.0AT
Labor
1 Year
Parts
3 Years
Motor
Elevation
Lifetime Lifetime
Break
NA
Frame
Lifetime
2.0AT
1 Year
3 Years
Lifetime Lifetime
NA
Lifetime
3.0AT
1 Year
3 Years
Lifetime Lifetime
NA
Lifetime
4.0AT
1 Year
3-5 Years Lifetime Lifetime
NA
Lifetime
5.0AT
1 Year
3-5 Years Lifetime Lifetime
NA
Lifetime
13.0AT
1 Year
3-5 Years Lifetime Lifetime
NA
Lifetime
14.0AT
1 Year
3-5 Years Lifetime Lifetime
NA
Lifetime
2.0AE
1 Year
2 Years
NA
NA
Lifetime Lifetime
3.0AE
1 Year
2 Years
NA
NA
Lifetime Lifetime
4.0AE
1 Year
3 Years
NA
2 Years
Lifetime Lifetime
14.0AE
1 Year
3 Years
NA
NA
Lifetime Lifetime
18.0AE
1 Year
3 Years
NA
2 Years
Lifetime Lifetime
2.0AR
1 Year
3 Years
NA
NA
Lifetime Lifetime
3.0AR
1 Year
3 Years
NA
NA
Lifetime Lifetime
4.0AR
1 Year
3-5 Years NA
NA
Lifetime Lifetime
3.0AH
1 Year
3-5 Years NA
NA
Lifetime Lifetime
4.0AH
1 Year
3-5 Years NA
NA
Lifetime Lifetime
2.0AS
1 Year
10 Years
NA
NA
NA
Lifetime
AFG warranties the frame, electronics, and parts against defects in workmanship and materials for the above
warranty periods, so long as it remains in the possession of the original owner.
AFG shall cover the labor cost for the repair of the device for the above warranty periods, so long as the device
remains in the possession of the original owner.
EXCLUSIONS AND LIMITATIONS
This warranty applies only to the original owner and is not transferable. This warranty is expressly limited to the
repair or replacement of a defective frame, electronic component, or defective part. The warranty does not cover
normal wear and tear, improper assembly or maintenance, or installation of parts or accessories not originally
intended or compatible with the Unit as sold. The warranty does not apply to damage or failure due to accident,
abuse, corrosion, discoloration of paint or plastic, or neglect. AFG shall not be responsible for incidental or
consequential damages. All returns must be pre-authorized by AFG. AFG’s obligation under this warranty is
limited to replacing or repairing, at AFG’s option, the product at one of its authorized service centers. An AFG
authorized service center must receive all products for which a warranty claim is made. These products must be
received with all freight and other transportation charges prepaid, accompanied by sufficient proof of purchase.
Parts and electronic components reconditioned to “As New” Condition by AFG or its vendors may
sometimes be supplied as warranty replacement parts and constitute fulfillment of warranty terms. This warranty
gives you specific legal rights, and your rights may vary from state to state.
WARRANTY REGISTRATION
Your warranty card must be completed and sent to AFG or register on line at www.advancedfitnessgroup.com,
before a warranty claim can be processed.
2008 AFG Service Seminar [rev 1.3] | Section One | Service and Billing Information
>> Service and Billing Information
AFG IS YOUR TOTAL SOLUTIONS PROVIDER
ServiceBench is a web-based system that will allow you to create parts orders, submit labor credits and
to track the process of each. Know instantly if a part is in stock! Have exploded diagram and parts list at
your disposal to use when it is convenient for you, not just when the Tech Support department is open.
You can access this site at www.servicebench.com. On the Left side of the screen are 3 boxes
(ServiceBench ID, User ID, and Password from top to bottom). The initial User ID is the word User. Your
ServiceBench ID and initial Password are available from Alan at 800-244-4192 ext. 3240 or
alan@horizonfitness.com.
Once logged in, you will need to answer a few one time only questions. You will also be asked for bank
account information. You do not have fill out the bank information, as we will not be sending out
electronic payments, we will continue to credit your account.
After answering these questions, you will go to the Main Menu for ServiceBench. From here the most
useful links will be the Claims Tab and the Dispatch Tab.
Claims Tab – used to track payment.
• Use the Claim Review to track the status of a particular claim number
• From the Claim Inbox you will be able to track the process of the submitted claim and verify
payment.
| 2008 AFG Service Seminar [rev 1.3]
Section One | Service and Billing Information
Dispatch Tab – Used to store and locate work orders (Dispatches) from Horizon Fitness.
• If you have a paper copy of the customer information, click Dispatch (it will be written in white
against dark blue background). Click Dispatch Review, type in the dispatch number and click
Search.
• If you do not have a paper copy of the customer information, click Dispatch (it will be written in white
against dark blue background). Click Dispatch Inbox, this will display all dispatches received in the
past week. If you have already accepted the dispatch, change Received to Accepted by clicking the
down arrow next to Received.
• Location E-mail Maintenance allows you to set e-mail addresses to receive notification when new
dispatches are received. Availability Maintenance allows you to set a number of dispatches that
you can receive on a certain day. This is not a scheduled appointment with a customer, but rather
allows you to adjust for vacation (keep zeroes in availability), or allow for more work orders
(set a maximum number of work orders that can be sent to you for a certain day). It is still up to you to
set an appointment with the customer depending on your schedule.
Business Management Systems - is the link which will allow any business software you currently use
to synchronize with ServiceBench.
If you have any questions please contact Alan with Horizon Fitness at 800-244-4192 ext. 3240 or
ServiceBench phone support at 877-472-3624 for technical assistance.
2008 AFG Service Seminar [rev 1.3] | Section One | Safety Instructions
Safety Instructions
>> Treadmills
WARNING STATEMENTS INDICATE A PARTICULARLY DANGEROUS ACTIVITY.
YOU SHOULD BE EXTREMELY CAUTIOUS WHEN DOING THE FOLLOWING:
• Removing power from the treadmill, or removing the power cord from the wall outlet. Always ensure that the treadmill is unplugged from the wall outlet when you inspect or adjust the treadmill, or when
you isolate, remove, or replace a treadmill component.
• Removing the motor cover exposes high voltage components and potentially dangerous machinery.
Exercise extreme caution when you perform maintenance procedures with the motor cover removed.
• During service operations you will be very close to moving machinery and high voltage components.
When you perform maintenance procedures with the hood removed, remove jewelry (especially from
ears and neck), tie up long hair, remove neckties, and do not wear loose clothing.
• When the treadmill is operating, the capacitor will hold a lethal amount of charge. Do not touch the
capacitor as serious injury or death might result.
• When the treadmill is turned off and the power cord is removed from the wall outlet, the capacitor will
hold voltage for 30-60 seconds. Allow the capacitor to discharge for a period of one minute before you
touch or work near the capacitor. Do not attempt to discharge the capacitor by any other means.
• Exercise caution when touching any wire or electrical component during treadmill operation.
• When it is necessary to lift the treadmill, ensure that the treadmill has adequate support. Do not lift the
treadmill by the front.
SAFETY GUIDELINES YOU SHOULD KNOW AND FOLLOW INCLUDE:
• Read the owner’s manual and follow all operation instructions.
• Operate the treadmill on a solid, level surface. Locate the rear of the treadmill at least four feet from
walls or furniture. Keep the area behind the treadmill clear.
• Visually check the treadmill before beginning service or maintenance operations. If it is not completely
assembled or is damaged in any way, exercise extreme caution while operating and checking the
treadmill.
• When operating the treadmill, do not wear loose clothing. Do not wear shoes with heels or leather soles.
Check the soles of your shoes and remove any embedded stones. Tie long hair back.
• Use care when getting on or off the treadmill. Use the handrails whenever possible. Do not get on or off
the treadmill when the running belt is moving.
• Before starting the running belt, straddle the belt by placing your feet firmly on the guiderails of the
treadmill. You should also step off the belt and onto the guiderails of the treadmill after turning off the
running belt.
• Do not rock the unit. Do not stand or climb on the handrails, electronic console, or motor cover.
• Do not set anything on the handrails, electronic console, or motor cover. Never place liquids on any part
of the treadmill.
• To prevent electrical shock, keep all electrical components, such as the drive motor, power cord, and
circuit breaker away from water and other liquids.
• Do not use accessory attachments that are not recommended by the manufacturer-such attachments
might cause injuries.
• Turn off the treadmill when adjusting or working near the rear roller. Do not make any adjustments to
the running belt when someone is standing on the machine.
• Keep all loose items away from the treadmill running surface. A treadmill running belt will not stop
immediately if an object becomes caught in the belt or rollers.
| 2008 AFG Service Seminar [rev 1.3]
Section One | Safety Instructions
WARNING
Connect this unit to a properly grounded, dedicated 20-amp outlet only.
See grounding instructions.
GROUNDING INSTRUCTIONS
This product must be grounded. If a treadmill should malfunction or breakdown, grounding provide
a path of least resistance for electrical current to reduce the risk of electrical shock. This product is
equipped with a cord having an equipment-grounding conductor and a grounding plug. The plug must
be plugged into an appropriate outlet that is properly installed and grounded in accordance with local
codes and ordinances.
WARNING
Improper connection of the equipment-grounding conductor can result in a risk of electric
shock. Check with a qualified electrician if you are in doubt as to whether the product is
properlygrounded. Do not modify the plug provided with the product, if it will fit in the
outlet; have a proper outlet installed by a qualified electrician.
Grounded Outlet
Adapter
Metal Screw
Grounding Pin
Grounded Outlet Box
TAS For
Grounding Screw
SAFETY TIPS
• Never use the treadmill before securing the safety tether clip to your clothing.
• If you experience chest pains, nausea, dizziness, or shortness of breath, stop exercising
immediately and consult your physician before continuing.
• Do not wear clothes that might catch on any part of the treadmill.
• Keep power cord away from heated surfaces.
• Keep children off of treadmill at all times.
• Do not use treadmill outdoors.
• Unplug treadmill before moving it.
• Do not remove the treadmill motor cover or roller covers.
• Treadmill should be plugged into a dedicated 20 amp circuit for optimal performance.
2008 AFG Service Seminar [rev 1.3] | Section One | Safety Instructions
Safety Instructions
>> Ellipticals/Bikes
SAVE THESE INSTRUCTIONS
Read all instructions before using this Elliptical/Bike. When using an electrical product, basic
precautions should always be followed, including the following: Read all instructions before using this
Elliptical/Bike. It is the responsibility of the owner to ensure that all users of this Elliptical/Bike are
adequately informed of all warnings and precautions. If you have any questions after reading this
manual, contact Customer Tech Support at the number listed on the back panel of this manual.
WARNING
To reduce the risk of burns, fire, electrical shock or injury follow the instructions below.
• If you experience any kind of pain, including, but not limited to chest pains, nausea, dizziness, or
shortness of breath, stop exercising immediately and consult your physician before continuing.
• Maintain a comfortable pace. Do not sprint above 80 rpms on this machine.
• To maintain balance, it is recommended to keep a grip on the handlebars while exercising, mounting
or dismounting the machine.
• Do not wear clothes that might catch on any part of the Elliptical/Bike.
• Do not turn pedal arms by hand.
• Make sure handlebars are secure before each use.
• Do not insert or drop any object into any opening.
• Unplug Elliptical/Bike before moving or cleaning it. To clean, wipe surfaces down with soap and
slightly damp cloth only; never use solvents. (See MAINTENANCE)
• This elliptical should not be used by persons weighing more than the weight limit stated in the owners
manual. Failure to comply will void the warranty.
• This elliptical is intended for in-home use only. Do not use this elliptical in any commercial, rental,
school or institutional setting. Failure to comply will void the warranty.
• Do not use elliptical in any location that is not temperature controlled, such as but not limited to
garages, porches, pool rooms, bathrooms, car ports or outdoors. Failure to comply may void the
warranty.
• Use the elliptical only as described in this manual.
• Keep the topside of the foot support clean and dry.
• Care should be taken when mounting or dismounting the equipment. Before mounting or dismounting
move the pedal on the mounting or dismounting side to its lowest position and bring the machine to a
complete stop.
• Disconnect all power before servicing the equipment.
At NO time should pets or children under the age of 12 be closer to the Elliptical/Bike
than 10 feet.
At NO time should children under the age of 12 use the Elliptical/Bike.
Children over the age of 12 should not use the Elliptical/Bike without adult supervision.
It is essential that your Elliptical/Bike is used only indoors, in a climate controlled room. If your
Elliptical/Bike has been exposed to colder temperatures or high moisture climates, it is strongly
recommended that the Elliptical/Bike is warmed up to room temperature before first time use.
