Horizon Fitness 1.0AT, 13.0AT, 14.0At, 2.0AE, 3.0AE Service Manual

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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 Resetting the Incline Motor

3 4

-Treadmill 6

-Elliptical | Bike 8

-Gym 10

Recommended Tools Parts Diagrams

12 -Treadmill 44

-Treadmill 13

-Elliptical 14

-Bike 15

-Gym 16 -Treadmill 48

Maintenance

-Treadmill 17 -Gym 69 >> Lubrication 18 >> Tensioning & Alignment 19

-Elliptical 20

-Bike 21

-Gym 22

Proper Heart Rate Usage

Horizon Fitness “5-Step” Diagnostic Process Wiring Diagrams and Schematics

Adjusting the Magnetic Break Voltage Checks Engineering Mode

-Elliptical | Bike 45

Section Three

Troubleshooting

-Elliptical | Bike 61

Known Issues

25 27 30 31 32

2 | 2008 AFG Service Seminar [rev 1.3]

>> 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 Labor Parts Motor Elevation Break Frame

1.0AT 1 Year 3 Years Lifetime Lifetime NA 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] | 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.

4 | 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] | 5

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.

6 | 2008 AFG Service Seminar [rev 1.3]

Section One | Safety Instructions

WA RN IN G

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.

Improper connection of the equipment-grounding conductor can result in a risk of electric

shock. Check with a qualied 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 t in the outlet; have a proper outlet installed by a qualied electrician.

Grounded Outlet

Grounding Pin

Grounded Outlet Box

SAFETY TIPS

Adapter

Metal Screw

TAS For

Grounding Screw

• 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] | 7

Section One | Safety Instructions

WA RN IN G

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.

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.

8 | 2008 AFG Service Seminar [rev 1.3]

Section One | Safety Instructions

WA RN IN G

Safety Instructions

>> Elliptical | Bike Continued

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.

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] | 9

Section One | Safety Instructions

WA RN IN G

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.

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

• 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.

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.

10 | 2008 AFG Service Seminar [rev 1.3]

Section One | Safety Instructions

WA RN IN G

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!

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.

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

•

• Needle nose pliers

• Damp cloth

• Rubber mallet

• Hammer

• Drop cloth

• Ruler

• Snap ring pliers

• Wire cutters

•

*Motor commutator stone

*Crank Puller (Park Tool CCP-2, 22mm)

•

*Crank Puller (26mm)

*Available through Horizon Fitness at Cost.

12 | 2008 AFG Service Seminar [rev 1.3]

>> Treadmill Parts Diagram

WATERBOTTLE HOLDER

TOUCHPAD PANEL WITH LED WINDOWS

READING RACK

GRIP PULSE HAND RAILS

SAFETY KEY PLACEMENT

HAND RAILS

MOTOR COVER

SIDE RAIL

ROLLER END CAP

REAR ROLLER ADJUSTMENT BOLTS

P6:

COUR

P7:

CER

: THR

ZONE

P10: CUS

TOM 2

: CUS

TOM 1

P1:

NUAL

P2:

NTERVALS

P3:

MTN C

P4:

WEIGH

T LOSS

P5:

PEA

INTERVALS

2 1

1 1

0 9

7 6

4 3

2 1

0 9

8 7

6 5

4 3

2 1

DISTANC

TIME

INE

ART RATE

PEED

CALORI

MPH

CHANGE

DIS

TAR

QUICK

STA

STO P

HOLD T

O RESET

PRES

NFIRM INCLI

ESS T

IRM

SPEED

ENT

BACK

CONSOLE

CONSOLE SKIRT

CONSOLE MAST

CIRCUIT BREAKER

ON/OFF SWITCH

POWER CORD

WHEEL LOCKS

SIDE COVER

TRANSPORT WHEEL

RUNNING BELT / RUNNING DECK

Section Three | Parts Diagrams >>Treadmill

Console

Console Skirt

Console Mast

Circuit Breaker

ON | OFF Switch

Power Cord

Wheel Locks

Side Cover

Transport Wheel

Running Belt | Running Deck

Water Bottle Holder

Touch Panel with LED Window

Reading Rack

Grip Pulse Hand Rails

Safety Key Placement

Hand Rails

Motor Cover

Side Rail

Roller End Caps

Rear Roller Adjustment Bolts

2008 AFG Service Seminar [rev 1.3] | 13

Section Three | Parts Diagrams >>Elliptical

CONSOLE

RIGHT HANDLEBAR

LOWER LINK ARM

ELBOW COVER

PULSE GRIP

CONSOLE MAST

DISPLAY

FOOT PAD

PEDAL ARM

BOTTLE HOLDER

POWER ADAPTOR SOCKET

HANDLEBAR COVERS

FOOT LEVELER

FRONT STABILIZER TUBE

CONSOLE MAST BOOT

TOP CAP

LEFT HANDLEBAR

>> Elliptical Parts Diagram

Display

Left Handlebar

Console Mast Boot

Top Cap

Pulse Grip

Bottle Holder

Console Mast

Foot Pad

Pedal Arm

Console

Right Handlebar

Handlebar Covers

Power Adaptor Socket

Elbow Cover

Front Stabilizer Tube

Lower Link Arm

Foot Leveler

14 | 2008 AFG Service Seminar [rev 1.3]

>> Bike Parts Diagram

CONSOLE

MAIN FRAME

WATER BOTTLE HOLDER

SEAT BACK

SEAT BASE

PULSE GRIP HANDLEBARS

PEDALS WITH FOOT STRAPS

SEAT FRAME

REAR PLASTIC CAP

SEAT BACK COVER

REAR STABILIZER TUBE

Section Three | Parts Diagrams >>Bike

Console

Pulse Grip Handlebars

Seat Back

Seat Base

Main Frame

Pedals with Foot Straps

Seat Back Cover

Water Bottle Holder

Rear Plastic Cap

Seat Frame

Rear Stabilizer Tube

2008 AFG Service Seminar [rev 1.3] | 15

Section Three | Parts Diagrams >>Gym

LAT PULLDOWN BAR

LAT BAR BRACKET ASSEMBLY

MAIN SUPPORT FRAME (RIGHT)

