AFG Sport 5.7AT, Service Manual

Page 1: ...1 5 7AT Service Manual ...

Page 2: ...2 Product Browse ...

Page 3: ...g Started Program Information 10 CHAPTER 4 ENGINEERING MODE 4 1 Engineering Mode 13 4 2 Engineering Mode Overview 13 CHAPTER 5 TROUBLESHOOTING 5 1 Electrical Diagram 15 5 2 MCB Wiring Instructions 16 5 3 Troubleshooting 17 5 3 1 No Power to the Console 17 5 3 2 Safety Key Does Not Function 18 5 3 3 No Response from Machine Console Motor 19 5 3 4 Incline Motor Issues 20 5 3 5 Noise Issues 21 5 3 6 ...

Page 4: ...Rail Replacement 28 6 4 Running Deck Replacement 29 6 5 Front Roller Replacement 30 6 6 Running Belt Replacement 31 6 7 Motor Control Board MCB Replacement 32 6 8 Motor Replacement 33 6 9 Drive Belt Replacement 34 6 10 Incline Motor Replacement 35 6 11 Console Replacement 36 6 12 Heart Rate Board Service 37 ...

Page 5: ...5 CHAPTER 1 Serial Number Location 1 1 Serial Number Location ...

Page 6: ...rneath 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 If any labels are damaged or illegible contact Customer Technical Support for replacements EVERY WEEK WEEKLY Clean underneath the treadmill following these steps T...

Page 7: ... treadmill came with a bottle of lubricant which can be used for two applications 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 to note the roller position Once the belt is loosened take the bottle of lubricant and using an S motion apply it to the e...

Page 8: ...ed at the factory before it was shipped At times the belt can move off center during shipment Before operating the treadmill make sure the belt is centered and remains centered to maintain smooth operation If the running belt is too far to the right side With the treadmill running at 1 mph turn the left adjustment bolt counter clockwise turn at a time using the supplied Allen wrench Check the belt...

Page 9: ...your workout or resume exercising after pause F STOP press to pause end your workout Hold for 3 seconds to reset the console G INCLINE KEYS used to adjust incline in small increments 0 5 increments 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 more quickly K FAN...

Page 10: ... is moving INCLINE Shown as percent Indicates the incline of your walking or running surface CALORIES Total calories burned or calories remaining left to burn during your workout HEART RATE Shown as BPM beats per minute Used to monitor your heart rate displayed when contact is made with both pulse grips 3 3 GETTING STARTED PROGRAM INFORMATION GETTING STARTED 1 Check to make sure no objects are pla...

Page 11: ...he SETTING by turning the workout knob and then pressing when your desired SETTING is displayed 5 Press START to begin WORKOUT PROFILES 1 MANUAL Adjust your speed and incline manually during your workout 2 INTERVALS Improves your strength speed and endurance by increasing and decreasing the speed throughout your workout to involve your heart and other muscles Includes 10 levels Speed changes and s...

Page 12: ...on the top right of the console and the headphone jack on your CD MP3 player 2 Use your CD MP3 player buttons to adjust song settings 3 Remove the AUDIO ADAPTOR CABLE when not in use 4 If you don t want to use the SPEAKERS you can plug your headphones into the AUDIO OUT JACK at the bottom of the console AFG TABLET CONNECTED FITNESS SYSTEM Your AFG machine is tablet ready allowing you to use Blueto...

Page 13: ...eadmill without powered elevation motor speed up speed down 1 3 Bike elliptical and ascent trainer without powered elevation motor resistance up resistance down 1 4 Elliptical and ascent trainer with powered elevation motor incline up resistance down 2 Some of machines do not have certain engineering menus The console displays NA or NOT AVAILABLE when these menus are selected 4 2 ENGINEERING MODE ...

Page 14: ...n speed down is pressed 6 All alpha numerical displays change from A to Z after each incline up key press 7 All alpha numerical display change from Z to A after each incline down key press 8 Matrix display lights one row up from bottom to top if a up arrow key is pressed 9 Matrix display lights one row up from top to bottom if a down arrow key is pressed 10 All the other keys or if there is a key ...

Page 15: ...15 CHAPTER 5 Troubleshooting 5 1 ELECTRICAL DIAGRAM 100032468 ...

Page 16: ...ooting 5 2 MCB WIRING INSTRUCTIONS CN1 Power light CN2 AC power cable socket CN3 Elevation motor cable socket CN4 Speed sensor cable socket Console set cable socket CN5 Error light near the chip CN6 Speed sensor cable socket ...

Page 17: ...e power check the connection of the power wiring from the power receptacle to the MCB Use a multi meter to measure AC1 AC2 The AC voltage should read 110V or 240V depending on your location s standard voltage If AC voltage value is standard replace the MCB e If the MCB does have power check the connection of the console cable wire at the MCB and UCB Remove the console cable from MCB and use a mult...

Page 18: ... safety key off 2 SOLUTION a Verify the safety key is fully inserted in the console If it is not detach the safety key and then insert it again b Check the safety key for signs of oxidization If signs are present replace the safety key c If the safety key is functional check the safety key sensor wires in the console Detach and then reconnect the wires if the issue remains replace the wires ...

Page 19: ...nged the console is ok If the data does not change replace the PCB c Turn off the power switch and then remove the motor cover Detach the red black motor wires from the MCB and then use a multi meter to measure the resistance from the drive motor If the resistance is higher than 10 Ω the drive motor is defective Replace the drive motor If the resistance is lower than 10 Ω the drive motor is ok d I...