Failure to do so may cause premature electronic failure.
| 2008 AFG Service Seminar [rev 1.3]
Section One | Safety Instructions
Safety Instructions
>> Elliptical | Bike Continued
WARNING
Connect this exercise product to a properly grounded outlet only.
See grounding instructions.
GROUNDING INSTRUCTIONS-Inclining Ellipticals Only
This product must be grounded. If a Elliptical/Bike should malfunction or breakdown, grounding
provides a path of least resistance for electrical current to reduce the risk of electrical shock. This
product is equipped with a cord having an equipment-grounding conductor and a grounding plug. The
plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance
with local codes and ordinances.
WARNING
There are several areas during the assembly process of an elliptical that special
attention must be paid. It is very important to follow the assembly instructions correctly
and to make sure all parts are firmly tightened. If the assembly instructions are not
followed correctly, the elliptical could have frame parts that are not tightened and will
seem loose and may cause irritating noises. To prevent damage to the elliptical, the
assembly instructions must be reviewed and corrective actions should be taken.
UNPACKING
Unpack the product where you will be using it. Place the product on a level flat surface. It is
recommended that you place a protective covering on your floor. During each assembly step, ensure that
ALL nuts and bolts are in place and partially threaded in before completely tightening any ONE bolt.
NOTE: A light application of grease may aid in the installation of hardware. Any grease, such as lithium
bike grease is recommended.
2008 AFG Service Seminar [rev 1.3] | Section One | Safety Instructions
Safety Instructions
>> Gym
FOR HOUSEHOLD USE ONLY
Read all instructions before using this home gym. Basic precautions should always be followed,
including the following: Read all instructions before using this home gym. It is the responsibility of the
owner to ensure that all users of this home gym are adequately informed of all warnings and precautions.
If you have any questions after reading this manual, contact AFG at the number listed on the back cover
of this manual.
WARNING
TO REDUCE THE RISK OF INJURY FOLLOW THE INSTRUCTIONS BELOW
• Close supervision is necessary when this home gym is used by, on, or near children or
disabled persons.
At NO time should pets or children under the age of 12 be closer to the home gym than 10
feet. At NO time should children under the age of 12 use the home gym.
Children over the age of 12 should not use the home gym without adult supervision.
• Use this appliance (or home gym) only for its intended use as described in this manual.
Do not use attachments not recommended by the manufacturer.
• Never drop or insert any object into any opening.
• If you experience any kind of pain, including but not limited to chest pains, nausea, dizziness, or
shortness of breath, stop exercising immediately and consult your physician before continuing.
• Do not wear clothes that might catch on any part of the home gym.
• Always wear athletic shoes while using this equipment.
• Do not jump on the home gym.
• At no time should more than one person be on home gym while in operation.
• The home gym should not be used by persons weighing more than 300 pounds.
Failure to comply will void the warranty.
• The home gym is intended for in-home use only. Do not use this home gym in any commercial, rental,
school or institutional setting. Failure to comply will void the warranty.
• Do not use outdoors.
10 | 2008 AFG Service Seminar [rev 1.3]
Section One | Safety Instructions
Safety Instructions
>> Gym Continued
During the assembly process there are several areas that special attention must be paid. It is very
important to follow the assembly instructions correctly and to make sure all parts are firmly tightened. If
the assembly instructions are not followed correctly, the home gym could have frame parts that are not
tightened and will seem loose and may cause irritating noises. There should be no side-to-side play in
the frame uprights. If there is any play in these areas, the home gym has not been properly assembled.
To prevent damage to the home gym, the assembly instructions must be reviewed and corrective actions
should be taken.
UNPACKING
Unpack the unit where it will be used. Place the home gym carton on a level flat surface.
It is recommended that you place a protective covering on your floor. Take CAUTION when handling and
transporting this unit. Never open box when it is on its side.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN INJURY!
WARNING
SEAT ASSEMBLY PIN
Ensure that the seat assembly safety pin is fully inserted before using the home gym.
Failure to do so may result in injury!
PROPER USAGE
Make sure to follow the MAINTENANCE schedule in this manual. Stop your workout immediately if you
feel pain, faint, dizzy or are short of breath. Reference Home Gym Maintenance p22.
WARNING
Do not operate the home gym if there is any noticeable damage to the cables or pulleys.
If any damage is noticeable, contact AFG at the number located on the back panel of
this manual.
2008 AFG Service Seminar [rev 1.3] | 11
Section One | Recommended Tools
>> Recommended Tools and Equipment
The following list is a summary of the tools and equipment required by the procedures in this manual.
Tools are not supplied by Horizon Fitness.
• Phillips screwdrivers
• Anti-static wrist strap (when handling electronic parts)
• Flat-head screwdrivers
• Digital multi-meter
• Drive belt tension gauge
• Allen wrench set (Metric)
• Open-end wrenches of assorted sizes (Metric)
• Clamp-on amp meter
• 1/2” drive ratchet and sockets of assorted sizes
• Blue Thread Lock
• Cable ties
• *Motor commutator stone
• Needle nose pliers
• Damp cloth
• Rubber mallet
• Hammer
• Drop cloth
• Ruler
• Snap ring pliers
• Wire cutters
• *Crank Puller (Park Tool CCP-2, 22mm)
• *Crank Puller (26mm)
*Available through Horizon Fitness at Cost.
12 | 2008 AFG Service Seminar [rev 1.3]
Section Three | Parts Diagrams >>Treadmill
>> Treadmill Parts Diagram
Console
CONSOLE
Water
Bottle Holder
WATERBOTTLE
HOLDER
12 MPH
12
DISTA
11
10
NCE
10 MPH
9
8
7
8 MPH
6
5
4
3
6 MPH
2
1
4 MPH
D
SPEE RIES
CALO
2 MPH
TIME
12
CONSOLEConsole
SKIRT
Skirt
12
11
10
9
%
P6:
8
6
P5:
5
10 %
4
3
INE
INCL T RATE
HEAR
2
P4:
1
P3:
8%
MTN
WEIGH
PEAK
COURS
INTERV
E
T LOSS
P10:
P9:
CUSTO
CUSTO
+1 MPH
M2
M1
S TO
IRM D
PRES
CONF SPEE
CLIMB
ALS
P2:
6%
P1:
MANUA
4%
INTERV
L
P8:
P7:
THR
ZONE
BAC
K
ENTER
ST
CH
ST
AR
OP
HOLD
PACER
TO
M
PRESS
CONFIR E
INCLIN
2%
+1%
CONSOLEConsole
MAST
GOLF
ALS
7
T
QUICK
START
AN
GE
DI
SP
L AY
TO
RESET
Touch
PanelPANEL
with LED
Window
TOUCHPAD
WITH
LED WINDOWS
Mast
Reading
Rack
READING
RACK
Breaker
CIRCUITCircuit
BREAKER
Grip
Rails
GRIPPulse
PULSEHand
HAND
RAILS
ON
| OFF Switch
ON/OFF
SWITCH
Safety
Key
Placement
SAFETY
KEY
PLACEMENT
Power
POWER CORD
Cord
Wheel
WHEEL LOCKS
Locks
Side
SIDE COVER
Cover
Transport
Wheel
TRANSPORT
WHEEL
Running
Belt/ |RUNNING
Running DECK
Deck
RUNNING
BELT
HAND Rails
RAILS
Hand
Motor
MOTORCover
COVER
Side Rail
SIDE
RAIL
ROLLER
END
CAP
Roller
End
Caps
REARRoller
ROLLER
ADJUSTMENT
Rear
Adjustment
BoltsBOLTS
2008 AFG Service Seminar [rev 1.3] | 13
Section Three | Parts Diagrams >>Elliptical
>> Elliptical Parts Diagram
Display
DISPLAY
Left
Handlebar
LEFT HANDLEBAR
PulseGRIP
Grip
PULSE
Bottle
Holder
BOTTLE
HOLDER
ConsoleMAST
Mast
CONSOLE
Console
MastBOOT
Boot
CONSOLE
MAST
Top
TOP Cap
CAP
Console
CONSOLE
Right
RIGHTHandlebar
HANDLEBAR
Handlebar
Covers
HANDLEBAR
COVERS
Power Adaptor
Socket
POWER
ADAPTOR
SOCKET
FootPAD
Pad
FOOT
PedalARM
Arm
PEDAL
Elbow Cover
ELBOW
COVER
Front Stabilizer
TubeTUBE
FRONT
STABILIZER
LOWERLink
LINK
ARM
Lower
Arm
Foot Leveler
FOOT
LEVELER
14 | 2008 AFG Service Seminar [rev 1.3]
Section Three | Parts Diagrams >>Bike
>> Bike Parts Diagram
Console
CONSOLE
Seat Back
SEAT
BACKCover
COVER
Water
Bottle
Holder
WATER
BOTTLE
HOLDER
Pulse
Grip
Handlebars
PULSE
GRIP
HANDLEBARS
SeatBACK
Back
SEAT
Seat BASE
Base
SEAT
Rear
CapCAP
REARPlastic
PLASTIC
Seat
SEATFrame
FRAME
MainFRAME
Frame
MAIN
Rear
Stabilizer
TubeTUBE
REAR
STABILIZER
Pedals
with
FootSTRAPS
Straps
PEDALS
WITH
FOOT
2008 AFG Service Seminar [rev 1.3] | 15
Section Three | Parts Diagrams >>Gym
>> Gym Parts Diagram
Cable
CABLEA
“A”
LAT Pulldown
PULLDOWN Bar
BAR
LAT
Upper
PulleyASSEMBLY
Assembly
UPPER PULLEY
LAT
Bar
Bracket
Assembly
LAT
BAR
BRACKET
ASSEMBLY
DUAL Floating
FLOATING Pulley
PULLEYBracket
BRACKET
Dual
CENTER
SUPPORTFrame
FRAME
Center
Support
Weight
Shield
WEIGHT SHIELD
MAIN
SUPPORT
FRAME(Right)
(RIGHT)
Main
Support
Frame
CABLEC
“C”
Cable
GUIDE ROD
Guide
Rod
RADIAL Arm
ARM ASSEMBLY
Radial
Assembly
RADIAL
ARM
ADJUSTMENTPin
PIN
Radian
Arm
Adjustment
SEAT
BACKPad
PAD
Seat
Back
SEATBottom
BOTTOMPad
PAD
Seat
WeightSELECTION
SelectionPIN
Pin
WEIGHT
Main
SupportFRAME
Frame(LEFT)
(Left)
MAIN SUPPORT
SINGLE
Single FLOATING
Floating PULLEY
Pulley BRACKET
Bracket
SEATAssembly
ASSEMBLY
Seat
Seat
AssemblySAFETY
SafetyPIN
Pin
SEAT ASSEMBLY
SEAT
HEIGHTAdjustment
ADJUSTMENTKnob
KNOB
Seat
Height
FOAM LEGROLLERS
Foam
Legrollers
Adjustable
Footplate
ADJUSTABLE FOOTPLATE
16 | 2008 AFG Service Seminar [rev 1.3]
BASE FRAME
Base
Frame
CABLE
Cable “B”
B
Section One | Maintenance
Maintenance
>> Treadmill Preventative Maintenance Procedures
Cleanliness of your treadmill and its operation environment will keep maintenance problems and service
calls to a minimum. For this reason, we recommend that the following preventive maintenance schedule
be followed.
AFTER EACH USE (DAILY)
Clean and inspect, following these steps:
• Turn off the treadmill with the on/off switch, then unplug the power cord at the wall outlet.
• Wipe down the running belt, deck, motor cover, and console casing with a damp cloth. Never use
solvents, as they can cause damage to the treadmill.
• Inspect the power cord. If the power cord is damaged, contact AFG.
• Make sure the power cord is not underneath the treadmill or in any other area where it can become pinched or cut.
• Check the tension and alignment of the running belt. Make sure that the treadmill belt will not damage
any other components on the treadmill by being misaligned.
EVERY WEEK
Clean underneath the treadmill, following these steps:
• Turn off the treadmill with the on/off switch, then unplug the power cord at the wall outlet.
• Fold the treadmill into the upright position, making sure that the lock latch is secure.
• Move the treadmill to a remote location.
• Wipe or vacuum any dust particles or other objects that may have accumulated underneath the
treadmill.
• Return the treadmill to its previous position.
EVERY MONTH - IMPORTANT!
• Turn off the treadmill with the on/off switch, then unplug the power cord at the wall outlet.