CENTER SUPPORT FRAME

CABLE “C”

RADIAL ARM ADJUSTMENT PIN

SEAT BACK PAD

SEAT BOTTOM PAD

SEAT ASSEMBLY

SEAT HEIGHT ADJUSTMENT KNOB

FOAM LEGROLLERS

ADJUSTABLE FOOTPLATE CABLE “B”

BASE FRAME

SEAT ASSEMBLY SAFETY PIN

MAIN SUPPORT FRAME (LEFT)

SINGLE FLOATING PULLEY BRACKET

WEIGHT SELECTION PIN

WEIGHT SHIELD

DUAL FLOATING PULLEY BRACKET

GUIDE ROD

UPPER PULLEY ASSEMBLY

RADIAL ARM ASSEMBLY

CABLE “A”

>> Gym Parts Diagram

Cable A

LAT Pulldown Bar

LAT Bar Bracket Assembly

Center Support Frame

Main Support Frame (Right)

Cable C

Upper Pulley Assembly

Dual Floating Pulley Bracket

Weight Shield

Guide Rod

Radial Arm Assembly

Radian Arm Adjustment Pin

Seat Back Pad

Seat Bottom Pad

Seat Assembly

Seat Height Adjustment Knob

Foam Legrollers

Adjustable Footplate

Weight Selection Pin

Main Support Frame (Left)

Single Floating Pulley Bracket

Seat Assembly Safety Pin

Base Frame

Cable B

16 | 2008 AFG Service Seminar [rev 1.3]

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 Teon 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.

If the running belt is not tracking properly, follow the procedures below:

2 |

• 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

WA RN IN G

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.

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

WA RN IN G

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.

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 oating 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.

Inner

Mounting

Positions

Twist Screw to

Adjust Tension,

Then Tighten

Lock Nut

Single pulley

Bracket Thread

22 | 2008 AFG Service Seminar [rev 1.3]

Twist Screw to

Adjust Tension,

Then Tighten

Cable Screw

And Nut

Bayonet

Lock Nut

Cable Screw

And Nut

Weight Plates

Section One | Proper Heart Rate Usage

WA RN IN G

>> 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.

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 uorescent 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 25 Wiring Diagrams and Schematics 27 Resetting the Incline Motor 30 Adjusting the Magnetic Break 31 Voltage Checks

-Treadmills 32

>>No Motor Movement 34 >>Motor | AC Wire 34 >>Console Cable 35 >>Speaker Amp Board 35 >>9 Wire Console Cable 36 >>12 Wire Console Cable 37 >>Incline Wire 38

-Ellipticals | Bikes

>>Incline Motor 39 >>Resistance Motor 40 >>Resistance Motor Cable 41 >>10 WireConsole Cable 42 >>Incline Console Cable 43

Engineering Mode

-Treadmill 44

-Elliptical | Bike 45

24 | 2008 AFG Service Seminar [rev 1.3]

Section Two | Voltage Checks

120 VAC

WA RN IN G

>> 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 sufcient.

• Make sure that proper voltage is being supplied from the wall outlet.

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.

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

NTC

30A 120/240V AC

JQX-15FS-A

COIL 12 VDC

C US

CQC

CHINA

30A 120/240V AC

JQX-15FS-A

COIL 12VDC

C US

CQC

CHINA

DLS2

NTC

TP1

R14

R17

TP2

R29

TP4

JOHNSONFITNESS

D10

SGND

R35

D17

C34

R27

R26

R28

JP5

C30

U3 U1

D18

D20

R32

R33

C33

D19

R18

D21

DLS3

R24

Q10

C20

C14

R10

C15

R11

C16

R12

C17

R13

SJED08043EE

R19

LED2

LED3

LED4

LED5

WJ28025T

04 08

02.31

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.

Red Motor

Black Motor Connection

Connection

Black

Motor Wire

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 ve-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]

MCB

WHITE

BLACK

RED

WHITE

BLACK

WHITE

GREEN

Power Cord

110-120 VAC

GREEN

+2.5vdc

EL - Vcc (+2.5v)

EL - Pot

Gnd

Digital Ground

RPM

Power Voltage (+15V)

Speed Command pwr

RELAY

DOWN Incline

UP Incline

Optic Speed Sensor

Speed Sensor

BLACK +GND

WHITE PULSE

RED +5V

BLUE GND

BLACK GND

GREEN

Drive Motor

0-90 VDC

BLACK

RED

BREAKER

Digital Ground

EL. Pol

EL. GND

Incline Motor

>> Digital Drive Wiring Diagram

Section Two | Wiring Diagrams and Schematics

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]

>> Power Source Wiring Diagram

Section Two | Wiring Diagrams and Schematics

To Motor Control Board

A – Socket wire to breaker or on/off switch.

A F

BreakerOn | Off SwitchSocket

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)

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 ush 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 ywheel/brake assembly is 1-2 mm from the ywheel at the

highest resistance level.

2008 AFG Service Seminar [rev 1.3] | 31

Section Two | Voltage Checks

>> No Motor Movement Voltage Checkpoints

Upper Board Checkpoints

Procedures:

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 Volatge After Start

Console Cable Grey to Yellow (Gnd) 0.0 vdc 0.3 +/- .3 vdc, increases as speed increases.

