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JOHNSON
Issue date 2017-8-29 Edition 01 Doc No. SM-TM-AF-007
Revision
date
Edition time 01 Page 29
Approval Review Editor
Kyle Schweitzer Alex Tang Dora Feng
Johnson Industries (Shanghai) Co., Ltd
AF5.5AE & 5.9AE
Service Manual
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5.5AE
Product Browse
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5.9AE
Product Browse
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Contents
CHAPTER 1: SERIAL NUMBER LOCATION ............................................................................................... 6
CHAPTER 2: CONSOLE INSTRUCTION
2.1 5.5AE Console Instruction ................................................................................................................. 8
2.2 5.9AE Console Instruction ............................................................................................................... 12
CHAPTER 3: ELECTRIC CONNECTION SYSTEM
3.1 5.5AE Electrical Diagram............................................................................................................... 14
3.1.1 5.5AE Wiring Schematic............................................................................................................... 14
3.1.2 5.5AE UCB Circuit Board Instructions .......................................................................................... 15
3.2 5.9AE ELECTRICAL DIAGRAM ...................................................................................................... 16
3.2.1 5.9AE Wiring Schematic............................................................................................................... 16
3.2.2 5.9AE UCB Circuit Board Instructions .......................................................................................... 17
3.2.3 5.9AE LCB ................................................................................................................................... 17
3.2.4 5.9AE LCB LED Description ......................................................................................................... 18
CHAPTER 4: ENGINEERING MODE………………………………………………………………………………..19
CHAPTER 5: TROUBLESHOOTING
5.1 Console Does Not Light Up ............................................................................................................. 21
5.2 Heart Rate Function Issues ............................................................................................................. 21
5.3 Incline Motor Issues ........................................................................................................................ 22
5.4 No Resistance or Incorrect Resistance Issues…………………………………………………................22
5.5 Speed Does Not Display ................................................................................................................. 24
CHAPTER 6: PART REPLACEMENT GUIDE
6.1 Console Replacement ..................................................................................................................... 25
6.2 Console Mast Replacement ............................................................................................................ 26
6.3 Arm Set Replacement ..................................................................................................................... 27
6.4 Link Arm Replacement .................................................................................................................... 28
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6.5 Crank Set Replacement .................................................................................................................. 29
6.6 Side Cover Replacement ................................................................................................................ 30
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CHAPTER 1: Serial Number Location
5 5.5AE
Serial number location
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CHAPTER 1: Serial Number Location
5.9AE
Serial number location
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CHAPTER 2: Console Instruction
2.1 5.5AE Console Instruction
2.1.1 CONSOLE OPERATION
Note: There is a thin protective sheet of clear plastic on the overlay of the console that should be removed before use.
A) LED DISPLAY WINDOWS: time, distance, calories, heart rate, speed, and incline.
B) TARGET LED INDICATORS: indicate what target (if any) is set for the current program.
C) WORKOUT LED INDICATORS: indicate what workout is set for the current program.
D) SELECT TARGET/WORKOUT KNOB: rotate/press to select your desired workout/target
E) START: press to begin exercising, start your workout, or resume exercising after pause.
F) STOP: press to pause/end your workout. Hold for 3 seconds to reset the console.
G) RESISTANCE / KEYS: used to adjust resistance.
H) RESISTANCE QUICK KEYS: used to reach desired resistance more quickly.
I) FAN KEY: press to turn fan on and off.
J) FAN: personal workout fan.
K) SPEAKERS: music plays through speakers when your CD / MP3 player is connected to the console.
L) AUDIO IN JACK: plug your CD / MP3 player into the console using the included audio adaptor cable.
M) AUDIO OUT / HEADPHONE JACK : plug your headphones into this jack to listen to your music through the headphones. Note: when
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CHAPTER 2: Console Instruction
headphones are plugged into the headphone jack the sound will no longer come out through the speakers.
N) USB INPUT: 1A/5V USB output power.
O) TABLET/READING RACK: holds tablet or reading material.
P) CHANGE DISPLAY: changes display level between top and bottom row. (5.7AT ONLY)
2.1.2 DISPLAY WINDOWS
• TIME: Shown as minutes : seconds. View the time remaining or the time elapsed in your workout.
• DISTANCE: Shown as miles. Indicates distance traveled during your workout.
• SPEED: Shown as MPH. Indicates how fast the foot pedals are moving.
• CALORIES: Total calories burned during your workout.
• HEART RATE: Shown as BPM (beats per minute). Used to monitor your heart rate (displayed when contact is
made with both pulse grips).
• LEVEL: Shows the current level of resistance.
• TARGETS:
LED lights up next to currently selected target. If no LED is lit, no target is activated.