• Inspect all assembly bolts of the machine for proper tightness.
• Turn off the treadmill and wait 60 seconds.
• Remove the motor cover. Wait until ALL LED lights turn off.
• Clean the motor and lower board area to eliminate any lint or dust particles that may have
accumulated. Failure to do so may result in premature failure of key electrical components.
• Vacuum and wipe down the belt with a damp cloth. Vacuum any black/white particles that may
accumulate around the unit. These particles may accumulate from normal treadmill use.
Note: Maintenance is NOT covered under manufacturer’s warranty.
2008 AFG Service Seminar [rev 1.3] | 17
Section One | Maintenance
Maintenance
>> Treadmill Lubrication
EVERY 6 MONTHS OR 150 MILES
It is necessary to lubricate your treadmill running deck every six months or 150 miles to maintain optimal
performance of your treadmill. Once the treadmill reaches 150 miles, the console will prompt you to
lubricate the treadmill. Only use lubricant provided by AFG!
• Turn off the treadmill with the on/off switch, then unplug the power cord at the wall outlet.
• Loosen both the rear roller bolts. (For best results, place two removable marks on both sides of the
frame and note roller position). Once the belt is loosened, take the bottle of lubricant and apply it to the
entire top surface of the running deck. Tighten both rear roller bolts (matching up the marks for proper
position) to original position. After you have applied lubricant, plug in the power cord, insert the safety
key, start the treadmill and walk on the belt for two minutes to spread the lubricant.
• Lubricate the air shocks with Teflon based spray.
• Once lubrication is complete, reset the console by pressing and holding ‘STOP’ and Speed (s) buttons
for 5 seconds.
LUBRICATION
Running Belt
Running Deck
18 | 2008 AFG Service Seminar [rev 1.3]
Section One | Maintenance
Maintenance
>> Tensioning and Aligning the Running Belt
If you can feel a slipping sensation when running on the treadmill, the running belt must be tightened.
In most cases, the belt has stretched from use, causing the belt to slip. This is a normal and common
adjustment. Make sure that the unit is turned off and not running. To eliminate this slipping, tension
both the rear roller bolts with the appropriate sized Allen wrench, turning both the left and right bolt 1/4
TURN as shown below. 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. Belt is too far to the left side.
Belt is too far to the right side.
1 | If the running belt moves rapidly to one side when performing the next step, press the Stop button
immediately.
• Turn on the treadmill. With the treadmill speed between 3-4mph, stand behind the treadmill and
watch the movement of the running belt. DO NOT STAND ON THE TREADMILL AND DO NOT
TOUCH THE TREADMILL WHILE PERFORMING THIS PROCEDURE. As you watch the running belt,
make sure that the belt runs without moving from one side to the other and that the belt is centered
between the side rails.
2 | If the running belt is not tracking properly, follow the procedures below:
• If the running belt tracks to the left, turn the left roller bolt clockwise 1/4 of a turn, keeping the belt
tension in mind. Over-tightening the running belt may cause damage to the running belt and roller
bearings.
• If the running belt tracks to the right, turn the right roller bolt clockwise 1/4 of a turn, keeping the belt
tension in mind. Over-tightening the running belt may cause damage to the running belt and roller
bearings.
2008 AFG Service Seminar [rev 1.3] | 19
Section One | Maintenance
Maintenance
>> Elliptical Preventative Maintenance Procedures
WHAT KIND OF ROUTINE MAINTENANCE IS REQUIRED?
We use sealed bearings throughout our ellipticals so lubrication is not needed. The most important
maintenance steps are to wipe perspiration off the unit after each use and periodically checking the
assembly bolts for tightness.
HOW DO I CLEAN MY ELLIPTICAL?
Clean with soap and water cleaners only. Never use solvents on plastic parts.
Cleanliness of your elliptical and its operating environment will keep maintenance problems and service
calls to a minimum. For this reason, AFG recommends that the following preventive maintenance
schedule be followed.
AFTER EACH USE (DAILY)
Turn off the elliptical by unplugging the power cord from the wall outlet
• Wipe down the elliptical with a damp cloth. Never use solvents, as they can cause damage to the
elliptical.
• Inspect the power cord. If the power cord is damaged, contact AFG.
• Make sure the power cord is not underneath the elliptical or in any other area where it can become
pinched or cut.
WARNING
To remove power from the elliptical, the power cord must be disconnected from the wall
outlet.
WEEKLY
Clean underneath the elliptical, following these steps:
• Turn off the elliptical.
• Move the elliptical to a remote location.
• Wipe or vacuum any dust particles or other objects that may have accumulated underneath the
elliptical.
• Return the elliptical to its previous position.
EVERY MONTH
• Inspect all assembly bolts and pedals on the machine for proper tightness.
• Clean any debris off of the pedal arm wheels and guide rails.
20 | 2008 AFG Service Seminar [rev 1.3]
Section One | Maintenance
Maintenance
>> Bike Preventative Maintenance Procedures
WHAT KIND OF ROUTINE MAINTENANCE IS REQUIRED?
We use sealed bearings throughout our bikes so lubrication is not needed. The most important
maintenance step is to simply wipe your perspiration off the bike after each use.
HOW DO I CLEAN MY Bike?
Clean with soap and water cleaners only. Never use solvents on plastic parts.
Cleanliness of your bike and its operating environment will keep maintenance problems and service calls
to a minimum. For this reason, AFG recommends that the following preventive maintenance schedule
be followed.
AFTER EACH USE (DAILY)
Turn off the bike by unplugging the power cord from the wall outlet.
• Wipe down the bike with a damp cloth. Never use solvents, as they can cause damage to the bike.
• Inspect the power cord. If the power cord is damaged, contact AFG.
• Make sure the power cord is not underneath the bike or in any other area where it can become pinched or cut.
WARNING
To remove power from the bike, the power cord must be disconnected from the wall
outlet.
WEEKLY
Clean underneath the bike, following these steps:
• Turn off the bike.
• Move the bike to a remote location.
• Wipe or vacuum any dust particles or other objects that may have accumulated underneath the bike.
• Return the bike to its previous position.
EVERY MONTH
• Inspect all assembly bolts and pedals on the machine for proper tightness.
• Clean any debris off of the seat guide rail.
2008 AFG Service Seminar [rev 1.3] | 21
Section One | Maintenance
Maintenance
>> Gym Preventative Maintenance Procedures
Cleanliness of your home gym and its operation environment will keep maintenance problems and
service calls to a minimum. For this reason, we recommend that the following preventive maintenance
schedule be followed.
AFTER EACH USE (DAILY)
• Wipe upholstery, handles, bars, and frame (if needed) with a soap and water cleaning solution.
EVERY WEEK
• Lubricate guide rods with a spray or silicone gel lubricant.
• Inspect cable ends and cable insulation for damage.
EVERY MONTH - IMPORTANT!
• Inspect all frame bolts and tighten as needed.
ADJUSTING CABLE TENSION
Regularly check the cable tension of your home gym. If
excessive slack exists adjust cable tension by removing
the pulley bolts and moving one or both pulleys to the inner
mounting position in the dual floating pulley bracket and
then reinstalling the pulley bolts. Cable tension may also
be adjusted using the threaded cable end on single pulley
bracket and weight stack. Twist threaded end to adjust
tension and then tighten lock nut.
NOTE: Always maintain at least ½˝ of threaded bolt in
bayonet.
Twist Screw to
Adjust Tension,
Then Tighten
Lock Nut
Twist Screw to
Adjust Tension,
Then Tighten
Lock Nut
Inner
Mounting
Positions
Cable Screw
And Nut
Cable Screw
And Nut
Bayonet
Single pulley
Bracket Thread
22 | 2008 AFG Service Seminar [rev 1.3]
Weight Plates
Section One | Proper Heart Rate Usage
>> Proper Heart Rate Usage
HAND GRIPS
Place the palm of you hands directly on the grip pulse handlebars. Both hands must grip the bars for your
heart rate to register. It takes 5 consecutive heartbeats (15-20 seconds) for your heart rate to register
accuratly. When gripping the pulse handlebars, do not grip tightly. Holding the grips tightly may elevate
your blood pressure. Keep a loose, cupping hold. You may experience an erratic readout if consistently
holding the grip pulse handlebars. Make sure to clean the pulse sensors to ensure proper contact can be
maintained.
WIRELESS CHEST TRANSMITTER 4.0AR, 4.0AH, 4.0AE, 14.0AT, 14.0AE, 5.0AT, 18.0AE
(3.0AE, 13.0AT, 4.0AT sold separately)
Prior to wearing the wireless chest transmitter, moisten the two rubber electrodes with water. Center the
chest strap just below the breast or pectoral muscles, directly over your sternum, with the logo facing
out. *Verify the chest strap is the Polar brand chest strap.
The chest strap must be tight and properly placed to receive an accurate and consistent
readout. If the chest strap is too loose, or positioned improperly, you may receive an
erratic or inconsistent heart rate readout.
WARNING
The heart rate function is not a medical device. Various factors may affect the accuracy
of your heart rate reading. The heart rate reading is intended only as an exercise aid.
Backside of Chest Transmitter
Apply Moisture Here
TROUBLESHOOTING-HEART RATE
Check your exercise environment for sources of interference such as fluorescent lights, computers,
underground fencing, home security systems or appliances containing large motors. These items may
cause erratic heart rate readouts.
You may experience an erratic readout under the following conditions:
• Gripping the heart rate handlebars too tight. Try to maintain moderate pressure while holding onto the
heart rate handlebars.
• Constant movement and vibration due to constantly holding the heart rate handlebars while
exercising. If you are receiving erratic heart rate readouts, try to only hold the grips long enough to
monitor your heart rate.
• When you are breathing heavily during a workout.
• When your hands are constricted by wearing a ring.
• When your hands are dry or cold. Try to moisten your palms by rubbing them together to warm them.
• Anyone with heavy arrhythmia.
• Anyone with arteriosclerosis or peripheral circulation disorder.
• Anyone whose skin on the measuring palm is especially thick.
2008 AFG Service Seminar [rev 1.3] | 23
Table of Contents
>> Section Two
Horizon Fitness “5-Step” Diagnostic Process
Wiring Diagrams and Schematics
Resetting the Incline Motor
Adjusting the Magnetic Break
Voltage Checks
-Treadmills
>>No Motor Movement
>>Motor | AC Wire
>>Console Cable
>>Speaker Amp Board
>>9 Wire Console Cable
>>12 Wire Console Cable
>>Incline Wire
-Ellipticals | Bikes
>>Incline Motor
>>Resistance Motor
>>Resistance Motor Cable
>>10 WireConsole Cable
>>Incline Console Cable
Engineering Mode
-Treadmill
-Elliptical | Bike
24 | 2008 AFG Service Seminar [rev 1.3]
25
27
30
31
32
34
34
35
35
36
37
38
39
40
41
42
43
44
45
Section Two | Voltage Checks
>> Horizon Fitness “5-Step” Treadmill Diagnostic Process
The following steps are provided as routine checkpoints when diagnosing problems on
a Horizon Fitness treadmill. If followed correctly, these checkpoints should help diagnos
the majority of problems that may be encountered.
1 | Proper supplying power to treadmill.
• Make sure the treadmill is not on an extension cord, surge protector or GFCI circuit. Extension
cords and surge protectors create energy loss, which prevents proper voltage from being
supplied to the treadmill.
• Make sure the treadmill is on a dedicated circuit. Horizon Fitness recommends a 20 amp
dedicated circuit, but a 15 amp dedicated circuit may be sufficient.
• Make sure that proper voltage is being supplied from the wall outlet.
WARNING
Hazardous voltages will be tested in the following procedure. Exercise extreme caution
when performing these procedures. Do not connect or disconnect any wiring,
connectors, or other components with the power applied to the treadmill.
• Disconnect the treadmill power cord from the wall outlet. Using an AC voltmeter, verify that the
proper AC voltage is present at the wall outlet. Nominal 120 volts AC may vary between
approximately 105 volts AC and 135 volts AC. If the AC voltage is missing or incorrect, check the AC service or consult an electrician.
120 VAC
2 | Proper Wiring
• Verify that all wires are secure and attached in the correct position.
(Reference Wiring Diagrams and Scematics section p27.)
• Verify that there aren’t any pinches or cuts in any of the wires, especially the console cable
connecting from the motor control board to the upper board. Replace any wires that are
pinched or cut.