(as shown on console)

Console Cable White to Yellow (Gnd) 4.3 +/- .3 vdc 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 Voltage Before Start Volatge After Start

Console Cable Grey to Yellow (Gnd) 0.0 vdc 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 Voltage With Sensor

Volatge With Sensor Not Obstructed

Obstructed

Yellow Digital Speed Sensor 5.0 +/- 0.4 vdc 0.3 vdc Red Digital Speed Sensor 5.0 +/- 0.4 vdc 5.0 +/- 0.4 vdc

32 | 2008 AFG Service Seminar [rev 1.3]

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 Voltage After Start @

Volatge After Start @ 10.0mph

0.5mph

Across Motor Out,

0.0-22.5 vdc 0.0-22.5 vdc 0.0-22.5 vdc No Motor Attached

Across Motor Out,

0.0 vdc 2.5- 0 vdc 80-100.0 vdc W/ Motor Attached

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

1.20

V DC

"$8JSFT



7"$

>> Motor Voltage Check | Spin motor ywheel to produce voltage

AC Wire Voltage Check

34 | 2008 AFG Service Seminar [rev 1.3]

V DC

GND

Dow

>> Console Cable Voltage Check

JOHNSON

Acepower

CON2

D12

Section Two | Voltage Checks

To check the voltage of a specic 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

Voltage In Voltage Out

120v 12v

2008 AFG Service Seminar [rev 1.3] | 35

Section Two | Voltage Checks

P7: Incline Pot/VREF+

P2: Incline Down P3: GND

P5: Drive Motor Relay

P4: Power Voltage (to UCB)

P6: Stop

P1: Incline Up

P8: Incline VCC/ELE P9: RPM

Polarity tab will face User

>> 9 Wire Console Cable Voltage Chart (DC Volts)

P1: Incline Up P2: Incline Down P3: GND P4: Power Voltage (to UCB) P5: Drive Motor Relay

P6: Stop P7: Incline Pot | VREF+ P8: Incline VCC | ELE P9: RPM

Polarity tab will face

User

Wire Color

1 Red Incline Up 0.0 vdc before started, +1.9

2 Brown Incline Down 0.0 vdc before started, 0.0

3 Orange GND n/a ground 0.0 vdc 0.0 vdc

4 Yellow Power

5 Green Drive Motor

6 Blue Stop Constantr 0.53 vdc-0.69

7 Purple Incline Pot/

Function Console Cable Voltage

no wires cut

vdc while inclining, 0.0 vdc while declining. Voltage constant while inclining/ declining.

vdc while inclining, +1.9 vdc while declining. Voltage constant while inclining/ declining.

Voltage (to UCB)

Relay

VREF+

+15 vdc constant range. 0.0 vdc 14.55 vdc Console will not turn on.

+1.6 vdc before started, 0.0 vdc after started.

vdc 3.6 vdcwhen the safety key is removed. Will remain at 3.6 vdc untill Start is pressed.

+2.5 vdc at 0.0% incline, +0.5 vdc at max incline. Voltage changes with each change in incline.

Voltage at UCB after wire’s cut

2.5 vdc b/f start,

5.0 vdc after start.

2.5 vdc b/f start,

0.8 vdc after start.

1.4 vdc b/f start

0.8 vdc after start

5.0 vdc safe off

1.3 vdc safe on

1.7 vdc running

1.9 vdc paused

2.5 vdc 3.7 vdc b/f start,

Voltage at MCB

after wire’s cut

3.7 vdc b/f start,

0.0 vdc after start.

0.0 vdc b/f start,

0.1 vdc after start.

0.0 vdc b/f start

1.4 vdc after start

16.6 vdc safe off

0.0 vdc safe on and running

5.0 vdc after start.

Physical Symptoms-If Wire Cut

Incline motor will go up but not down.

Incline motor will go down but not up.

Console will not turn on.

No belt movement.

No physical symptoms were noticed when this wire was removed.

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

9 White RPM When the speed sensor is

+2.5 vdc constant. 3.8 vdc b/f start

aligned to the magnet; short,

0.0vdc. When the speed sensor is not aligned: open, +5.0 vdc.

Note: Wire colors are subject to change.

36 | 2008 AFG Service Seminar [rev 1.3]

4.8 vdc after start

5.0 vdc 0.0 vdc Console will use default PWM value or

2.5 vdc Incline constant up as soon as start is pressed. Incline will work in Hardware test.

auto-cal values. Will not auto-cal, will not show speed in Hardware Test.

B7: Power Voltage (to UCB)

B2: Incline Pot B3: Incline GND

B5: Digital GND

B4: Digital GND

B6: RPM

B1: Incline VCC

B8: Power Voltage (to UCB) B9: Speed Command (PWM) B10: Drive Motor Relay B11: Incline Down B12: Incline Up

>> 12 Wire Console Cable Voltage Chart (DC Volts)

B1: Incline VCC B2: Incline POT B3: Incline GND B4: Digital GND B5: Digital GND B6: RPM B7: Power Voltage (to UCB) B8: Power Voltage (to UCB) B9: Speed Command (PWM) B10: Drive Motor Relay B11: Incline Down B12: Incline Up

Section Two | Voltage Checks

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

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.

each change in incline.

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

5 Yellow Digital

GND

6 Green RPM When speed sensor

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 mo-

n/a ground 0.0 vdc 0.0 vdc

tor hums and gets hot quickly. See below for voltage chart if both grounds removed.

5.0 vdc 0.0 vdc Everything works in normal mode but the console

aligned to magnet: short, 0.0vdc.

does not register a speed in Hardware Test or Auto Calibration

When sensor not aligned:open,5.0 vdc

7 Blue Power

Voltage

8 Purple 15 vdc constant

(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

0.0 vdc 17 vdc

1.4 vdc, all others 0.0 vdc.

Range=15 to 17 vdc

9 Grey Speed

Command (PWM)

10 White Drive Motor

Relay

0.0 vdc before started,

0.5 vdc at 0.5 mph, 4 vdc at 10 mph. Voltage changes as speed changes.

4.3 vdc before started

0.0 vdc after started

“0.0 vdc b/f start

0.36vdc aft start

increases as console speed increased”

“5.0 vdc b/f start

0.0 vdc aft start”

“0.8 vdc b/f start

0.7 vdc aft start no change as console speed increased”

“1.4 vdc b/f start

1.4 vdc aft start”

No belt movement, MCB relay clicks. LCD 1 lights. When measuring MCB voltage, there is a slight belt movement, then stops

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.