• WORKOUTS:
LED lights up next to currently selected workout. If no LED is lit, no workout is activated.
2.1.3 GETTING STARTED
1) Check to make sure no objects are nearby that will hinder the movement of the elliptical.
2) Plug in the power cord to turn the elliptical ON.
3) A) QUICK START UP
Simply press the START key to begin working out. The time will count up from 0:00, the resistance level will default to level 1. OR...
B) SELECT A TARGET AND WORKOUT
1) Select your USER by turning the workout knob and then pressing when your desired USER is displayed.
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CHAPTER 2: Console Instruction
2) Select your WEIGHT by turning the workout knob and then pressing when your desired WEIGHT is displayed.
3) Select your PROGRAM by turning the workout knob and then pressing when your desired PROGRAM is displayed.
4) Adjust the SETTING by turning the workout knob and then pressing when your desired SETTING is displayed.
5) Press START to begin.
2.1.4 WORKOUT PROFILES
1) MANUAL: Adjust your resistance manually during your workout.
2) INTERVALS: Improves your strength, speed and endurance by increasing and decreasing the resistance throughout your workout to
involve your heart and other muscles. Includes 10 levels.
Notes: Resistance changes and segments repeat 30 seconds and 90 seconds.
3) WEIGHT LOSS: A workout designed specifically to target fat. Promotes weight loss by increasing and decreasing the resistance, while
keeping
you in your fat burning zone. Includes 10 levels
Resistance changes, segments repeat every 60 seconds.
2.1.5 TARGET PROFILES
1) TARGET 1 – DISTANCE: Push yourself and go further during your workout with 13 distance workouts. Choose from 1 mile, 2 miles,
5k,
5 miles, 10k, 8 miles, 15k, 10 miles, 20k, half marathon, 15 miles, 20 miles and marathon goals. User sets starting resistance levels.
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CHAPTER 2: Console Instruction
2) TARGET 2 – CALORIES: Set goals for burning calories with nine workouts. Choose from 100, 200, 300, 400, 500, 600, 700, 800, or
900 calorie burn workouts. User sets starting resistance levels. Calories burned are calculated using weight input of user profile.
2.1.6 TO RESET THE CONSOLE
Hold STOP key for 3 seconds.
2.1.7 FINISHING YOUR WORKOUT
When your workout is complete, the unit will beep. Your workout information will stay displayed on the console for 30 seconds and then
reset.
2.1.8 USING YOUR CD / MP3 PLAYER
1) Connect the included AUDIO ADAPTOR CABLE to the AUDIO IN JACK on the bottom left of the console and the
headphone jack on your CD / MP3 player.
2) Use your CD / MP3 player buttons to adjust song settings.
3) Remove the AUDIO ADAPTOR CABLE when not in use.
4) If you don’t want to use the SPEAKERS, you can plug your headphones into the AUDIO OUT JACK at the bottom of the
console.
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CHAPTER 2: Console Instruction
2.2 5.9AE Console Instruction
2.2.1 CONSOLE OPERATION
Note: There is a thin protective sheet of clear plastic on the overlay of the console that should be removed before use.
A) LED DISPLAY WINDOWS: time, distance, calories, heart rate, speed, and incline.
B) TARGET LED INDICATORS: indicate what target (if any) is set for the current program.
C) WORKOUT LED INDICATORS: indicate what workout is set for the current program.
D) SELECT TARGET/WORKOUT KNOB: rotate/press to select your desired workout/target
E) START: press to begin exercising, start your workout, or resume exercising after pause.
F) STOP: press to pause/end your workout. Hold for 3 seconds to reset the console.
G) RESISTANCE / KEYS: used to adjust resistance.
H) RESISTANCE QUICK KEYS: used to reach desired resistance more quickly.
I) FAN KEY: press to turn fan on and off.
J) FAN: personal workout fan.
K) SPEAKERS: music plays through speakers when your CD / MP3 player is connected to the console.
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CHAPTER 2: Console Instruction
L) AUDIO IN JACK: plug your CD / MP3 player into the console using the included audio adaptor cable.
M) AUDIO OUT / HEADPHONE JACK : plug your headphones into this jack to listen to your music through the headphones. Note: when
headphones are plugged into the headphone jack the sound will no longer come out through the speakers.
N) USB INPUT: 1A/5V USB output power.
O) TABLET/READING RACK: holds tablet or reading material.
P) CHANGE DISPLAY: changes display level between top and bottom row.
2.2.2 DISPLAY WINDOWS
• TIME: Shown as minutes : seconds. View the time remaining or the time elapsed in your workout.
• DISTANCE: Shown as miles. Indicates distance traveled during your workout.
• SPEED: Shown as MPH. Indicates how fast the foot pedals are moving.