2008 AFG Service Seminar [rev 1.3] | 25
Section Two | Horizon Fitness “5-Step” Diagnostic Process
3 | Proper Motor Function
• Verify that the treadmill is properly lubricated (Reference Maintenance Section p17.) and drive motor is operating at the proper amperage rating. To verify the current draw, place a clamp
meter around the red motor wire. If a clamp meter is not available, an additional wire harness
can be produced to measure amperage with a standard voltmeter.
Black Motor Connection
UP
R9
LED 4
R7
Q4
SJED08043EE
LED 5
Q2
LED 3
Q1
ZJ
D18
D6
R14
C8
TP1
R29
C9
US
NTC
COIL 12VDC
JQX-15FS-A
JP5
C30
U1
U3
D17
L3
TP4
CHIN A
CQC
C
30A 120/240V AC
R28
Q9
D10
D3 FZ
CHI N A
C1
R26
C34
12
R35
SGND
JOHNSONFITNESS
R8
LED 2
R6
R27
C14
R10
C15
R11
C16
R12
C17
R13
Q3
DW
US
JQX-15FS-A
CQC
COIL 12 VDC
WJ28025T
08
04
D5
C
30A 120/240V AC
Red Motor
Connection
R5
R24
D20
07
R32
R33
C33
08
D9
Q10
DLS3
R17
D21
D19
TP2
DLS2
BL
R19
NTC
D1
R18
C20
Black
Motor Wire
02.31
Red Motor
Wire
• Remove the brush covers on the drive motor and inspect the brushes and the motor commutator
for any uneven wear. If the surface of the motor brush is pitted, rough, has burn marks, or the
commutator has a black residue on it, replace the motor.
4 | Proper Speed Calibration
• To ensure proper belt speed and proper calibration use engineering mode to verify that machine
is running in MPH not KM (all models). (Reference Engineering Mode Section p44.)
• Auto-calibrate the machine from engineering mode if the belt speed is erratic or the belt speed
does not correspond to what is displayed on the console.
(Reference Engineering Mode Section p44.)
5 | Voltage Checkpoints
• Verify that proper voltage is being transferred through the console cable.
(Reference Voltage Checks p35.)
If the techniques described in the five-step diagnostic process did not resolve the
problem, reference the symptoms in the table of contents and review other possible
causes in the troubleshooting section.
26 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Wiring Diagrams and Schematics
>> Digital Drive Wiring Diagram
Optic Speed Sensor
BLACK
WHITE
RED
BLUE
BLACK
GREEN
+GND
PULSE
+5V
GND
GND
Speed Sensor
Drive Motor
0-90 VDC
BLACK
RED
EL - Vcc (+2.5v)
EL - Pot
Gnd
Digital Ground
Digital Ground
MCB
RPM
Power Voltage (+15V)
Power Voltage (+15V)
Speed Command pwr
RELAY
DOWN Incline
UP Incline
BLACK
RED
WHITE
WHITE
BLACK
+2.5vdc
EL. Pol
EL. GND
GREEN
BREAKER
Incline Motor
GREEN
WHITE
BLACK
Power Cord
110-120 VAC
2008 AFG Service Seminar [rev 1.3] | 27
Section Two | Wiring Diagrams and Schematics
>> Elliptical Wiring Diagram Schematics
28 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Wiring Diagrams and Schematics
>> Power Source Wiring Diagram
To Motor Control Board
D
E
F
C
A
A
B
F
C
Socket
On | Off Switch
Breaker
A – Socket wire to breaker or on/off switch.
Wire Length will determine connection point.
B – Ground
C – Socket wire to breaker or on/off switch.
Wire Length will determine connection point.
D – On/Off switch to motor control board.
E – On/Off switch to motor control board.
F – On/Off switch to breaker.
Note: Wires A & C are interchangeable.
2008 AFG Service Seminar [rev 1.3] | 29
Section Two | Resetting The Incline Motor
>> Resetting the Incline Motor after replacing the Motor Control Board
Tools Required:
• Philips Screwdriver
• 17mm Socket
• 17mm Combination Wrench
Procedure:
1 | Turn off power to the treadmill and unplug power cord from wall outlet.
2 | Replace the Motor Control Board.
3 | Fold treadmill into locked position.
4 | Undo bolt that attaches the elevation tube to the bottom of the machine (F1)
F2
F1
17 mm Nut
17 mm Bolt
Proper Zero
Shaft Position
5 | Power up the machine and let the incline spin freely in the tube until it reaches its “zero” position,
and then turn power off.
6 | Spin shaft manually until it is almost flush with the incline motor casing and only about 1 thread is
visible (F2).
7 | Reinsert bolt and power up the machine.
8 | Test the incline function and calibrate the unit.
30 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Adjusting the Magnetic Break
>> Adjusting the Magnetic Break
Tools Required:
• Phillips Screwdriver
• 8mm, 13mm, 17mm Socket and Combination Wrenches
• 5mm Allen Wrench
• Crank Puller
Procedure:
1 | Turn on unit and Press start.
2 | Set resistance highest level and power off unit.
3 | Remove side covers.
4 | Loosen the short nut (A), and adjust the long nut (B) clockwise to reduce the brake resistance and counterclockwise to increase the brake resistance.
The correct position for the flywheel/brake assembly is 1-2 mm from the flywheel at the
highest resistance level.
A
B
2008 AFG Service Seminar [rev 1.3] | 31
Section Two | Voltage Checks
>> No Motor Movement Voltage Checkpoints
Upper Board Checkpoints
Procedures:
Using a dc volt meter (if non-auto ranging set for the 20vdc range), test the voltage at the grey and again at the
white console cable connections using the yellow, orange or red wires as ground. Two tests are to be performed;
test once with power on before the treadmill is started and again after Start is pressed.
Desired Results:
The voltage charts contain typical desired results on a fully functional system. A variance from the norm would
indicate a defective component.
Checkpoint
Console Cable Grey to Yellow (Gnd)
Voltage Before Start
0.0 vdc
Console Cable White to Yellow (Gnd)
4.3 +/- .3 vdc
Volatge After Start
0.3 +/- .3 vdc, increases as speed increases.
(as shown on console)
0.0 vdc
Lower Board Checkpoints
Console Cable Connection
Procedures:
Using a dc volt meter (if non-auto ranging set for the 20vdc range), test the voltage at the grey and again at the
white console cable connections using the yellow, orange or red wires as ground. Two tests are to be performed;
test once with power on before the treadmill is started and again after Start is pressed. Note: this is the same
procedure as the upper board console cable connection. If results vary from the upper board, the console cable is
the likely cause and a continuity check should be performed.
Desired Results:
The voltage charts contain typical desired results on a fully functional system. A variance from the norm would
indicate a defective component.
Checkpoint
Console Cable Grey to Yellow (Gnd)
Voltage Before Start
0.0 vdc
Volatge After Start
0.3 vdc, increases as speed increases.
(as shown on console)
Console Cable White to Yellow (Gnd) 4.3 vdc
0.0 vdc
Note: 2.75 Hp motors and higher: the reading on the console cable -white to yellow (gnd) is 1.6 + or - .3vdc
Digital Speed Sensor Connection
Procedures:
Using a dc volt meter (if non-auto ranging set for the 20vdc range); test the voltage at the red wire and again at
the yellow wire using the blue, black or black as ground. The yellow wire should be measure twice, once with the
optic speed sensor obstructed and once not obstructed.This can be done by slowly turning the motor and aligning
the tines or open spaces of the optic disk with the sensor.
Desired Results:
The voltage charts contain typical desired results on a fully functional system. A variance from the norm would
indicate a defective component.
Checkpoint
Yellow Digital Speed Sensor
Red Digital Speed Sensor
32 | 2008 AFG Service Seminar [rev 1.3]
Voltage With Sensor
Obstructed
5.0 +/- 0.4 vdc
5.0 +/- 0.4 vdc
Volatge With Sensor Not Obstructed
0.3 vdc
5.0 +/- 0.4 vdc
Section Two | Voltage Checks
>> No Motor Movement Voltage Checkpoints Continued
Drive Motor Connection
Procedures:
Using a dc volt meter (if non-auto ranging set for the 200vdc range), test the voltage at the red and black motor
leads with the motor still attached.
Note: This should be tested after the console cable and optic sensor points because they can give the same
results as a defective lower board.
Note: A non-functional system may still have a voltage present with no motor attached. For accurate results, the
motor must be attached when the voltage is checked.
Desired Results:
The voltage charts contain typical desired results on a fully functional system. A variance from the norm would
indicate a defective component.
Checkpoint
Voltage Before Start
Across Motor Out, 0.0-22.5 vdc
No Motor
Attached
Across Motor Out, 0.0 vdc
W/ Motor
Attached
Voltage After Start @
0.5mph
0.0-22.5 vdc
Volatge After Start @ 10.0mph
2.5- 0 vdc
80-100.0 vdc
0.0-22.5 vdc
Drive Motor Checkpoints
Procedures:
Unplug the motor from the lower board. Using a dc volt meter (if non-auto ranging set for the 20vdc range), attach
volt meter leads directly into the motor leads and turn the running belt.
Desired Results:
The motor should generate 5-15 vdc depending on the speed it is turned.
Procedures:
Unplug the motor from the lower board. Using an ohm meter (if non-auto ranging set for the 200 ohm range),
attach ohm meter leads directly into the motor leads.
Desired Results:
The motor should read approximately 1.0-1.5 ohms.
2008 AFG Service Seminar [rev 1.3] | 33
Section Two | Voltage Checks
>> Motor Voltage Check | Spin motor flywheel to produce voltage
1.20
V DC
>> AC Wire Voltage Check
7"$
"$8JSFT
34 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Voltage Checks
>> Console Cable Voltage Check
V DC
GND
GND
M
VD
P
Mo
Dow
UP
To check the voltage of a specific function (i.e. elevation, motor control, etc), place the negative lead of
your multi-meter on pin B3, B4 or B5, and place the positive lead on the desired pin. Follow the voltage
charts on p37 (12pin) and p36 (9pin).
Note | 1: Wire colors are subject to change.
Note | 2: It may be necessary to remove the glue from the console cable to access the pins.
>> Speaker Amp Board Voltage
wer
Acepo
CON2
D12
JOHNSON
Voltage In
Voltage Out
120v
12v
2008 AFG Service Seminar [rev 1.3] | 35
Section Two | Voltage Checks
>> 9 Wire Console Cable Voltage Chart (DC Volts)
Polarity tab will face User
P1:
Up
P1: Incline
Incline Up
P2: Incline
Down
Incline Down
P3:
P3: GND
GND
P4: Power
Voltage
(to UCB)
Power Voltage
(to UCB)
P5: Drive
Drive Motor
Relay
P5:
Motor
Relay
Stop
P6: Stop
P7: Incline
Incline Pot/VREF+
P7:
Pot | VREF+
P8:
VCC | ELE
P8: Incline
Incline VCC/ELE
RPM
P9: RPM
Polarity tab will face
Polarity tab will face User
User
Wire
Color
Function
Console Cable Voltage
no wires cut
Voltage at UCB
after wire’s cut
Voltage at MCB
after wire’s cut
Physical Symptoms-If Wire Cut
1
Red
Incline Up
0.0 vdc before started, +1.9
vdc while inclining, 0.0 vdc
while declining. Voltage
constant while inclining/
declining.
2.5 vdc b/f start,
5.0 vdc after start.
3.7 vdc b/f start,
0.0 vdc after start.
Incline motor will go up but not down.
2
Brown
Incline Down
0.0 vdc before started, 0.0
vdc while inclining, +1.9
vdc while declining. Voltage
constant while inclining/
declining.
2.5 vdc b/f start,
0.8 vdc after start.
0.0 vdc b/f start,
0.1 vdc after start.
Incline motor will go down but not up.
3
Orange
GND
n/a ground
0.0 vdc
0.0 vdc
4
Yellow
Power
Voltage (to
UCB)
+15 vdc constant range.
0.0 vdc
14.55 vdc
Console will not turn on.
5
Green
Drive Motor
Relay
+1.6 vdc before started, 0.0
vdc after started.
1.4 vdc b/f start
0.8 vdc after start
0.0 vdc b/f start
1.4 vdc after start
No belt movement.
6
Blue
Stop
Constantr 0.53 vdc-0.69
vdc 3.6 vdcwhen the safety
key is removed. Will remain
at 3.6 vdc untill Start is
pressed.
5.0 vdc safe off
1.3 vdc safe on
1.7 vdc running
1.9 vdc paused
16.6 vdc safe off
0.0 vdc safe on
and running
No physical symptoms were noticed when
this wire was removed.
7
Purple
Incline Pot/
VREF+
+2.5 vdc at 0.0% incline,
+0.5 vdc at max incline.