12 Light

Blue

Incline Up 0.0 vdc before started,

1.9 vdc while inclining,

0.0 vdc while declining.

Note: Wire colors are subject to change.

“0.0 vdc b/f start

5.0 vdc if press

incline down”

“0.0 vdc if at 0%

5.0 vdc if not at

0% or at console height”

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.

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%.

2008 AFG Service Seminar [rev 1.3] | 37

Section Two | Voltage Checks

>> Incline Wire Voltage Chart

Small Connector

Wire

Color

Blue Ground n/a Ground n/a Ground n/a Ground Constant up incline,

Function Before Start At 0.0% At 10% Physical

Symptoms-If Wire

Cut

no down incline.

ENG 1 Test Results

Incline value 0, no down incline.

Brown Incline Pot 2.3 vdc* 0.6 vdc* 0.6 vdc* Constant down in-

cline, no up incline.

Orange VCC 2.4 vdc

constant

* The voltage changes as the incline changes

2.4 vdc constant 2.4 vdc constant Constant down incline, no up incline.

Large Quick Connects

Wire

Color

Black w/white as ground

Red w/white as ground

Red w/black as

ground

Function Before

Start

Incline Up 0.15 vac 0.15 vac 171 vac 120 vac Up incline works, no down

Incline Down

Ground 0.03 vac 0.03 vac 219 vac 228 vac Neither up nor down func-

0.15 vac 0.15 vac 120 vac 186 vac Down incline works, no up

After Start,

Not Inclining

Declining

While

Inclining

While

Declining

Physical

Symptoms-If Wire

Cut

incline.

tion.

Incline value at max, no up incline.

Incline value started one less than max, pressed up once and value maxed out, thereafter no up incline.

ENG 1 Test Results

Up incline works, down does not. Value increases, does not decrease.

Down incline works (until value 0), up does not. Value decreases to 0 then no down incline, does not increase.

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]

Section Two | Voltage Checks

>> Elliptical Incline Motor Voltage Checks

Wire Color Function Voltage at Zero Voltage

w/ Increase

1 Brown Voltage in

(VCC)

2 Orange POT Sensor

(ADC)

3 Blue Ground n/a n/a n/a Normal: Upon start-up incline continuously goes

5V 5V 5V Normal: After start and pressing incline up and down

4.2V Deacreases to 1.7V Increases to 4.2V Normal: After pressing incline- no incline movement.

Voltage

w/ Decrease

Physical Symptoms-If Wire Cut

value is displayed, but there is no incline function. Eng4: When pressing incline up no motor movement, Incline - functions normally

Eng4: Incline + functions normal, no movement with incline - .

down. Eng4: When pressing up incline does not go up

distance value ickers at max value.

Wire Color Function Voltage at Zero Voltage

1 Black Incline Up 0-1 VAC 171 VAC 120 VAC Normal: No incline function and value is displayed

2 Red Incline Down 0-1 VAC 120 VAC 172 VAC Normal: Incline is at a constant down upon start-up.

3 White NC n/a n/a n/a Normal: after pressing start and incline up and down

w/ Increase

Voltage

w/ Decrease

Physical Symptoms-If Wire Cut

Eng4: Incline + functions normal, no movement with incline - .

Eng4: Operates normal, value at max

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

2.0AE | 2.0AR | 3.0AR | 4.0AR |3.0AH | 4.0AH

Wire Color

1 Red Power to

2 Black Ground

3 Brown Optic

4 Orange Zero

Function

DC Motor I.C. Board.

-From Motor

Count

-from motor

Switch Sensor

Voltage | Ohm

Readings

+5vdc 5V 5V Normal: After pressing start and resistance+

n/a ground n/a n/a Normal: After pressing start and resistance+

5vdc 180mV 180mV Normal: After pressing start and resistance+

5V 180mV 180mV Normal: After pressing start and

Voltage

w/ Increase

Voltage

w/ Decrease

Physical Symptoms-If Wire Cut

motor continues to rotate upward during pressingn resistance- motor stops, but does not zero itself. Eng1:Motor operates but no change in motor count

motor continues to rotate upward during pressing resistance- motor stops and does not zero. Eng1:Motor operates but no change in motor count.

motor continues to rotate upward during pressing resistance- motor zeros itself. Eng1: Motor operates but no change in motor count.

resistance + motor constantly rotates. If pressing resistance - motor zeros itself. Eng1: No motor movement . Value is displayed and does not change when pressing resistance +/-.

5 Green Power to

Resistance up

6 White Power to

Resistance down

Note: Wire colors are subject to change.

40 | 2008 AFG Service Seminar [rev 1.3]

12mV 8.5-9.7v 110mV Normal: After pressing start and resistance+

12mV 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.

>> Elliptical Resistance Motor Cable Voltage Checks

3.0AE | 4.0AE | 14.0AE | 18.0AE

Section Two | Voltage Checks

Wire Color

1 Red Power to

2 Black Ground

3 Brown Optic

4 Orange Zero

Function

DC Motor I.C. Board.

-From Motor

Count

-from motor

Switch Sensor

Voltage | Ohm

Readings

+5vdc 5V 5V Normal: After pressing start and resistance+

n/a ground n/a n/a Normal: After pressing start and resistance+

5.0vdc 0.0vdc 0.0vdc Normal: After pressing start and resistance+

5V 0.0vdc 0.0vdc Normal: After pressing start and

Voltage

w/ Increase

Voltage

w/ Decrease

Physical Symptoms-If Wire Cut

motor continues to rotate upward during pressing resistance- motor stops, but does not zero itself. Eng1:Motor operates but no change in motor count

motor continues to rotate upward during pressing resistance- motor stops and does not zero. Eng1:Motor operates but no change in motor count.

motor continues to rotate upward during pressing resistance- motor zeros itself. Eng1: Motor operates but no change in motor count.

resistance + motor constantly rotates. If pressing resistance - motor zeros itself. Eng1: No motor movement . Value is displayed and does not change when pressing resistance +/-.

