Horizon Fitness 1.0AT, 13.0AT, 14.0At, 2.0AE, 3.0AE Service Manual
...
AFG Service Seminar
Horizon Fitness
Models
1.0AT, 2.0AT, 2.0AT,
4.0AT, 5.0AT, 13.0AT,
14.0At
Models
2.0AE, 3.0AE, 4.0AE,
14.0AE, 18.0AE
Models
2.0AR, 3.0AR, 4.0AR,
3.0AH, 4.0AH
Models
2.0AS
Table of Contents
>> Table of Contents
Section One Section Two
Warranty
Service and Billing Information
Safety Instructions 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
23
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
71
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
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 qualied 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 qualied 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
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
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:
G
O
L
F
COUR
S
E
P7:
P
A
CER
P8
: THR
ZONE
P10: CUS
TOM 2
P9
: CUS
TOM 1
P1:
MA
NUAL
P2:
I
NTERVALS
P3:
MTN C
LI
MB
P4:
WEIGH
T LOSS
P5:
PEA
K
INTERVALS
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
DISTANC
E
TIME
IN
C
L
INE
HE
ART RATE
S
PEED
CALORI
ES
8
6
4
2
+
1
%
%
%
%
1
0
%
1
2
%
%
1
0
8
6
4
2
MPH
1
2
MPH
MPH
MPH
MPH
MPH
+
1
MPH
CHANGE
DIS
P
L
A
Y
S
TAR
T
QUICK
STA
RT
STO P
HOLD T
O RESET
PRES
S
T
O
CO
NFIRM
INCLI
NE
PR
ESS T
O
CO
N
F
IRM
SPEED
ENT
ER
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 Teon 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
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