Voltage changes with each
change in incline.
2.5 vdc
3.7 vdc b/f start,
5.0 vdc after start.
If the incline is changed from 0.0%, the
motor will move constant up untill the incline on the console is returned to 0.0%. it
will then stop in place and NOT go down.
8
Grey
Incline VCC/
ELE
+2.5 vdc constant.
3.8 vdc b/f start
4.8 vdc after start
2.5 vdc
Incline constant up as soon as start is
pressed. Incline will work in Hardware
test.
9
White
RPM
When the speed sensor is
aligned to the magnet; short,
0.0vdc. When the speed
sensor is not aligned: open,
+5.0 vdc.
5.0 vdc
0.0 vdc
Console will use default PWM value or
auto-cal values. Will not auto-cal, will not
show speed in Hardware Test.
Console will not turn on.
Note: Wire colors are subject to change.
36 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Voltage Checks
>> 12 Wire Console Cable Voltage Chart (DC Volts)
B1:
VCC
B1: Incline
Incline VCC
B2:
POT
B2: Incline
Incline Pot
B3:
GND
B3: Incline
Incline GND
B4: Digital
Digital GND
B4:
GND
B5: Digital
Digital GND
B5:
GND
B6: RPM
RPM
B6:
B7: Power
Power Voltage
(to UCB)
B7:
Voltage
(to UCB)
B8:
Voltage
(to UCB)
B8: Power
Power Voltage
(to UCB)
B9:
Command
(PWM)
B9: Speed
Speed Command
(PWM)
B10: Drive
Motor
RelayRelay
B10:
Drive
Motor
B11: Incline
Down
B11:
Incline
Down
B12: Incline
UpUp
B12:
Incline
Wire
Color
Function
Console Cable
Voltage
no wires cut
Voltage at
UCB
no wires cut
Voltage at MCB
after wire’s cut
Physical Symptoms-If Wire Cut
1
Black
Incline VCC
2.5 vdc
0.0 vdc
2.5 vdc
After Start pressed constant down incline, down LED
constant on. In Hardware Test the motor moves down
but not up, value always at maximum.
2
Brown
Incline Pot
2.5 vdc at 0.0% incline,
0.5 vdc at max incline.
Voltage changes with
each change in incline.
2.5 vdc
0.0 vdc
After Start pressed constant down incline, down LED
constant on. In Hardware Test the motor moves down
but not up, value always at maximum.
3
Red
Incline
GND
n/a ground
2.5 vdc, grounded
at MCB not UCB.
0.0 vdc, grounded at
MCB not UCB.
Constant up incline. In Hardware Test, motor moves
up and down. Incline value started low and went
down to 0 but not up past 10. Value changes very
slowly.
4
Orange
Digital
GND
n/a ground
0.0 vdc
0.0 vdc
5
Yellow
Digital
GND
n/a ground
0.0 vdc
0.0 vdc
If one removed, no issues. If both removed: UCB does
not turn on. Both incline lights are on and incline motor hums and gets hot quickly. See below for voltage
chart if both grounds removed.
6
Green
RPM
When speed sensor
aligned to
magnet: short, 0.0vdc.
When sensor not
aligned:open,5.0 vdc
5.0 vdc
0.0 vdc
Everything works in normal mode but the console
does not register a speed in Hardware Test or Auto
Calibration
7
Blue
15 vdc constant
Range=15 to 17 vdc
0.0 vdc
17 vdc
8
Purple
Power
Voltage
(to UCB)
15 vdc constant
Range=15 to 17 vdc
0.0 vdc
17 vdc
If one removed, no issues. If both removed: UCB does
not turn on. At UCB green measures 0.46 vdc, white
1.4 vdc, all others 0.0 vdc.
9
Grey
Speed
Command
(PWM)
0.0 vdc before started,
0.5 vdc at 0.5 mph, 4
vdc at 10 mph. Voltage changes as speed
changes.
“0.0 vdc b/f start
0.36vdc aft start
increases as
console speed
increased”
“0.8 vdc b/f start
0.7 vdc aft start no
change as console
speed increased”
No belt movement, MCB relay clicks. LCD 1 lights.
When measuring MCB voltage, there is a slight belt
movement, then stops
10
White
Drive Motor
Relay
4.3 vdc before started
0.0 vdc after started
“5.0 vdc b/f start
0.0 vdc aft start”
“1.4 vdc b/f start
1.4 vdc aft start”
No belt movement, no click from MCB relay. LED 1
does not light.
11
Pink
Incline
Down
0.0 vdc before started,
0.0 vdc while inclining,
1.9 vdc while declining.
Voltage constant while
inclining/declining.
“0.0 vdc b/f start
5.0 vdc if press
incline down”
0.0 vdc
Up incline functions, no down incline, LED’s function
for up, not for down. If incline then decline, motor
does not move again until past incline point. Ex. If incline to 2.0 % then back down to 0%, the motor will not
move until 2.5 %. In Hardware Test, on;ly up incline,
value increases, does not decrease.
12
Light
Blue
Incline Up
0.0 vdc before started,
1.9 vdc while inclining,
0.0 vdc while declining.
“0.0 vdc if at 0%
5.0 vdc if not at
0% or at console
height”
0.0 vdc
Down incline functions, no up incline, LED’s function
for down but not up. In Hardware Test, down incline
functions until value at 0, no up incline. Similar phenomenon to cut Pink wire if incline stopped not at 0%.
Note: Wire colors are subject to change.
2008 AFG Service Seminar [rev 1.3] | 37
Section Two | Voltage Checks
>> Incline Wire Voltage Chart
Small Connector
Wire
Color
Blue
Function
Ground
Before Start
At 0.0%
At 10%
Physical
Symptoms-If Wire
Cut
ENG 1 Test Results
n/a Ground
n/a Ground
n/a Ground
Constant up incline,
no down incline.
Incline value 0, no down incline.
0.6 vdc*
Constant down incline, no up incline.
Incline value at max, no up
incline.
Constant down incline, no up incline.
Incline value started one less
than max, pressed up once and
value maxed out, thereafter no
up incline.
Brown
Incline Pot
2.3 vdc*
0.6 vdc*
Orange
VCC
2.4 vdc
constant
2.4 vdc constant 2.4 vdc constant
* The voltage changes as the incline changes
Large Quick Connects
Wire
Color
Function Before
Start
After Start,
Not Inclining
Or
Declining
While
Inclining
While
Declining
Physical
Symptoms-If Wire
Cut
Black
w/white
as
ground
Incline Up
0.15 vac
0.15 vac
171 vac
120 vac
Up incline works, no down
incline.
Up incline works, down does not.
Value increases, does not decrease.
Red
w/white
as
ground
Incline
Down
0.15 vac
0.15 vac
120 vac
186 vac
Down incline works, no up
incline.
Down incline works (until value 0), up
does not. Value decreases to 0 then
no down incline, does not increase.
Red
w/black
as
ground
Ground
0.03 vac
0.03 vac
219 vac
228 vac
Neither up nor down function.
Neither up nor down function. Value
does not change.
Parameter: Use functioning incline motor and remove one wire at a time to observe malfunction
38 | 2008 AFG Service Seminar [rev 1.3]
ENG 1 Test Results
Section Two | Voltage Checks
>> Elliptical Incline Motor Voltage Checks
DC
Wire Color
Function
Voltage at Zero
Voltage
w/ Increase
Voltage
w/ Decrease
Physical Symptoms-If Wire Cut
1
Brown
Voltage in
(VCC)
5V
5V
5V
Normal: After start and pressing incline up and down
value is displayed, but there is no incline function.
Eng4: When pressing incline up no motor movement,
Incline - functions normally
2
Orange
POT Sensor
(ADC)
4.2V
Deacreases to 1.7V
Increases to 4.2V
Normal: After pressing incline- no incline movement.
Eng4: Incline + functions normal, no movement with
incline - .
3
Blue
Ground
n/a
n/a
n/a
Normal: Upon start-up incline continuously goes
down. Eng4: When pressing up incline does not go up
distance value flickers at max value.
AC
Wire Color
Function
Voltage at Zero
Voltage
w/ Increase
Voltage
w/ Decrease
Physical Symptoms-If Wire Cut
1
Black
Incline Up
0-1 VAC
171 VAC
120 VAC
Normal: No incline function and value is displayed
Eng4: Incline + functions normal, no movement with
incline - .
2
Red
Incline Down
0-1 VAC
120 VAC
172 VAC
Normal: Incline is at a constant down upon start-up.
Eng4: Operates normal, value at max
3
White
NC
n/a
n/a
n/a
Normal: after pressing start and incline up and down
no incline movement. Eng4: no incline movement,
value does not change.
2008 AFG Service Seminar [rev 1.3] | 39
Section Two | Voltage Checks
>> Elliptical | Bike Resistance Motor Voltage Checks
Wire
Color
1 Red
2.0AE | 2.0AR | 3.0AR | 4.0AR |3.0AH | 4.0AH
Function
Voltage | Ohm
Readings
Voltage
w/ Increase
Voltage
w/ Decrease
Physical Symptoms-If Wire Cut
Power to
DC Motor
I.C. Board.
+5vdc
5V
5V
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressingn resistance- motor stops, but does not
zero itself. Eng1:Motor operates but no change
in motor count
2 Black
Ground
-From
Motor
n/a ground
n/a
n/a
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor stops and does not
zero. Eng1:Motor operates but no change in
motor count.
3 Brown
Optic
Count
-from
motor
5vdc
180mV
180mV
5V
180mV
180mV
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor zeros itself. Eng1:
Motor operates but no change in
motor count.
Normal: After pressing start and
resistance + motor constantly rotates. If
pressing resistance - motor zeros
itself. Eng1: No motor movement .
Value is displayed and does not change when
pressing resistance +/-.
4 Orange Zero
Switch
Sensor
5 Green
Power to
12mV
Resistance
up
8.5-9.7v
110mV
Normal: After pressing start and resistance+
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
6 White
Power to
12mV
Resistance
down
120mV
8.5-9.7v
Normal: After pressing start and resistance up
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
Note: Wire colors are subject to change.
40 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Voltage Checks
>> Elliptical Resistance Motor Cable Voltage Checks
Wire
Color
1 Red
3.0AE | 4.0AE | 14.0AE | 18.0AE
Function
Voltage | Ohm
Readings
Voltage
w/ Increase
Voltage
w/ Decrease
Physical Symptoms-If Wire Cut
Power to
DC Motor
I.C. Board.
+5vdc
5V
5V
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor stops, but does not
zero itself. Eng1:Motor operates but no change
in motor count
2 Black
Ground
-From
Motor
n/a ground
n/a
n/a
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor stops and does not
zero. Eng1:Motor operates but no change in
motor count.
3 Brown
Optic
Count
-from
motor
5.0vdc
0.0vdc
0.0vdc
5V
0.0vdc
0.0vdc
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor zeros itself. Eng1:
Motor operates but no change in
motor count.
Normal: After pressing start and
resistance + motor constantly rotates. If
pressing resistance - motor zeros itself.
Eng1: No motor movement .
Value is displayed and does not change when
pressing resistance +/-.
4 Orange Zero
Switch
Sensor
5 Green
Power to
0.0-0.4vdc
Resistance
up
8.5-9.7vdc
0.6-2.0vdc
Normal: After pressing start and resistance+
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
6 White
Power to
0.0-0.4vdc
Resistance
down
8.5-9.7vdc
0.6-2.0vdc
Normal: After pressing start and resistance up
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
Note: Wire colors are subject to change.
2008 AFG Service Seminar [rev 1.3] | 41
Section Two | Voltage Checks
>> 10 Wire Elliptical Console Cable Voltage Chart (DC Volts)
Wire Color
Function
Voltage | Ohm Readings
Physical Symptoms-If Wire Cut
1
Purple Ground from n/a ground
RPM sensor
Normal: No speed/ rpm readings.Eng1 No rpm
readings.
2
Black
Ground from n/a ground
motor
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor stops and does not
zero. Eng1:Motor operates but no change in
motor count.
3
Orange
Zero switch
sensor
4
Brown Optic count
from motor
5
Green Power to
resistance
up
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor stops and does not
zero. Eng1: Motor operates but no change in
motor count.
Normal: After pressing start and resistance+
motor continues to rotate upward during
pressing resistance- motor zeros itself. Eng1:
Motor operates but no change in motor count.
Normal: After pressing start and resistance up
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
Normal: After pressing start and resistance up
value is displayed and there is no motor
movement.Eng1: No motor movement and
motor count does not change.