5 Green Power to

Resistance up

6 White Power to

Resistance down

Note: Wire colors are subject to change.

0.0-0.4vdc 8.5-9.7vdc 0.6-2.0vdc Normal: After pressing start and resistance+

0.0-0.4vdc 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.

2008 AFG Service Seminar [rev 1.3] | 41

Section Two | Voltage Checks

>> 10 Wire Elliptical Console Cable Voltage Chart (DC Volts)

Wire Color Function

1 Purple Ground from

Voltage | Ohm Readings

n/a ground Normal: No speed/ rpm readings.Eng1 No rpm

RPM sensor

2 Black Ground from

n/a ground Normal: After pressing start and resistance+

motor

3 Or-

ange

Zero switch sensor

If zero switch engaged (lowest resistance level) +5.0vdc, open. Any other resistance position: 0.0vdc, short.

4 Brown Optic count

from motor

5 Green Power to

resistance up

+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.

6 White power to

resistance down

+0.0 to 0.4vdc if motoridle. +8.5vdc if resistance decreasing +0.6 to 2.0vdc if resistance increasing.

7 Yellow RPM sensor If magnet aligned with rpm

sensor: 0.0vdc, short. If magnet not aligned withrpm sensor: 5.0vdc, open.

8 Grey Power to

console from

Dependent upon power

supply. power supply

9 Blue Ground from

n/a ground No power to console power supply

10 Red Power to

+5.0vdc Normal: After pressing start and resistance+ DC motor i.c.board

Physical Symptoms-If Wire Cut

readings.

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 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: No speed/ rpm readings.Eng1 No rpm readings.

No power to console

motor continues to rotate upward during 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]

>> Elliptical Incline Console Cable Voltage Check

Section Two | Voltage Checks

Wire Color Function

1 White/

Power 12.6VDC If both wires are cut, the console will have no

Orange

Voltage | Ohm Readings

Physical Symptoms-If Wire Cut

power.

2 Orange Power 12.6VDC If both wires are cut, the console will have no

power.

3 White/

Green

Signal Receive

Receives signals from incline motor, and resistance

Will give “Connect” error if cut - on select models.

motor and RPM. 5V

4 Blue Signal

Send

Receives signals from incline motor, and resistance

If cut there will be no incline or resistance

movement, and no RPM reading. motor. 0 to .1V before Start | .1 to .2V after start.

5 White/

Blue

Signal Receive

Receives signals from inclinemotor, resistance motor

Will give “Connect” error if cut - on select

models. and RPM. 5V

6 Green Signal

Send

Sends signals to incline motor and resistance motor. 0 to .1V

If cut there will be no incline or resistance

movement, and no RPM reading. before Start | .1 to .2V after Start.

7 White/

Brown

Ground n/a Ground If both wires are cut, the console will have no

power.

8 Brown Ground n/a ground 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)

Eng0 appears in the time window. DISPLAY TEST will scroll in the matrix or will be static in

text box.

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 . Press START to begin.

-Speed “+” (s) or “-” (t) will change the speed.

-Speed quick keys will change the speed.

Preset to be within 20%.

-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.

Auto Calibrate (Eng2) Eng2

appears in the time window. AUTO CALIBRATE will scroll in the matrix or will be static in text box. Press ENTER to select . Press START to begin.

-There should be no excessive speed overshoot.

-The engineering menu will be exited upon successful

completion of the auto calibration.

Note: The auto calibration process takes about two minutes to complete.

Switch Function (Eng3)

Eng3 appears in the time window. SWITCH FUNCTION will scroll in the matrix or will be

static in text box. Press ENTER to select.

If the treadmill has a Demo Mode then:

-The brickyard will scroll “DEMO ON” or “DEMO OFF”.

-Default will be “DEMO ON”.

-The “+” (s) or “-” (t) buttons will change the Demo on/off

settings.

Start Selects miles or km.

-The display will show “0” for miles or “1” for km.

-The display will scroll “MILES” OR “KM” when Start is

pressed to change.

-The new setting is automatically saved when Start is pressed, no other buttons need to be pressed to save.

Information (Eng4)

Eng4

appears in the time window. INFORMATION will scroll in the matrix or will be static in text box. Press ENTER to select .

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. If console has an accumulated reset function, hold Start for 5 seconds to reset. This will not apply to most models.

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)

Eng0 appears in the time window. DISPLAY TEST will scroll in the matrix or will be static in text

box.

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)

Eng2

appears in the time window. SWITCH FUNCTION will scroll in the matrix or will be static in text box. Press ENTER to select.

If the treadmill has a Demo Mode then:

-The brickyard will scroll “DEMO ON” or “DEMO OFF”.

-Default will be “DEMO ON”.

-The “+” (s) or “-” (t) buttons will change the Demo on/off

settings.

Start Selects miles or km.

-The display will show “0” for miles or “1” for km.

-The display will scroll “MILES” OR “KM” when Start is pressed

to change.

-The new setting is automatically saved when Start is pressed, no other buttons need to be pressed to save.

-Enter changes the ep/bi setting. Display will show EP for elliptical and BI for bike.

-The new setting is automatically saved when Enter is pressed, no other buttons need to be pressed to save.

Information (Eng3)

Eng3 appears in the time window. INFORMATION will scroll in the matrix or will be static in text

box. Press ENTER to select.

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.

Note: This menu is only for incline ellipticals. All other bikes and ellipticals will not have this menu.

-MIN ADC will how in the text box. The ADC value will be the current height.

-Change the value with the incline “+” (s) or “-” (t). Range= 100-250. Press Enter to save the value. If the value is out of range then OUT OF RANGE will show and the value will not be saved.

-ADC IS SAVED will show for three seconds if the value is in range.