• CALORIES: Total calories burned during your workout.
• HEART RATE: Shown as BPM (beats per minute). Used to monitor your heart rate (displayed when contact is
made with both pulse grips).
• INCLINE: Shown as percent. Indicates the incline level of the power ramp.
• TARGETS:
LED lights up next to currently selected target. If no LED is lit, no target is activated.
• WORKOUTS:
LED lights up next to currently selected workout. If no LED is lit, no workout is activated.
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CHAPTER 3: Electrical Connection System
3.1 5.5AE ELECTRICAL DIAGRAM
3.1.1 5.5AE WIRING SCHEMATIC
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CHAPTER 3: Electrical Connection System
3.1.2 5.5AE UCB CIRCUIT BOARD INSTRUCTIONS
Function
Function
CN1 speaker CN5 Console wire
CN2 Audio in & out CN6 keypad
CN3 keypad CN7 Hand grip
CN4 fan
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CHAPTER 3: Electrical Connection System
3.2 5.9AE ELECTRICAL DIAGRAM
3.2.1 5.9AE WIRING SCHEMATIC
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CHAPTER 3: Electrical Connection System
3.2.2 5.9AE UCB CIRCUIT BOARD INSTRUCTIONS
Function Function
CN1 Speaker CN6 Keypad
CN2 Audio in & out CN7 Heart Rate Grips
CN3 Keypad CN8 polar
CN4 Fan CN9 Handlebar keypad
CN5 Console wire
3.2.3 5.9AE MCB
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CHAPTER 3: Electrical Connection System
3.2.3 5.9AE MCB
Function
CN1 Console wire connector
CN2 Speed sensor connector
CN3 Incline motor connector
3.2.4 MCB LED Description
LED Flash Times
Status
1 Normal
2 No RPM
6 No incline count
7 Communication Abnormal
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CHAPTER 4: Engineer Mode
Press resistance ▲ and resistance▼ at the same time for 3 sec--5.5AE.
Press incline ▲and resistance ▼ at same time for 3 sec--5.9AE
1) Rotate clockwise and press "Push to Select" to enter ENG mode.
2) You can press “▲/▼” to select ENG mode;
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CHAPTER 5: Troubleshooting
5.1 Console Does Not Light Up
1) Symptoms and Possible Causes
a .The power switch is in the on position, but the console will not turn on.
b. The console is damaged or the console cable is not connected properly.
c. Connection to the terminals on the lower control board or console.
d. The lower control board is damaged not output voltage.
e. The Power adaptor is damaged.
2) SOLUTION:
1. Check if the outlet the machine is plugged into is functional.
2. Check if the correct power cord is being used. Only use the power cord included or provided by
customer tech Support.
3. Check if the power cord is not pinched or damaged and is properly plugged into the outlet and the
machine.
4. Remove the console and check if the console has good connection.
Test console cable (JP2) for 12VDC between pin1 & pin8.If power and connection is good then replace
console.
5. Remove the side cover and check to see if console cable is connected well.
6. Check to see if the console upper cable and console lower is connected well.
5.2 Heart Rate Function Issues
1) Symptom: Heart Rate Function Does Not Work or is Reading Incorrectly
2) Solution:
a. Re-center the HR strap on user's chest, strap must have some moisture for good connection.
b. Replace the battery in the wireless HR Strap.
c. Wet the user's hand, and then reestablish contact with the HR grip.
d. With a multi-meter set for DC voltage, place one terminal on each of the HR grip plates. The HR
grip should give a voltage reading of between 0.5 and 2.0VDC. If the voltage is not between 0.5
and 2.0VDC remove the screws holding the HR grip together and check the connection of the HR grip
wire.
e. If the console still does not display proper HR, replace the HR grips.
f. Check a - e. If the HR still does not work, replace the console.
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CHAPTER 5: Troubleshooting
5.3 Incline Motor Issues
1) SYMPTOM:
The incline motor does not lift up or down.
2) SOLUTION:
Enter Engineering Mode, and scroll to ENG 1 (Hardware Test). Press the key “ENTER” first and then the
key ”START”.
Press the key “INCLINE ▲/▼”.to see if the incline motor moves smoothly. If not, the MCB or incline motor
may be damaged.
If can hear beeps from two relays at the MCB, the MCB is ok. Then check the connection of the incline
motor at the MCB first, try to unplug and re-plug these two pins. If cannot resolve the issue, replace the
incline motor. If there is no beeps from these two relays, MCB is defective and replace the MCB.
if the LED on the MCB blinks 6 times it means the MCB does not receive signal count. Maybe incline
motor connection wire (CN3 Page 22) is not connected or damaged. Check the motor connection wire
for proper connection and replace if necessary. Change incline motor if problem still is not resolved.