Normal: No speed/ rpm readings.Eng1 No rpm
readings.
6
7
8
9
10
If zero switch engaged
(lowest resistance level)
+5.0vdc, open. Any other
resistance position: 0.0vdc,
short.
+5.0vdc. Ifslot in optic disk
aligned with sensor, 0.0vdc
+0.0 to 0.4vdc if motor idle.
+8.5vdc if resistance
increasing. +0.6 to 2.0vdc if
resistance increasing.
White power to
+0.0 to 0.4vdc if motoridle.
resistance
+8.5vdc if resistance
down
decreasing +0.6 to 2.0vdc if
resistance increasing.
Yellow RPM sensor If magnet aligned with rpm
sensor: 0.0vdc, short. If
magnet not aligned withrpm
sensor: 5.0vdc, open.
Grey Power to
Dependent upon power
No power to console
console from supply.
power supply
Blue
Ground from n/a ground
No power to console
power supply
Red
Power to
+5.0vdc
Normal: After pressing start and resistance+
DC motor
motor continues to rotate upward during
i.c.board
pressing resistance- motor stops, but does not
zero itself. Eng1:Motor operates but no change
in motor count.
Note: Wire colors are subject to change.
42 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Voltage Checks
>> Elliptical Incline Console Cable Voltage Check
Wire Color
1
Function
Voltage | Ohm Readings
White/ Power
Orange
Orange Power
12.6VDC
3
White/
Green
Signal
Receive
4
Blue
Signal
Send
5
White/
Blue
Signal
Receive
6
Green
Signal
Send
7
White/
Brown
Brown
Ground
Receives signals from incline
motor, and resistance
motor and RPM. 5V
Receives signals from incline
motor, and resistance
motor. 0 to .1V before Start | .1
to .2V after start.
Receives signals from inclinemotor, resistance motor
and RPM. 5V
Sends signals to incline motor
and resistance motor. 0 to .1V
before Start | .1 to .2V after
Start.
n/a Ground
Ground
n/a ground
2
8
12.6VDC
Physical Symptoms-If Wire Cut
If both wires are cut, the console will have no
power.
If both wires are cut, the console will have no
power.
Will give “Connect” error if cut - on select
models.
If cut there will be no incline or resistance
movement, and no RPM reading.
Will give “Connect” error if cut - on select
models.
If cut there will be no incline or resistance
movement, and no RPM reading.
If both wires are cut, the console will have no
power.
If both wires are cut, the console will have no
power.
Note: Wire colors are subject to change.
2008 AFG Service Seminar [rev 1.3] | 43
Section Two | Engineering Mode
Engineering Mode
>> Treadmills
Note: At Any time, Press and hold the STOP button to exit the engineering menu.
1 | Turn the treadmill power to ON.
2 | Place the safety key in position on the console.
3 | Simultaneously press and hold (for about three seconds) the incline “+” (s) and speed “-” (t) buttons.
4 | The console should beep three times and ENG0 (EN90) should be displayed in the time window, “ENGINEERING MENU” scrolls in matrix or is static in the text box.
Note: To navigate through the engineering menu, use the incline “+” (s) and speed “-” (t) buttons.
Display | Button Test (Eng0)
Switch Function (Eng3)
Eng0 appears in the time window.
DISPLAY TEST will scroll in the matrix or will be static in
text box.
Eng3 appears in the time window.
SWITCH FUNCTION will scroll in the matrix or will be
static in text box.
Press ENTER to select.
Press ENTER to select .
When selected each display segment should be lit up.
If the treadmill has a Demo Mode then:
When pressed each button should have a unique display
-The brickyard will scroll “DEMO ON” or “DEMO OFF”.
change.
-Default will be “DEMO ON”.
-Stop button turns off all lights.
-The “+” (s) or “-” (t) buttons will change the Demo on/off
-Start button turns all lights on.
settings.
Hardware Test (Eng1)
Start Selects miles or km.
Eng0 appears in the time window.
-The display will show “0” for miles or “1” for km.
HARDWARE TEST will scroll in the matrix or will be static
-The display will scroll “MILES” OR “KM” when Start is
in text box.
pressed to change.
Press ENTER to select .
-The new setting is automatically saved when Start is
Press START to begin.
pressed, no other buttons need to be pressed to save.
-Speed “+” (s) or “-” (t) will change the speed.
Information (Eng4)
-Speed quick keys will change the speed.
Preset to be within 20%.
Eng4 appears in the time window.
-Incline “+” (s) or “-” (t) will change the incline.
INFORMATION will scroll in the matrix or will be static in
-Quick incline keys will beep but do not function.
text box.
-Incline motor will stop at minimum or maximum incline (not Press ENTER to select .
continue to move) if “+” ((s)or “-” (t) is held.
Auto Calibrate (Eng2)
ACCUMULATED will scroll in matrix.
Time window will show accumulated time.
Eng2 appears in the time window.
AUTO CALIBRATE will scroll in the matrix or will be static Distance window will show accumulated distance.
If Time and Distance are in the same window, the time will
in text box.
show F00 and the distance will show F01. Press“+” (s) or “-”
Press ENTER to select .
(t) to change.
Press START to begin.
If console has an accumulated reset function, hold Start for
-There should be no excessive speed overshoot.
5
seconds to reset. This will not apply to most models.
-The engineering menu will be exited upon successful
completion of the auto calibration.
Note: The auto calibration process takes about two minutes to complete.
44 | 2008 AFG Service Seminar [rev 1.3]
Section Two | Engineering Mode
Engineering Mode
>> Ellipticals | Bikes
Note: At Any time, Press and hold the STOP button to exit the engineering menu.
Entering the Engineering Mode
1 | Turn the elliptical power to ON.
2 | Simultaneously press and hold (for about three seconds) the resistance “+” (s) and “-” (t) buttons.
3 | The console should beep two times and ENG0 (EN90) should be displayed in the time window, “ENGINEERING MENU” scrolls in matrix or is static in the text box.
Note: To navigate through the engineering menu, use the resistance and/or the incline “+” (s) or “-” (t) buttons.
Display Test (Eng0)
Information (Eng3)
Eng0 appears in the time window.
DISPLAY TEST will scroll in the matrix or will be static in text
box.
Eng3 appears in the time window.
INFORMATION will scroll in the matrix or will be static in text
box.
Press ENTER to select.
Press ENTER to select.
When selected each display segment should be lit up.
When pressed each button should have a unique display change.
-Stop button turns off all lights.
-Start button turns all lights on.
Hardware Test (Eng1)
Eng0 appears in the time window.
HARDWARE TEST will scroll in the matrix or will be static in
text box.
Press ENTER to select.
-Resistance “+” (s) or “-” (t) will change the resistance.
-Incline “+” (s) or “-” (t) will change the incline.
-Quick incline keys will beep but do not function.
-Incline motor will stop at minimum or maximum incline (not
continue to move) if “+” (s) or “-” (t) is held.
Switch Function (Eng2)
ACCUMULATED will scroll in matrix.
-Time window will show accumulated time.
-Distance window will show accumulated distance.
-If Time and Distance are in the same window, the time will
show F00 and the distance will show F01. Press“+” (s) or “-” (t)
to change.
Note: If console has an accumulated reset function, hold Start
for 5 seconds to reset. This will not apply to most
models.
Incline Test (Eng4)
Eng4 appears in the time window.
INCLINE TEST will scroll in the matrix or will be static in text
box.
Press ENTER to select.
Eng2 appears in the time window.
Note: This menu is only for incline ellipticals. All other bikes and
SWITCH FUNCTION will scroll in the matrix or will be static in
ellipticals will not have this menu.
text box.
Press ENTER to select.
-MIN ADC will how in the text box. The ADC value will be the
current height.
If the treadmill has a Demo Mode then:
-Change the value with the incline “+” (s) or “-” (t). Range=
-The brickyard will scroll “DEMO ON” or “DEMO OFF”.
100-250. Press Enter to save the value. If the value is out of range
-Default will be “DEMO ON”.
then OUT OF RANGE will show and the value will not be saved.
-The “+” (s) or “-” (t) buttons will change the Demo on/off
-ADC IS SAVED will show for three seconds if the value is in
settings.
range.
-Press resistance “+” (s) to change the Max.
Start Selects miles or km.
-MAX ADC will show in the text box. The ADC value will show
-The display will show “0” for miles or “1” for km.
the current height.
-The display will scroll “MILES” OR “KM” when Start is pressed
-Change the value with the incline “+” (s) or “-” (t).
to change.
Range=550-750. Press enter to save the value. If the value is out
-The new setting is automatically saved when Start is pressed,
of range, OUT OF RANGE will show and the value will not be
no other buttons need to be pressed to save.
saved.
-Enter changes the ep/bi setting. Display will show EP for ellipti-ADC IS SAVED will show for three seconds if the value is in
cal and BI for bike.
range.
-The new setting is automatically saved when Enter is pressed,
-Press resistance “-” (t). to change the Min.
no other buttons need to be pressed to save.
2008 AFG Service Seminar [rev 1.3] | 45
Table of Contents
>> Section Three
Troubleshooting
-Treadmill
-Elliptical | Bike
-Gym
Known Issues
-Treadmill
-Elliptical | Bike
46 | 2008 AFG Service Seminar [rev 1.3]
50
61
69
71
73
Table of Contents
Treadmill Troubleshooting
Failed Auto Calibration
Console | Upper Board
Membrane | Keypad | Overlay
Safety Key | Reed Switch
Heart Rate
Erratic Speed
Elevation
No Motor Movement
Circuit Breaker
Noise
48
49
51
52
53
54
56
57
58
59
2008 AFG Service Seminar [rev 1.3] | 47
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Failed Auto Calibration
Symptom
Possible Cause
Failed Auto Calibration
– Belt runs for a few
seconds and then stops
and E1 message on
console.
Failed RPM sensor.
Test Procedure
Repair
-Put machine into Eng1
(Reference p44) and
check for slight
fluctuation of speed in
speed window of
display. (Speed should
not fluctuate more than
a few hundredths.)
RPM sensor misaligned. -Adjust sensor bracket
to correct position.
Magnet missing in front
roller pulley.
Replace RPM sensor.
Failed console cable.
Replace console cable.
Failed Auto Calibration
– Belt never runs and E1
message on console.
Failed Auto
RPM sensor not aligned
Calibration – Board
properly or has failed.
never sets speeds. Belt
will
continue to run and not
stop.
Failed motor control
board (MCB).
48 | 2008 AFG Service Seminar [rev 1.3]
-Check voltage and
continuity of console
cable. Reference p35.
- Verify positioning of
sensor wire. (Wire
coming from RPM
sensor points toward the
front of the unit, sensor
is as close as possible to
the magnet in the pulley
without touching, and
the sensor bracket
90-degree angle, not
bent in any way.)
- Put machine into Eng1
(Reference p44) and
check for slight
fluctuation of speed in
speed window of
display. (Speed should
not fluctuate more than
a few hundredths.)
Replace magnet.
See troubleshooting for
no motor movement.
Reference p57.
Replace RPM sensor.
Replace MCB.
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Console | Upper Board
Symptom
Possible Cause
No display on the console and the power
switch is dark.
Circuit breaker in home
has tripped.
No display on the console and power switch
on machine is lit.
Test Procedure
Repair
-Check for dedicated
circuit (20 amp is ideal)
and check wall outlet
voltage (120 VAC).
Reference p26.
Failed power switch.
-Make sure power
switch is turned on.
Failed power cord.
-Take voltage check of
power cord.
Reference p25.
Breaker on machine has -Reset breaker.
tripped or has failed.
Reset breaker.
Improper wiring or AC
wires have failed.
Connect wires correctly
or replace as needed.
Failed console cable.
Failed upper board.
Failed motor control
board. (MCB)
-Check all wiring
coming in from the
power switch to the
motor control board and
to the upper board.
Reference p29.
-Check console cable
voltages at B7, B8
Reference p35.
-Check voltage and
continuity of console
cable. Reference p35.
-Check voltage and
continuity of console
cable. Reference p35.
-Verify the power LED is
lit on the MCB.
Replace power switch if
necessary.
Replace power cord.
Replace breaker if
necessary.
Replace console cable.
Replace upper board.
Replace motor control
board
2008 AFG Service Seminar [rev 1.3] | 49
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Console | Upper Board Continued
Symptom
Possible Cause
Test Procedure
Repair
Running belt stops and
console resets during
workout.
Safety key or reed
switch is positioned
incorrectly or Safety key
is damaged.