-Press resistance “+” (s) to change the Max.

-MAX ADC will show in the text box. The ADC value will show

the current height.

-Change the value with the incline “+” (s) or “-” (t). Range=550-750. Press enter to save the value. If the value is out of range, OUT OF RANGE will show and the value will not be saved.

-ADC IS SAVED will show for three seconds if the value is in range.

-Press resistance “-” (t). to change the Min.

2008 AFG Service Seminar [rev 1.3] | 45

Table of Contents

>> Section Three

Troubleshooting

-Treadmill 50

-Elliptical | Bike 61

-Gym Known Issues

-Treadmill 71

-Elliptical | Bike 73

46 | 2008 AFG Service Seminar [rev 1.3]

Treadmill Troubleshooting

Failed Auto Calibration 48 Console | Upper Board 49 Membrane | Keypad | Overlay 51 Safety Key | Reed Switch 52 Heart Rate 53 Erratic Speed 54 Elevation 56 No Motor Movement 57 Circuit Breaker 58 Noise 59

Table of Contents

2008 AFG Service Seminar [rev 1.3] | 47

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Failed Auto Calibration

Symptom Possible Cause Test Procedure Repair

Failed Auto Calibration – Belt runs for a few seconds and then stops and E1 message on console.

Failed Auto Calibration – Belt never runs and E1 message on console.

Failed Auto Calibration – Board never sets speeds. Belt will continue to run and not stop.

Failed RPM sensor. -Put machine into Eng1

(Reference p44) and check for slight

uctuation of speed in

speed window of display. (Speed should

not uctuate more than

a few hundredths.)

RPM sensor misaligned. -Adjust sensor bracket

to correct position.

Magnet missing in front roller pulley.

Failed console cable. -Check voltage and

continuity of console cable. Reference p35.

RPM sensor not aligned properly or has failed.

Failed motor control board (MCB).

- 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

uctuation of speed in

speed window of display. (Speed should

not uctuate more than

a few hundredths.)

Replace RPM sensor.

Replace magnet.

Replace console cable.

See troubleshooting for no motor movement. Reference p57.

Replace RPM sensor.

Replace MCB.

48 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Console | Upper Board

Symptom Possible Cause Test Procedure Repair

No display on the console and the power switch is dark.

No display on the console and power switch on machine is lit.

Circuit breaker in home has tripped.

Failed power switch. -Make sure power

Failed power cord. -Take voltage check of

Breaker on machine has tripped or has failed.

Improper wiring or AC wires have failed.

Failed console cable. -Check console cable

Failed upper board. -Check voltage and

Failed motor control board. (MCB)

-Check for dedicated circuit (20 amp is ideal) and check wall outlet voltage (120 VAC). Reference p26.

switch is turned on.

power cord. Reference p25.

-Reset breaker. Replace breaker if

-Check all wiring coming in from the power switch to the motor control board and to the upper board. Reference p29.

voltages at B7, B8 Reference p35.

continuity of console cable. Reference p35.

-Check voltage and continuity of console cable. Reference p35.

-Verify the power LED is lit on the MCB.

Reset breaker.

Replace power switch if necessary.

Replace power cord.

necessary.

Connect wires correctly or replace as needed.

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.

Inadequate power. -Check for dedicated

Damaged or improper wiring.

-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.)

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.

-Verify there are no pinches or cuts in the power cord, power wires motor wires, or console cable.

-Verify the connections of above wires and cords.

- Replace safety key.

- If plastic tab is broken replace console shell. (Slot style safety key only.)

If the AC voltage is missing or incorrect, check the AC service or consult an electrician.

Replace parts as needed.

Inadequate lubrication on deck and running belt.

Membrane keys. Reference Membrane

50 | 2008 AFG Service Seminar [rev 1.3]

-Place hand underneath running belt and feel for adequate silicone application.

Troubleshooting p51.

Apply silicone.

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Membrane | Key Pad | Overlay

Symptom Possible Cause Test Procedure Repair

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.

Membrane keypad defective.

Upper board defective. -Keys are pressed and

-Verify the ribbon cables are connected securely into the upper board.

-Keys are pressed, some of the buttons may function but there are no corresponding beeps.

-Put in Eng0 to chech button function. Reference p44.

there are corresponding beeps, but console does not respond. (Sometimes the key will not beep until it is released).

Remove and reseat cables.

Replace membrane keypad.

Replace upper board.

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.

2008 AFG Service Seminar [rev 1.3] | 51

Replace membrane keypad.

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 will only register if moved outside of the proper position.

Safety key is positioned incorrectly or has failed.

Failed reed switch or failed uper control board.

Improperly aligned reedswitch.

-Remove safety key and reapply.

-Test magnet.

-Short the switch connector on the upper

board by using a at

blade screwdriver or by placing a jumper switch on the connector.

Remove glue from reedswitch and reposition.

Replace safety key.

If the upper board still displays dashes then replace upper board. Otherwise replace reedswitch.

Test for proper function and glue into place.

52 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Heart Rate

Symptom Possible Cause Test Procedure Repair

Heart rate erratic. User error. Reference Proper Heart

Rate Usage p23.

Failed heart rate receiver.

Failed upper board. Reference Proper Heart

No heart rate function. (Hand Grips)

Heart rate erratic. User error. Reference Proper Heart

No heart rate function. (Telemetric chest strap)

Failed heart rate grips. Reference Proper Heart

Electromagnetic interference.

Failed telemetric chest strap or polar receiver.

Reference Proper Heart Rate Usage p23.

Rate Usage p23.

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.

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.

Failed motor control board (MCB).

Machine not calibrated properly.

Inadequate power. -Check for dedicated

Failed or improper wiring. -Verify there are no

-Running belt is too loose or too tight.

-Drive belt is too loose or too tight.

-Run auto calibration. Reference Eng. Mode p44.

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.

pinches or cuts in the power cord, power wires, motor wires, or console cable.

-Verify the connections of above wires and cords.