5.4 No Resistance Or Incorrect Resistance
1. General information:
Symptom Possible Cause Test Procedure Repair
No resistance change
or erratic or continuous
resistance change.
Tension cable is not
connected to the brake or
has failed
Verify that the tension cable
is connected to the brake or
has not failed.
Reattach cable.
Failed or improper power
supply
Perform voltage check on
adapter.
-Verify the adapter is the
correct voltage.
Replace power
supply
Failed console cable.
- Verify console cable is not
pinched or damaged
-Perform voltage check on
console cable.
Replace console
cable
Failed servomotor
-Perform voltage check on
servomotor.
Replace
servomotor.
Fail quick key cable
-Perform resistor check on
Quick key cable pin
Replace handle bar
Quick key cable
Failed console. Replace console.
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Resistance is Too
Hard or Too Weak.
Tension cable is not
connected to the brake or
has failed.
Verify that the tension cable
is connected to the brake or
has not failed.
Reattach cable.
Magnetic brake is
positioned improperly.
-Verify the correct
Position of magnetic brake.
Reposition the
magnetic brake
2) Symptoms & Possible Causes:
a. The resistance is un-adjustable during exercise.
b. The resistance is reverse or much too heavy.
3) Reason.
a. The speed sensor wire is defective.
b.The console cable or ECB motor is defective.
c. The steel rope of the magnet system is not routed correctly.
d.The inside magnet is defective.
4) SOLUTION:
1. Check if the console shows RPM value. If no, refer to solution for “Speed Does Not Display”.
in section 5.5.
2. Turn on the console, and check the ECB motor. At resistance level 1, the head of steel rope points to
top right side (around 45 degrees). If the head of steel rope directs to bottom left side, the resistance
will be reversed, adjust the head of steel rope to the correct position.
3. Press key up “ ↑” to Increase the resistance.
A) . If the ECB motor does not move， the resistance will not be changed. The ECB motor or console
cable is defective. Check the console cable connection at the ECB motor. Use a multi-meter to
measure the voltage through the console cable. It should be 12VDC.
b. If there is no voltage present， the console cable is defective. Replace the console cable.
c. If the voltage is 12VDC， the ECB motor is defective. Replace ECB motor.
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B) If the ECB motor can move, the resistance can be adjusted. If the resistance is still much too heavy.
Check the gap (Fig1) between orange block and the bottom. It shall be within 1-2 mm. If the gap is bigger than
1-2 mm, the resistance will be heavier than normal. Adjust the cable to the correct gap range(Fig2).
4. If all above conditions are ok, and the resistance is still much heavier, inside magnet is defective. Replace
the flywheel
.
Fig1 Fig2
5.5 Speed Does Not Display
1) SYMPTOM:
The speed value does not display on console
2) SOLUTION:
1. Unplug power adaptor remove the console and check that all connections to the console are
Secure and not damaged or pinched.
2. Remove the side cover and check the number of times the LCB error light flashes (refer to section 3.2.4).
3. If it flashes 2 times, then check speed sensor, ECB and LCB in turn. If needed, replace them.
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CHAPTER 6: Part Replacement Guide
6.1 Console Replacement
1. Remove the 4 screws from the console mast. (Fig.A)
2. Take off the console and you can see the wire connections (Fig.B)
3. Disconnect the wires and connect them in the new console.
4. Tuck the wires into the console mast and reinstall the screws.
FIG.A FIG.B
6.2 Console Mast Replacement
1. Remove the cover of console mast
2. Loosen the 4 bolts to remove the mast, carefully pulling the console cables out of the mast.
3. Pull the console cable up through the new mast.
4. Install new console mast with 4 bolts.
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CHAPTER 5: Part Replacement Guide
6.3 Arm Set Replacement
1. Loosen the screw and take off the washers, then move to next step（Fig.A）
2. Loosen the screw and remove the washers at the bottom of the arm to remove the arm set (Fig B).
3. Remove the arm set and replace it with the new one.
Fig.A Fig.B
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CHAPTER 5: Part Replacement Guide
6.4. Link Arm Replacement
1. Loosen the screws and washers to remove the link arm from the arm set.
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CHAPTER 5: Part Replacement Guide
6.5. Crank Set Replacement
1. Remove the pedal arm
2. Loosen the screws and remove the cover.
3. 3. Remove the crank bolt and nut. When replacing the crank, torque this bolt to 70 Nm.
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CHAPTER 5: Part Replacement Guide
6.6 Side cover Replacement
1. Remove crank arm as section 6.5.
2. Loosen the 4 screws in the center cover. (Fig.A)
3. Loosen the screws in the cover as below shows.(Fig.B）
Fig.A Fig.B
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