-Verify that the safety
key is in position and
that it is secure.
-Manually adjust the
position of the reed
switch trigger and/or
the plastic tab on the
console shell. (Slot style
safety key only.)
-Check for dedicated
circuit (20 amp is ideal).
and check wall outlet
voltage (120 VAC).
Reference p25.
-Make sure machine is
not on extension cord or
surge protector.
- Replace safety key.
- If plastic tab is broken
replace console shell.
(Slot style safety key
only.)
Inadequate power.
Damaged or improper
wiring.
Inadequate lubrication
on deck and running
belt.
Membrane keys.
50 | 2008 AFG Service Seminar [rev 1.3]
If the AC voltage is
missing or incorrect,
check the AC service or
consult an electrician.
-Verify there are no
Replace parts as
pinches or cuts in the
needed.
power cord, power wires
motor wires, or console
cable.
-Verify the connections
of above wires and
cords.
-Place hand underneath
running belt and feel for
adequate silicone
application.
Reference Membrane
Troubleshooting p51.
Apply silicone.
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Membrane | Key Pad | Overlay
Symptom
Possible Cause
Test Procedure
All or some of the keys
on the console will not
work.
Ribbon cables
connecting the
membrane keypad to
upper board are not
seated properly or are
disconnected.
-Verify the ribbon cables Remove and reseat
are connected securely cables.
into the upper board.
Membrane keypad
defective.
-Keys are pressed, some Replace membrane
of the buttons may
keypad.
function but there are
no corresponding beeps.
-Put in Eng0 to chech
button function.
Reference p44.
-Keys are pressed and
Replace upper board.
there are corresponding
beeps, but console does
not respond.
(Sometimes the key
will not beep until it is
released).
Upper board defective.
Unit starts as soon as
safety key is in place or
console will reset itself
after a few seconds of
use.
Membrane keypad
defective.
-Massage buttons on
keypad to make sure
that none are stuck.
-Remove overlay and
press keypad for proper
function.
-Put in Eng0 to chech
button function.
Reference p44.
Repair
Replace membrane
keypad.
2008 AFG Service Seminar [rev 1.3] | 51
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Safety Key | Reed Switch
Symptom
Possible Cause
Test Procedure
Repair
Console only displays
dashes or ‘Safety Key
Off’ in the display
window – Magnet style
key.
Safety key is positioned
incorrectly or has failed.
Replace safety key.
Safety key will only
register if moved
outside of the proper
position.
Improperly aligned
reedswitch.
-Remove safety key and
reapply.
-Test magnet.
-Short the switch
connector on the upper
board by using a flat
blade screwdriver or by
placing a jumper switch
on the
connector.
Remove glue from
reedswitch and
reposition.
Failed reed switch
or failed uper control
board.
52 | 2008 AFG Service Seminar [rev 1.3]
If the upper board still
displays dashes then
replace upper board.
Otherwise replace
reedswitch.
Test for proper function
and glue into place.
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Heart Rate
Symptom
Possible Cause
Test Procedure
Heart rate erratic.
User error.
Reference Proper Heart
Rate Usage p23.
Reference Proper Heart
Rate Usage p23.
Failed heart rate
receiver.
Failed upper board.
No heart rate function.
(Hand Grips)
Failed heart rate grips.
Heart rate erratic.
User error.
Electromagnetic
interference.
No heart rate function.
(Telemetric chest strap)
Failed telemetric chest
strap or polar receiver.
Reference Proper Heart
Rate Usage p23.
Reference Proper Heart
Rate Usage p23.
Reference Proper Heart
Rate Usage p23.
Check immediate area
for causes of
interference (Florescent
lighting, electric dog
fences, large electric
motors, etc.)
Reference Proper Heart
Rate Usage p23.
Repair
If proper heart rate
instructions are followed
and heart rate continues
to be erratic, replace
heart rate receiver.
Replace upper board.
If there is absolutely no
heart response, replace
heart rate grips.
Remove interference
from vicinity of the unit.
Replace chest strap
and/or upper board.
2008 AFG Service Seminar [rev 1.3] | 53
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Erratic Speed
Symptom
Possible Cause
Test Procedure
Repair
Erratic speeds - Upon
pressing start, belt speed
increases rapidly for a few
second and then comes to
a complete stop.
Erratic speeds - Upon
pressing start, belt speed
increases rapidly and
does not stop.
Erratic speeds - Running
belt speed is not stable.
Failed optic sensor.
-Test voltage from Optic
Sensor. Reference p32.
Replace optic sensor.
Failed motor control
board (MCB).
Machine not calibrated
properly.
Inadequate power.
Replace MCB.
-Run auto calibration.
Reference Eng. Mode
p44.
If unit fails to auto
calibrate, refer to auto
calibration
troubleshooting.
Reference p48.
If the AC voltage is
missing or incorrect,
check the AC service or
consult an electrician.
-Check for dedicated
circuit (20 amp is ideal)
and check wall outlet
voltage (120 VAC).
Reference p25.
-Make sure machine is
not on extension cord,
surge protector or GFCI
circuit.
Failed or improper wiring. -Verify there are no
Replace parts as needed.
pinches or cuts in the
power cord, power wires,
motor wires, or console
cable.
-Verify the connections of
above wires and cords.
-Running belt is too loose -The running belt should Set proper drive belt and
or too tight.
not slip at all when
running belt tension.
-Drive belt is too loose or customer is using the
too tight.
machine. Reference Belt
Tensioning p19.
-The drive belt should
have approximately 3/8 of
inch deflection.
54 | 2008 AFG Service Seminar [rev 1.3]
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Erratic Speed Continued
Symptom
Possible Cause
Erratic speeds Running belt speed is
not stable. (Continued)
Inadequate lubrication on -Place hand underneath
deck and running belt.
running belt and feel for
adequate silicone
application. Reference
Maintenance p17.
Apply silicone.
Failed motor control
board (MCB).
In a program.
Replace MCB.
Erratic Speeds-belt
speed increases without
command, but shows
change on display and
beeps.
Stuck button.
Failed upper board.
Test Procedure
Repair
-Remove safety key,
then replace.
-Start in P1 and see if
reoccurs.
Reference membrane
keypad and overlay
troubleshooting p51.
Replace UCB.
2008 AFG Service Seminar [rev 1.3] | 55
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Elevation
It’s recommended to send console cables for elevation repairs on all models using
sectional console cables.
Symptom
Possible Cause
Elevation motor starts
Failed lower board.
running as soon as the power
is turned on. Constant down
or up..
Elevation motor bobs up and
down with out command.
Elevation motor does not
reach minimum or maximum
settings.
Failed elevation motor.
Elevation is stuck down and
does not function. Console
is responsive to the buttons
being pressed.
Failed console cable (CC).
-Failed elevation motor.
-Failed console cable (CC).
-Improperly calibrated
elevation motor.
Failed elevation motor.
Failed upper board.
Elevation is stuck at the
highest position and will
not come down. Console is
responsive to the buttons being pressed.
The incline will go up, but
not down. (very rare)
Failed upper board, lower
board, console cable, and
elevation motor.
Failed lower board.
56 | 2008 AFG Service Seminar [rev 1.3]
Test Procedure
Repair
-Turn on power. Do not press Replace lower board.
start. Wait 30-60 seconds and
see if motor is hot. Use
caution. Motor can get very
hot.
Replace elevation motor.
-Verify there are no pinches
or cuts on the elevation
wires. Reference CC
continuity p35.
-Verify the connections of
above wires.
-Verify console cable
connections. Verify there
are no pinches or cuts in the
cable. Reference CC
continuity p35.
-Put machine in hardware
test (Eng1) and press start.
Elevation doesn’t respond
when buttons are pressed.
(You may see a value for
elevation that reads 255 or
1023. That value will not
change when the buttons are
pressed).
Reference Eng. Mode p44.
-Put machine in hardware
test (Eng1) and press start.
Incline will work in hardware
test only.
Reference Eng. Mode p44.
-Verify all wire connections.
-Recalibrate elevation motor
by hand. Reference Resetting
the Incline Motor p30.
-Replace elevation motor.
Replace console cable.
Replace elevation motor.
Replace upper board.
Replace upper board, console
cable, and elevation motor.
-The incline will act normally Replace lower board.
when going up, bet when the
down incline is pressed there
is no movement.
Section Three | Troubleshooting
Treadmill Troubleshooting
>> No Motor Movement
Symptom
Possible Cause
Test Procedure
Repair
No Motor Movement
- Upon pressing start,
console responds
normally, keys respond
normally, and elevation
works but no belt
movement.
Inadequate power.
-Check for dedicated
circuit (20 amp is ideal)
and check wall outlet
voltage (120 VAC).
-Make sure machine is
not on extension cord or
surge protector or GFCI.
Reference p25.
-Verify there are no
pinches or cuts in the
power cord, power wires
motor wires, or console
cable.
-Verify console cable
continuity.
Reference p37.
-Verify the connections
of above wires and
cords.
-Verify power from
MCB.
Reference p32 and p33.
-Measure voltage output
from motor. Reference
motor, AC Wire Voltage
Check p34.
-Verify voltage of digital
sensor. Reference p32.
If the AC voltage is
missing or incorrect,
check the AC service or
consult an electrician.
Damaged or improper
wiring.
Failed motor control
board (MCB).
Failed drive motor.
Failed optic sensor.
Replace parts as
needed.
Replace MCB.
Replace drive motor.
Replace optic sensor.
2008 AFG Service Seminar [rev 1.3] | 57
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Circuit Breaker
Symptom
Possible Cause
Test Procedure
Repair
Machine will trip home
circuit breaker.
Inadequate power.
-Check for dedicated
circuit (20 amp is ideal)
and check wall outlet
voltage. (120 VAC).
Reference p25.
-Make sure machine is
not on extension cord,
surge protector or GFCI.
-Place hand underneath
running belt and feel for
adequate silicone
application.
-Feel underside of
running belt. It should
have a rough feel to it.
(similar to denim)
-Perform AMP draw test
on motor. Reference
AMP Draw, p26.
If the AC voltage is
missing or incorrect,
check the AC service or
consult an electrician.
Inadequate lubrication
on deck and running
belt.
Failed running belt.
Failed drive motor.
Machine breaker will
trip.
Failed motor control
board (MCB).
Failed circuit breaker.
58 | 2008 AFG Service Seminar [rev 1.3]
Apply Silicon
lubrication. Reference
Lubrication p18.
Replace running belt.
Replace drive motor.
Replace MCB.
Replace circuit breaker.
Section Three | Troubleshooting
Treadmill Troubleshooting
>> Noise
Symptom
Possible Cause
Test Procedure
Thumping sound when
running belt is
engaged.
New treadmill.
Let the treadmill run for
about 30 min. at 5mph
without a load to break
in new running belt in.
Failed roller.
Rubbing or grinding
sound from underneath
motor cover.
Misaligned drive belt.
Optic disk is hitting the
optic sensor/guard.
Failed drive motor
bearings.
Motor brushes are not
seated properly.
Banging or clunking
sound.
-Unit not level.
-Bent frame.
- Remove motor cover
and verify alignment of
drive belt.
- Inspect for debris on
drive motor pulley, front
roller pulley, or on drive
belt.
-Run unit and look for
optic sensor/disk
missalignment.
Inspect motor brushes
and commutator for
abnormal wear.
-Check levelers and the
floor.
-Inspect frame for
damage.
Repair
Replace front or rear
roller as needed.
Align drive belt and/or
replace drive belt.
Bend optic disk to
straighten or replace
optic disk.
Replace drive motor.
Replace motor brushes
and/or stone
commutator.
-Adjust levelers.
-Move unit to a level
surface.
-Place on rubber mat.
-Take photos of frame
damage and consult
AFG Customer Tech
Support. Reference the
number on the bak of
the manual.
2008 AFG Service Seminar [rev 1.3] | 59
Table of Contents
Elliptical | Bike
Troubleshooting
Noise | Drive Train
Console
Heart Rate
Resistance
Alignment Issues
60 | 2008 AFG Service Seminar [rev 1.3]
61
63
65
66
67
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Noise | Drive Train
Symptom
Possible Cause
Test Procedure
Repair
Noise internally while
pedaling at higher
resistance levels only.
Magnetic brake is
rubbing against the
flywheel.
-Verify the correct
position of magnetic
brake. Reference p31.
Noise internally/
externally while
pedaling or rough feel
while pedaling.
Machine may not be on
level surface.
Improper assembly or
loose assembly bolts.
-Verify surface is level.
Reposition the
magnetic brake.
Reference Adjusting the
Magnetic Break p31.
Adjust levelers on
machine.
Tighten all bolts used
for assembly. Reference
Maintenance p20.
Alignment issues with
pedal arms due to
improper assembly or
improper welds.
Build up on, or defective
roller wheels.
-Reference Alignment
Issues with Pedal Arms
Troubleshooting.
Reference p67.
-Wipe off roller wheels
Replace roller wheels.
and guide rails with
damp cloth.
- Check roller wheels
for any abnormal wear.
Roller wheels should
have smooth texture.
- If the rough feel seems
to be on one side only,
try switching suspect
roller wheel to opposite
pedal arm.
Tighten crank arms.
Noise may present itself Align drive belt and
multiple times during
adjust to proper tension
one pedaling motion.
or replace flywheel.
Loose crank arms.
Improper drive belt
alignment, improper
drive belt tension, or
failed flywheel.
-Verify assembly steps
using owner’s guide.
2008 AFG Service Seminar [rev 1.3] | 61
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Noise | Drive Train Continued
Symptom
Possible Cause
Noise internally/
externally while
pedaling or rough feel
while pedaling.
(Continued)
Failed pedal axle set.
Test Procedure
There might be a
persistent grinding
noise or knocking with
every pedaling motion.
The noise usually
presents itself only once
during each rotation.
Defective pivot tube.
-Remove pedal arm and
spin pivot tube to see if
noise is still there.
Clicking noise in front of -Remove foot pad and
foot pad on Mini-E.
tighten bolt.
Gap between front
Check to see if there is
stabilizer and elliptical
a large gap between the
frame.
front stabilizer and
elliptical frame.
Flywheel defective
-Verify the noise
(Bike Only).
continues a few seconds
after the pedal stops
moving.
62 | 2008 AFG Service Seminar [rev 1.3]
Repair
Replace pedal axle set.
Replace Pivot Tube(s).
Replace pivot block
bushing, bolt and nut.
Tighten bolts. If gap is
still present use flexible
Teflon washers to fill the
space.
Replace the Flywheel.
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Console
Symptom
Possible Cause
Test Procedure
Repair
No display on console.
Improper wiring.
- Verify the connections
between the power
supply and the power
jack.
- Verify the connections
between console cable
and console.
- Perform voltage check
on console cable.
Reference p42.
- Verify power supply is
not pinched or
damaged.
- Perform voltage check
on power supply.
- Verify the power
supply and make sure
the adapter is the
correct voltage.
Connect wires
correctly or replace parts
as needed.
Failed or improper
power supply.
Partial LCD Display on
Console.
Failed console.
Console was subjected
to cold temperatures.
Failed or improper
power supply.
Failed console.
- Perform voltage check
on power supply.
- Verify the power
supply and make sure
the adapter is the
correct voltage.
Replace power supply.
Replace console.
Allow machine to warm
to room temperature.
It may be necessary to
gently massage the LCD
crystal with your hand
to allow for full
display. *Important
Note* - Pressing against
the LCD crystal with
excessive force may
damage the crystal.
Replace power supply.
Replace console.
2008 AFG Service Seminar [rev 1.3] | 63
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Console Continued
Symptom
Possible Cause
Test Procedure
Console Resets
Intermittently.
Poor connection
between power supply
and power jack.
-Verify that the power
supply is securely
inserted into the power
jack.
-Perform voltage check
on power supply.
Failed power supply.
Failed console cable.
Only Time Works on
Console (No workload,
distance or calories.)
Failed console.
Failed sensor wire.
- Verify console cable is
not pinched or
damaged.
-Perform voltage check
on console cable.
Reference p42.
Repair
Replace power supply.
Replace console cable.
Replace console.
Replace sensor wire.
-Perform RPM
continuity check.
Missing rpm magnet on -Visually verify presence Replace magnet and/or
crank assembly or
of magnet in pedal axel reposition RPM sensor.
misaligned RPM sensor. and alignment of RPM
sensor.
Failed console.
Replace console.
64 | 2008 AFG Service Seminar [rev 1.3]
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Heart Rate
Symptom
Possible Cause
Test Procedure
Heart rate erratic or
no heart rate function.
(Hand Grips)
User error.
Reference Proper Heart
Rate Usage p23.
Reference Proper Heart
Rate Usage p23.
Heart rate erratic or
no heart rate function.
(Telemetric chest strap)
Failed heart rate grips.
Failed heart rate
receiver.
Reference Proper Heart
Rate Usage p23.
User error.
Reference Proper Heart
Rate Usage p23.
Electromagnetic
interference.
Check immediate area
for causes of
interference (Florescent
lighting, electric dog
fences, large electric
motors, etc.)
Reference Proper Heart
Rate Usage p23.
Failed telemetric chest
strap or polar receiver.
Repair
If there is absolutely no
heart response, replace
heart rate grips.
If proper heart rate
instructions are followed
and heart rate continues
to be erratic, replace
console.
Remove interference
from vicinity of the unit.
Replace chest strap and
or Polar reciever and the
console set.
2008 AFG Service Seminar [rev 1.3] | 65
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Resistance
Symptom
Possible Cause
Test Procedure
Repair
No resistance change
or erratic or continuous
resistance change.
Tension cable is not
connected to the brake
or has failed.
-Verify that the tension
cable is connected to
the break or has not
failed.
-Perform voltage check
on adapter.
-Verify the adapter is
the correct voltage.
- Verify console cable is
not pinched or damaged
-Perform voltage check
on console cable.
Reference p42.
-Perform voltage check
on servomotor.
Reference p40 and p41.
Reattach cable.
Failed or improper
power supply.
Failed console cable.
Failed servomotor.
Resistance is Too Hard
or Too Weak.
Failed console.
Tension cable is not
connected to the brake
or has failed.
Magnetic brake is
positioned improperly.
66 | 2008 AFG Service Seminar [rev 1.3]
-Verify that the tension
cable is connected to
the break or has not
failed.
-Verify the correct
position of magnetic
brake.
Reference p31.
Replace power supply.
Replace console cable.
Replace servomotor.
Replace console.
Reattach cable.
Reposition the
magnetic brake.
Section Three | Troubleshooting
Elliptical | Bike Troubleshooting
>> Alignment Issues with Pedal Arms
Symptom
Possible Cause
Test Procedure
Repair
Noise externally while
pedaling, rough feel
while pedaling, or (for
elliptical only) the pedal
arm will jump off of
guide rail.
Improper assembly or
loose assembly bolts.
-Verify assembly steps
using owner’s guide.
Tighten all bolts used
for assembly. Reference
Maintenance p20 and
p21.
Tighten crank arms.
- If the noise ceases or
pedal does not jump
off guide rail replace
handlebar.
- If there is no change
replace link arm, pedal
arm, and crank.
Loose crank arms.
Alignment issues with
pedal arms due to
improper welds.
-Disconnect
appropriate link arm
from lower handle bar
assembly and pedal
unit.
2008 AFG Service Seminar [rev 1.3] | 67
Table of Contents
Gym Troubleshooting
Noise | Rough Cables
Weight Selector Pin
68 | 2008 AFG Service Seminar [rev 1.3]
69
70
Section Three | Troubleshooting
Gym Troubleshooting
>> Noise | Rough Cables
Symptom
Possible Cause
Test Procedure
Repair
The cables feel rough
and are noisy during
use.
Cables are damaged.
-Verify there is no
Adjust cable for proper
noticable damage to the tension.
cables.
Replace cable.
-Verify that all cables are
secured into the pulleys.
-Verify that the weight
stack guiderods are
lubricated with silicon
spray or gel.
-Verify that there is no
excessive slack in the
cables.
Reference p22.
2008 AFG Service Seminar [rev 1.3] | 69
Section Three | Troubleshooting
Gym Troubleshooting
>> Weight Selector Pin
Symptom
Possible Cause
Weight selector pin
cannot be inserted.
70 | 2008 AFG Service Seminar [rev 1.3]
Test Procedure
-Verify that the selector
pin isn’t bent or
damaged.
Repair
-Adjust threaded bolt
on top plate so that the
holes in the bayonette
align with the weight
NOTE: Always maintain plate.
at least ½˝ of threaded
-Replace selector pin.
bolt in bayonette.
Reference p. 22.
Section Three | Known Issues
Known Issues
>> Treadmills
Issue
Solution | Plan of Action
Models | T4, T6 (2007)
There is a swaying/bouncing motion at 0% incline
with descriptions that the unit is like a
springboard. All the weight is being put on the
incline bracket due to the unit having no air
shocks. It is causing the bracket to bend as the
person is running.
Rattling noise from inside the console.
The levelers on the main frame need to be
loosened so that they sit securely against the
elevation frame at 0%.
Due to the Console cable length it may rattle if
loose. Tie the console cable down.
Side rail edges are very sharp. A tech cut his hand If there is a repair needed on unit with the side
open needed to get 5 or 6 stitches.
rails involved send technician. Do not let the
customer repair or replace. This is being changed
to reduce the sharpness of the edge.
There is also a clanking noise which is due to the Quality has improved the bolt size to make it a
bolt being smaller then the hole in the bottom
better fit.
incline bracket.
Serial # for the T4 & T6 models is located on the
It is important that we get as much information
plastic motor cover.
from that unit as possible in case the motor cover
is replaced.
Incline bracket creaking when unit is in incline
Use teflon washers on brackets to keep the motor
position above 0.5%
from rubbing against the bracket.
2008 AFG Service Seminar [rev 1.3] | 71
Section Three | Known Issues
Known Issues
>> Treadmills
Issue
Solution | Plan of Action
Models | 2.3T, 3.3T, 5.3T (2007)
Making noise when at the 0% incline, makes no
noise when there is no weight on the unit but
as soon as weight is applied it makes a banging
noise. If unit is put inclined the noise stops.
Polar receivers seem to have a too short of a range
so that the customer has to lean into the console
to get a reading.
Manually screw the incline motor shaft further into
the motor another thread.
Try repositioning the receiver and testing. If that
does not work replace with a PST8 polar receiver.
It has a longer wire and can be positioned under
the console plastic.
200 units produced where the shading is incorrect Replace overlay
on the overlays. You can see the UCB and not the
LCD screens.
Models | 4.2T, 5.2T (2006)
4.2T and 5.2T speed increases gradually when the Replace UCB with updated software
pulse grips are held. The speed doesn’t go down
when the customer releases the grips. The
console does beep signifying the change in speed.
Models | 3.2T (2006)
Hardware/software compatibility issues, 2nd
generation digital MCB.
72 | 2008 AFG Service Seminar [rev 1.3]
Replace UCB with updated software
Section Three | Known Issues
Known Issues
>> Ellipticals | Bikes
Issue
Solution | Plan of Action
Models | E6, 4.3E (2007)
4.3E and E6 have a quick resistance switch on the
upper handlebar and the screw is too long.
Symptoms include: scrolling, resistance that is
hard or may bob up and down.
The E6 requires a larger size crank puller for
removal. Our standard crank is 22mm. The E6 is
26mm.
E6 issues with the crank hitting bolt for the
flywheel.
There have been some reports of the pedal arm
rubbing against the shroud plastic on right side.
Replace the screw and the switch. The temporary
fix is to take out the screw and/or disconnect the
wire (an assembly step).
Use a 26mm crank puller. If one is not available it
can be hammered off.
Verify that the flywheel is mounted properly.
If the pedal arm is rubbing on the plastic the
shroud may be installed incorrectly or missing
screws. Most likely the plastic slit is misshaped so
either it should be filed or dremmeled to give
clearance or the shroud should be replaced.
Models | 2.3E, 3.3E, 4.3E (2007)
2007 Elite models sometimes have a clicking
sound in the pivot block set attached at the crank
arm. The issue is being caused by the silver inner
bushing being slightly higher than the copper
bushing therefore causing the copper bushing to
click up and down on the U-bracket of the Pedal
arm.
The inner bushings have been modified to
eliminate this problem and should be sent.
There are updated bolts | nuts that can be sent
when other repairs fail.
Models | 2.0AH
(2008 Hybrid Bike)
During life testing, a sample at the factory had the A cup washer is being placed at the point where
cranks loosen.
the crank attaches to the axle to prevent this
problem.
2008 AFG Service Seminar [rev 1.3] | 73
Horizon Fitness | 1620 Landmark Drive, Cottage Grove WI 53527
Phone 877-GOAFG55 (462-3455) | Fax 608.839.1280 | retailers@advancedfitnessgroup.com
Version 1.1 JHP September 2007