Johnson AFG 5.5AT, Service Manual

Page 1: ...1 JOHNSON Issue date 2016 9 27 Edition 01 Doc No Revision date Edition time 01 Page 34 Johnson Industries Shanghai Co Ltd AFG 5 5AT 5 9AT Service Manual Approval Review Editor Kyle Schweitzer Dora Feng ...

Page 2: ...2 Product Browse 5 5AT ...

Page 3: ...3 Product Browse 5 9AT ...

Page 4: ...ABLET CONNECTED FITNESS SYSTEM 5 7AT 5 9AT ONLY 10 CHAPTER 3 ELECTRIC CONNECTION SYSTEM 3 1 Electrical Diagram 11 3 2 UCB Circuit Board Instruction 14 3 3 MCB Circuit Board Instruction 15 CHAPTER 4 ENGINEERING MODE 17 CHAPTER 5 TROUBLESHOOTING 5 1 Error Code List 19 5 2 No Power To The Console 19 5 3 No Function For Safety Key 20 5 4 No Response For Machine Console Motor 20 5 5 Incline Motor Issue...

Page 5: ...r Replacement 26 6 3 Side Rail Replacement 27 6 4 Running Deck Replacement 28 6 5 Front Roller Replacement 29 6 6 Running Belt Replacement 30 6 7 Motor Control Board MCB Replacement 31 6 8 Drive Belt Replacement 32 6 9 Incline Motor Replacement 33 6 10 Console Replacement 34 ...

Page 6: ...CHAPTER 1 Serial Number Location 6 SERIAL NUMBER ...

Page 7: ...ents H SPEED KEYS used to adjust speed in small increments 0 1 mph increments I INCLINE QUICK KEYS used to reach desired incline more quickly J SPEED QUICK KEYS used to reach desired speed morequickly K FAN KEY press to turn fan on and off L FAN personal workout fan M SPEAKERS music plays through speakers when your CD MP3 player is connected to the console N AUDIO IN JACK plug your CD MP3 player i...

Page 8: ...er cord and turn the treadmill ON The ON OFF switch is next to the powercord 3 Stand on the side rails of the treadmill 4 Attach the safety key clip to part of your clothing making sure that it is secure and will not become detached during operation 5 Insert the safety key into the safety keyhole in theconsole 6 You have two options to start your workout A QUICK START UP Simply press the START key...

Page 9: ... increasing and decreasing the speed and incline while keeping you in your fat burning zone Includes 10 levels Speed and Incline changes segments repeat every 30 seconds 2 5 TARGET PROFILES 1 TARGET 1 DISTANCE Push yourself and go further during your workout with 13 distance workouts Choose from 1 mile 2 miles 5k 5 miles 10k 8 miles 15k 10 miles 20k half marathon 15 miles 20 miles and marathon goa...

Page 10: ...tom of the console 2 9 AFG TABLET CONNECTED FITNESS SYSTEM 5 7AT 5 9AT ONLY Your AFG machine is tablet ready allowing you to use Bluetooth 4 0 technology to wirelessly connect your tablet to your AFG sport treadmill Using the free downloadable AFG Fitness app will enable you to control your treadmill s operating functions via your tablet The app will also allow you to monitor your workout track yo...

Page 11: ...CHAPTER 3 Electrical Connection System 11 3 1 ELECTRICAL DIAGRAM 5 5AT Console Wire ...

Page 12: ...CHAPTER 3 Electrical Connection System 12 5 5AT Console Wire 5 5AT USB Wire Function Function 1 VBUS1 8 IGND 2 GND 9 RIGHT 3 USB_DP 10 SEL 4 USB_DM 11 SW 5 LED CTL1 12 SIG 6 LED CTL2 13 SIG 7 LEFT ...

Page 13: ...CHAPTER 3 Electrical Connection System 13 Console wire ...

Page 14: ...CHAPTER 3 Electrical Connection System 14 USB Connector Wire 3 2 UCB CIRCUIT BOARD INSTRUCTIONS LED1 speed LED2 Incline LED3 Weight loss LED4 fan LED5 interval LED6 distance LED7 bluetooth LED8 calories ...

Page 15: ... 3 Electrical Connection System 15 3 3 MCB CIRCUIT BOARD INSTRUCTIONS 5 5AT MCB CN1 Power line CN2 Incline motor power connector CN3 Console cable connector CN4 Speed sensor connector CN5 Drive motor connector ...

Page 16: ...Connection System 16 3 3 MCB CIRCUIT BOARD INSTRUCTIONS 5 9AT MCB CN1 Power Line CN2 Incline motor power cable CN3 Speed sensor cable CN4 Console set cable CN5 Software burning cable CN6 Drive motor cable MCB LED Configure ...

Page 17: ...CHAPTER4 Engineer Mode 17 Press incline and speed 3 seconds at the same time to enter ENG mode 1 You can clockwise rotate push to select to select ENG mode 2 You can press to select ENG mode ...

Page 18: ...CHAPTER4 Engineer Mode 18 ...

Page 19: ...nue to step b b Check the MCB is providing power to the console Measure the pins in the yellow circle in the picture below If approximately 12 VDC is measured at these pins replace the console cable c Check that the MCB is receiving 120 VAC Measure the black and white wires which connect to the MCB If there is approximately 120 VAC 15 VAC on these wires replace the MCB As previously mentioned this...

Page 20: ...eys are pressed If no replace thekeypads b Enter Engineering Mode and scroll to ENG 1 Hardware Test Press the key ENTER first and then the key START When press the key SPEED if the data on windows TIME DISTANCE is changed the console is ok If not replace the PCB c Turn off the power switch and open the motor upper cover Remove the red black wires of motor from the MCB and use a multi meter to meas...

Page 21: ... under the motor cover d Banging or clunking sound e Slapping thunking squeaking sound with each footstep f Rubbing sound underneath the treadmill g Squeaking noise when raising lowering the deck into storage positions h Squeaking grinding noise when using elevation 2 SOLUTION a This noise is from the roller or running belt a If this is a new unit some noise is normal as the running belt forms aro...

Page 22: ...l to another flat surface e This sound is from the running deck belt Check that the running deck is tightly attached to the frame Check the deck shocks for denigration or crumbling Replace if needed Check to see if the air shock is making this noise lubricate or replace ifneeded f This sound is likely due to the air shock Lubricate or replace the air shock as needed g This sound is likely from the...

Page 23: ...l replace the HRboard f If replacing the HR grips and board does not resolve the issues replace theconsole 5 8 TROUBLESHOOTING SPEAKER AUDIO ISSUES 1 SYMPTOM a No sound through the speakers but headphones work b No sound through headphones but the speakers work c No sound through speakers or headphones d IPod not charging e Speakers buzzing f Sound from one speaker only g Shock from headphones 2 S...

Page 24: ...fy the connection of the music player to the dock or audio adaptor cable Verify the audio adaptor cable connection at the console Replace the audio adaptor cable Replace the console d Speakers are not getting a clear signal through the speaker wires Check the speaker wire connections Replace the speaker wiring Replace the speakers e The speaker or speaker wiring is bad Check the speaker wire conne...

Page 25: ...holding the motor cover to the frame Fig 1 2 Pull up the cover from frame Fig 2 3 Fig 3 shows the motor area with the motor cover removed 4 Reverse Steps 1 3 to install a new motor cover 5 confirm drive belt tension is correct after replacing motor see section 4 5 Fig 1 Fig 2 Fig 3 ...

Page 26: ...CHAPTER 6 Part Replacement Guide 26 6 2 REAR ROLLER REPLACEMENT 1 Remove the rear end caps 2 Remove both roller adjustment screws Fig 2 Fig 2 Fig 1 Fig 2 3 Remove the roller ...

Page 27: ... Slide the rail off the back of the treadmill 3 Reverse Steps 1 2 to install a new side rail NOTE After reinstalling the side rail make sure the rear end cap is on first before tightening the screws for proper gap spacing Be careful not to over tighten the screws or they will poke through the top of the side rail ...

Page 28: ... Remove the end cap in section 4 2 4 Remove the running deck screws Fig 1 Fig 1 Fig 2 5 Remove the running deck from the running belt 6 Reverse Steps 1 4 to install a new running deck Fig 1 Fig 2 7 The running deck is silicon on desk New deck surfaces must ALWAYS be matched to a new running not Slip 8 Adjust the tension after replace new running deck Section 4 6 Note ...

Page 29: ...LER REPLACEMENT 1 Remove the motor cover as outlined in Section 4 1 2 Loosen both of the rear roller screws to remove tension from the running belt Figure1 Fig 1 5 Remove the drive belt from the front roller and remove the roller from the running belt ...

Page 30: ...ese bolts adjust the rear roller Do not adjust until the treadmill is on This will prevent over tightening of one side Step2 The belt should have equal distance on either side between the frames If the belt is touching one side do not start the treadmill Turn the bolts counter clockwise approximately one full turn one each side Manually center the belt by pushing the belt from side to side Tighten...

Page 31: ...ord from the machine 2 Remove the motor cover as outlined in Section 4 1 3 Disconnect the wire connectors at the MCB Fig 1 4 Remove the 2 screws holding each side of the MCB to the frame Fig 1 5 Remove the MCB 6 Reverse Steps 1 5 to install a new MCB Make sure that all wires removed during Step 3 are re connected ...

Page 32: ... 3 Remove the front roller in section 4 5 4 Lift the roller and remove the old drivebelt Fig 1 Fig 2 5 Install new drive belt and Reverse Steps 1 3 Fig 1 6 After installing a new belt check it for correct alignment by jig Fig 1 the specification is 1 5 7 Check belt tension with equipment Fig 2 Specification 1 Initial belt tension 215 273Hz 2 After 10min running 192 244Hz Fig 2 ...

Page 33: ...eadmill and support it so that the front wheels are off the floor 4 Remove the screws from the elevation rack Fig 1 2 Fig 1 2 Fig 3 5 Disconnect the incline motor from the top mounting bracket Fig 3 6 Reverse Steps 1 5 to install a new incline motor NOTE When installing a new incline motor make sure to replace the white nylon washers at the top and bottom connection points of the incline motor ...

Page 34: ...admill and disconnect the power cord 2 Remove the screws holding the console form heart rate bars 3 Remove the screws holding the console from the console mast 4 Remove the console from the console frame 5 Replace new console and fasten frame screws 6 Reversed step 1 5 7 Turn on the power ...