-The running belt should not slip at all when customer is using the machine. Reference Belt Tensioning p19.

-The drive belt should have approximately 3/8 of

inch deection.

Replace optic sensor.

Replace MCB.

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.

Replace parts as needed.

Set proper drive belt and running belt tension.

54 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Erratic Speed Continued

Symptom Possible Cause Test Procedure Repair

Erratic speeds Running belt speed is not stable. (Continued)

Erratic Speeds-belt speed increases without command, but shows change on display and beeps.

Inadequate lubrication on deck and running belt.

Failed motor control

-Place hand underneath running belt and feel for adequate silicone application. Reference Maintenance p17.

Apply silicone.

Replace MCB.

board (MCB). In a program. -Remove safety key,

then replace.

-Start in P1 and see if reoccurs.

Stuck button. Reference membrane

keypad and overlay troubleshooting p51.

Failed upper board. 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 Test Procedure Repair

Elevation motor starts 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.

Elevation is stuck down and does not function. Console is responsive to the buttons being pressed.

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 lower board. -Turn on power. Do not press

start. Wait 30-60 seconds and see if motor is hot. Use caution. Motor can get very hot.

Failed elevation motor. Replace elevation motor.

-Failed elevation motor.

-Failed console cable (CC).

-Improperly calibrated elevation motor.

Failed console cable (CC). -Verify console cable

Failed elevation motor. -Put machine in hardware

Failed upper board. -Put machine in hardware

Failed upper board, lower board, console cable, and elevation motor.

Failed lower board. -The incline will act normally

-Verify there are no pinches or cuts on the elevation wires. Reference CC continuity p35.

-Verify the connections of above wires.

connections. Verify there are no pinches or cuts in the cable. Reference CC continuity p35.

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.

test (Eng1) and press start. Incline will work in hardware test only. Reference Eng. Mode p44.

-Verify all wire connections. Replace upper board, console

when going up, bet when the down incline is pressed there is no movement.

Replace lower board.

-Recalibrate elevation motor by hand. Reference Resetting the Incline Motor p30.

-Replace elevation motor.

Replace console cable.

Replace elevation motor.

Replace upper board.

cable, and elevation motor.

Replace lower board.

56 | 2008 AFG Service Seminar [rev 1.3]

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.

Damaged or improper wiring.

Failed motor control board (MCB).

Failed drive motor. -Measure voltage output

Failed optic sensor. -Verify voltage of digital

-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.

from motor. Reference motor, AC Wire Voltage Check p34.

sensor. Reference p32.

If the AC voltage is missing or incorrect, check the AC service or consult an electrician.

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.

Machine breaker will trip.

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. Inadequate lubrication on deck and running belt.

Failed running belt. -Feel underside of

Failed drive motor. -Perform AMP draw test

Failed motor control board (MCB).

Failed circuit breaker. Replace circuit breaker.

-Place hand underneath

running belt and feel for

adequate silicone

application.

running belt. It should

have a rough feel to it.

(similar to denim)

on motor. Reference

AMP Draw, p26.

If the AC voltage is missing or incorrect, check the AC service or consult an electrician.

Apply Silicon lubrication. Reference Lubrication p18.

Replace running belt.

Replace drive motor.

Replace MCB.

58 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Treadmill Troubleshooting

>> Noise

Symptom Possible Cause Test Procedure Repair

Thumping sound when running belt is engaged.

Rubbing or grinding sound from underneath motor cover.

Banging or clunking sound.

New treadmill. Let the treadmill run for

about 30 min. at 5mph

without a load to break

in new running belt in. Failed roller. Replace front or rear

roller as needed.

Misaligned drive belt. - Remove motor cover

and verify alignment of

drive belt.

- Inspect for debris on

drive motor pulley, front

roller pulley, or on drive

belt. Optic disk is hitting the

optic sensor/guard.

Failed drive motor bearings.

Motor brushes are not seated properly.

-Unit not level.

-Bent frame.

-Run unit and look for

optic sensor/disk

missalignment.

Inspect motor brushes

and commutator for

abnormal wear.

-Check levelers and the

oor.

-Inspect frame for

damage.

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

61 63 65 66 67

60 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Elliptical | Bike Troubleshooting

>> Noise | Drive Train

Symptom Possible Cause Test Procedure Repair

Noise internally while pedaling at higher resistance levels only.

Noise internally/ externally while pedaling or rough feel while pedaling.

Magnetic brake is rubbing against the

ywheel.

Machine may not be on level surface.

Improper assembly or loose assembly bolts.

Alignment issues with pedal arms due to improper assembly or improper welds.

Build up on, or defective roller wheels.

Loose crank arms. Tighten crank arms. Improper drive belt

alignment, improper drive belt tension, or

failed ywheel.

-Verify the correct

position of magnetic

brake. Reference p31.

-Verify surface is level. Adjust levelers on

-Verify assembly steps

using owner’s guide.

-Reference Alignment

Issues with Pedal Arms

Troubleshooting.

Reference p67.

-Wipe off 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.

Noise may present itself

multiple times during

one pedaling motion.

Reposition the magnetic brake. Reference Adjusting the Magnetic Break p31.

machine. Tighten all bolts used

for assembly. Reference Maintenance p20.

Replace roller wheels.

Align drive belt and adjust to proper tension

or replace ywheel.

2008 AFG Service Seminar [rev 1.3] | 61

Section Three | Troubleshooting

Elliptical | Bike Troubleshooting

>> Noise | Drive Train Continued

Symptom Possible Cause Test Procedure Repair

Noise internally/ externally while pedaling or rough feel while pedaling. (Continued)

Failed pedal axle set. 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

foot pad on Mini-E. Gap between front

stabilizer and elliptical frame.

Flywheel defective (Bike Only).

-Remove foot pad and

tighten bolt.

Check to see if there is

a large gap between the

front stabilizer and

elliptical frame.

-Verify the noise

continues a few seconds

after the pedal stops

moving.