Page 20: ...e and scroll to ENG 1 Hardware Test Press the key ENTER first and then the key START Press the keys INCLINE If you hear clicks from two relays at the MCB the MCB is ok Check the connection of the elevation motor at the MCB Unplug and re plug these two pins If the issue remains replace the elevation motor If there are no beeps from these two relays MCB is defective Replace the MCB ...

Page 21: ...and tensioned correctly Remove and clean the rollers if needed Replace the rollers or running belt as needed b This sound is likely a moving component Remove the motor cover and check the drive belt for alignment and make sure it is not slipping or is frayed cut in any way Replace the drive belt if needed Make sure the optic disk on the motor is not rubbing the speed sensor Turn the motor by hand ...

Page 22: ...f needed Check to see if the air shock is making this noise lubricate or replace if needed 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 incline motor Check that the incline motor connection points include Teflon washers Lubricate the incline motor worm screw and connection points with grease Replace the incline motor C ...

Page 23: ...ing from the amp board to the console Replace the speaker or amp boards and wiring Replace the speakers If the speaker board amp board wiring and speakers do not solve the issue replace the console b There is a bad connection between the headphones and the console Verify the connection of the music player to the dock or audio adaptor cable Verify the audio adaptor cable connection at the console R...

Page 24: ...iring is bad Check the speaker wire connections Switch the speaker connections from one speaker to the other to see if sound switches sides If the sound does not switch sides replace the speaker board If the sound does switch sides replace the speaker and speaker wires f Grounding issue Try a different set of headphones Check the grounding of the console ...

Page 25: ...he chest strap is damaged d The HR grips are damaged e Heart rate board damaged f The UCB is damaged 2 SOLUTION a Re center the chest strap below the user s pectoral muscle and check again b Replace the battery in the chest strap c Replace the chest strap d If there is no HR present replace the HR grips e If there is a HR present but it is much higher than normal replace the HR board f If replacin...

Page 26: ...LACEMENT 1 Remove the two screws holding the motor cover to the frame Figures A 2 Lift the cover from the frame Figures B FIGURE A FIGURE B 3 Figure C shows the motor area with the motor cover removed FIGURE C 4 Reverse Steps 1 3 to install a new motor cover ...

Page 27: ...7 CHAPTER 6 Parts Replacement Guide 6 2 REAR ROLLER REPLACEMENT 1 Remove the rear end caps Figure A 2 Remove both roller adjustment screws Figure B FIGURE A FIGURE B 3 Remove the roller Figure C FIGURE C ...

Page 28: ...he back of the treadmill Figures B FIGURE A FIGURE B 4 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 29: ...e motor cover as outlined in Section 6 1 2 Remove the side rail as outlined in Section 6 3 3 Remove the end cap 4 Remove the running deck screws Figure A FIGURE A FIGURE B 5 Remove the running deck from the running belt Figure B 6 Reverse Steps 1 4 to install a new running deck ...

Page 30: ...NT 1 Remove the motor cover as outlined in Section 6 1 2 Loosen both of the rear roller screws to remove tension from the running belt Figure A FIGURE A FIGURE B 4 Walk the drive belt off of the motor pulley Figure B 5 Remove the front roller from the running belt ...

Page 31: ... cover as outlined in Section 6 1 2 Remove the rear roller as outlined in Section 6 2 3 Remove the running deck as outlined in Section 6 4 4 Remove the front roller as outlined in Section 6 5 5 Remove the running belt Figures A FIGURE A 6 Reverse Steps 1 5 to install a new running belt ...

Page 32: ...from the machine 2 Remove the motor cover as outlined in Section 6 1 3 Disconnect the wire connectors at the MCB 4 Remove the two screws holding each side of the MCB to the frame Figures A Figures A 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 33: ...he drive belt off of the motor pulley 4 Disconnect the motor cable ground wire from the grounding post 5 Disconnect the motor cable from the MCB 6 Remove the four screws holding the motor to the frame Figure A FIGURE A 7 Remove the motor from the treadmill 8 Reverse Steps 1 7 to install a new motor NOTE Be sure that the motor isolator pad is in place prior to mounting the new motor ...

Page 34: ...2 Remove the motor cover as outlined in Section 6 1 3 Walk the drive belt off of the motor pulley Figure A FIGURE A 6 Loosen the rear roller screws to relieve tension on the running belt 7 Remove the two 8 mm screws from front roller 8 Lift the roller and remove the old drive belt 9 Reverse Steps 1 8 to install a new drive belt ...

Page 35: ...o that the front wheels are off the floor or the unit may be tipped on its side 4 Remove the screws from the elevation rack Figure A Figure A Figure B 5 Disconnect the incline motor from the top mounting bracket Figure B 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...

Page 36: ...nnect the power cord 2 Remove the four screws holding the console from the console mast Figure A Figure A Figure B 3 Remove the screws holding the back of console Figure B 4 Disconnect the wires connections from the console Figure C Figure C 5 Remove the console 6 Reverse Steps 1 5 to install a new console ...

Page 37: ...e treadmill and remove the power cord 2 Remove the console as outlined in Section 6 12 3 Loose the screws which fix the heart rate sensor Figure A Figure A 4 Disconnect the wires connections that go to the heart rate board Figure B Figure A 5 Reverse Steps 1 3 to install a new heart rate board ...