Replace pedal axle set.

Replace Pivot Tube(s).

Replace pivot block bushing, bolt and nut.

Tighten bolts. If gap is

still present use exible Teon washers to ll the

space. Replace the Flywheel.

62 | 2008 AFG Service Seminar [rev 1.3]

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.

Partial LCD Display on Console.

Failed or improper power supply.

Failed console. Replace console. Console was subjected

to cold temperatures.

Failed or improper power supply.

Failed console. Replace console.

- Perform voltage check

on power supply.

- Verify the power

supply and make sure

the adapter is the

correct voltage.

- 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.

Replace power supply.

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.

2008 AFG Service Seminar [rev 1.3] | 63

Section Three | Troubleshooting

Elliptical | Bike Troubleshooting

>> Console Continued

Symptom Possible Cause Test Procedure Repair

Console Resets Intermittently.

Only Time Works on Console (No workload, distance or calories.)

Poor connection between power supply and power jack.

Failed power supply. -Perform voltage check

Failed console cable. - Verify console cable is

Failed console. Replace console. Failed sensor wire. -Perform RPM

Missing rpm magnet on crank assembly or misaligned RPM sensor.

Failed console. Replace console.

-Verify that the power

supply is securely

inserted into the power

jack.

on power supply.

not pinched or

damaged.

-Perform voltage check

on console cable.

Reference p42.

continuity check.

-Visually verify presence

of magnet in pedal axel

and alignment of RPM

sensor.

Replace power supply.

Replace console cable.

Replace sensor wire.

Replace magnet and/or reposition RPM sensor.

64 | 2008 AFG Service Seminar [rev 1.3]

Section Three | Troubleshooting

Elliptical | Bike Troubleshooting

>> Heart Rate

Symptom Possible Cause Test Procedure Repair

Heart rate erratic or no heart rate function. (Hand Grips)

Heart rate erratic or no heart rate function. (Telemetric chest strap)

User error. Reference Proper Heart

Rate Usage p23. Failed heart rate grips. Reference Proper Heart

Rate Usage p23.

Failed heart rate receiver.

User error. Reference Proper Heart

Electromagnetic interference.

Failed telemetric chest strap or polar receiver.

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.

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.

Resistance is Too Hard or Too Weak.

Tension cable is not connected to the brake or has failed.

Failed or improper power supply.

Failed console cable. - Verify console cable is

Failed servomotor. -Perform voltage check

Failed console. Replace console. Tension cable is not

connected to the brake or has failed.

Magnetic brake is positioned improperly.

-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.

not pinched or damaged

-Perform voltage check

on console cable.

Reference p42.

on servomotor.

Reference p40 and p41.

-Verify that the tension

cable is connected to

the break or has not

failed.

-Verify the correct

position of magnetic

brake.

Reference p31.

Reattach cable.

Replace power supply.

Replace console cable.

Replace servomotor.

Reattach cable.

Reposition the magnetic brake.

66 | 2008 AFG Service Seminar [rev 1.3]

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.

Loose crank arms. Tighten crank arms. Alignment issues with

pedal arms due to improper welds.

-Verify assembly steps

using owner’s guide.

-Disconnect

appropriate link arm

from lower handle bar

assembly and pedal

unit.

Tighten all bolts used for assembly. Reference Maintenance p20 and p21.

- 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.

2008 AFG Service Seminar [rev 1.3] | 67

Table of Contents

Gym Troubleshooting

Noise | Rough Cables Weight Selector Pin

69 70

68 | 2008 AFG Service Seminar [rev 1.3]

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

noticable damage to the

cables.

-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.

Adjust cable for proper tension. Replace cable.

2008 AFG Service Seminar [rev 1.3] | 69

Section Three | Troubleshooting

Gym Troubleshooting

>> Weight Selector Pin

Symptom Possible Cause Test Procedure Repair

Weight selector pin cannot be inserted.

-Verify that the selector

pin isn’t bent or

damaged.

NOTE: Always maintain

at least ½˝ of threaded

bolt in bayonette.

Reference p. 22.

-Adjust threaded bolt on top plate so that the holes in the bayonette align with the weight plate.

-Replace selector pin.

70 | 2008 AFG Service Seminar [rev 1.3]

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. Due to the Console cable length it may rattle if

Side rail edges are very sharp. A tech cut his hand open needed to get 5 or 6 stitches.

There is also a clanking noise which is due to the bolt being smaller then the hole in the bottom incline bracket.

Serial # for the T4 & T6 models is located on the plastic motor cover.

Incline bracket creaking when unit is in incline position above 0.5%

The levelers on the main frame need to be

loosened so that they sit securely against the

elevation frame at 0%.

loose. Tie the console cable down.

If there is a repair needed on unit with the side

rails involved send technician. Do not let the

customer repair or replace. This is being changed

to reduce the sharpness of the edge.

Quality has improved the bolt size to make it a

better t.

It is important that we get as much information

from that unit as possible in case the motor cover

is replaced.

Use teon washers on brackets to keep the motor

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.

200 units produced where the shading is incorrect 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 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.

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.

Replace overlay

Replace UCB with updated software

Models | 3.2T (2006)

Hardware/software compatibility issues, 2nd generation digital MCB.

Replace UCB with updated software

72 | 2008 AFG Service Seminar [rev 1.3]

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

ywheel.

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

x 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 ywheel 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 led 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.

Models | 2.0AH (2008 Hybrid Bike)

During life testing, a sample at the factory had the cranks loosen.

The inner bushings have been modied to

eliminate this problem and should be sent.

There are updated bolts | nuts that can be sent

when other repairs fail.

A cup washer is being placed at the point where

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

Version 1.1 JHP September 2007

Phone 877-GOAFG55 (462-3455) | Fax 608.839.1280 | retailers@advancedtnessgroup.com

Horizon Fitness 1.0AT, 13.0AT, 14.0At, 2.0AE, 3.0AE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual