Johnson AFG Series User manual

1
JOHNSON
Issue date
2016-9-27
Edition
01
Doc No.
Revision
date
Edition time
01
Page
34
Johnson Industries (Shanghai) Co., Ltd
AFG 5.5AT & 5.9AT
Service Manual
Approval
Review
Editor
Kyle Schweitzer
Dora Feng

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Product Browse
5.5AT

3
Product Browse
5.9AT

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Contents
CHAPTER 1: SERIAL NUMBER LOCATION............................................................................................................. 6
CHAPTER 2: CONSOLE INSTRUCTION
2.1 Console Operation..................................................................................................................................................7
2.2 Display Window...................................................................................................................................................... 8
2.3 Getting Started........................................................................................................................................................ 8
2.4 Workout Profiles..................................................................................................................................................... 9
2.5 Target Profiles......................................................................................................................................................... 9
2.6 Reset The Console...............................................................................................................................................10
2.7 Finishing Your Workout....................................................................................................................................... 10
2.8 Using Your CD/MP3 Player................................................................................................................................ 10
2.9 AFG TABLET CONNECTED FITNESS SYSTEM (5.7AT & 5.9AT ONLY).................................................10
CHAPTER 3: ELECTRIC CONNECTION SYSTEM
3.1 Electrical Diagram................................................................................................................................................ 11
3.2 UCB Circuit Board Instruction.............................................................................................................................14
3.3 MCB Circuit Board Instruction............................................................................................................................ 15
CHAPTER 4: ENGINEERING MODE.........................................................................................................................17
CHAPTER 5: TROUBLESHOOTING
5.1 Error Code List...................................................................................................................................................... 19
5.2 No Power To The Console..................................................................................................................................19
5.3 No Function For Safety Key................................................................................................................................ 20
5.4 No Response For Machine (Console & Motor)............................................................................................... 20
5.5 Incline Motor Issues............................................................................................................................................. 21
5.6 Noise Issues..........................................................................................................................................................21
5.7 Heart Rate Function Issue.................................................................................................................................. 24
5.8 Speaker / Audio Issues........................................................................................................................................24

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CHAPTER 6: PART REPLACEMENT GUIDE
6.1 Motor Replacement........................................................................................................................................... 25
6.2 Rear Roller Replacement................................................................................................................................. 26
6.3 Side Rail Replacement......................................................................................................................................27
6.4 Running Deck Replacement............................................................................................................................ 28
6.5 Front Roller Replacement.................................................................................................................................29
6.6 Running Belt Replacement............................................................................................................................... 30
6.7 Motor Control Board (MCB) Replacement..................................................................................................... 31
6.8 Drive Belt Replacement.....................................................................................................................................32
6.9 Incline Motor Replacement............................................................................................................................... 33
6.10 Console Replacement.....................................................................................................................................34

CHAPTER 1: Serial Number Location
6
SERIAL NUMBER

CHAPTER 2: Console Instruction
7
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) INCLINE / KEYS: used to adjust incline in small increments (0.5% increments).
H) SPEED / KEYS: used to adjust speed in small increments (0.1 mph increments).
I) INCLINE QUICK KEYS: used to reach desired incline more quickly.
J) SPEED QUICK KEYS: used to reach desired speed more quickly.
K) FAN KEY: press to turn fan on and off.
L) FAN: personal workout fan.
M) SPEAKERS: music plays through speakers when your CD / MP3 player is connected to the console.
N) AUDIO IN JACK: plug your CD / MP3 player into the console using the included audio adaptor cable.
O) 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.
P) USB INPUT: 1A/5V USB output power. (5.7AT & 5.9AT ONLY)
Q) WATER BOTTLE POCKETS: holds personal workout equipment.
R) TABLET/READING RACK: holds tablet or reading material.
S) CHANGE DISPLAY: changes display level between top and bottom row. (5.7AT & 5.9AT ONLY)

CHAPTER 2: Console Instruction
8
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 or distance remaining during your workout.
SPEED: Shown as MPH. Indicates how fast your walking or running surface is moving.
INCLINE: Shown as percent. Indicates the incline of your walking or running surface.
CALORIES: Total calories burned or calories remaining left to burn during your workout.
HEART RATE: Shown as BPM (beats per minute). Used to monitor your heart rate (displayed when contact
is
made with both pulse grips).
2.3 GETTING STARTED
1) Check to make sure no objects are placed on the belt that will hinder the movement of the treadmill.
2) Plug in the power cord and turn the treadmill ON. (The ON/OFF switch is next to the power cord.)
3) Stand on the side rails of the treadmill.
4) Attach the safety key clip to part of your clothing making sure that it is secure and will not become
detached during operation.
5) Insert the safety key into the safety keyhole in the console.
6) You have two options to start your workout:
A) QUICK START UP
Simply press the START key to begin working out.
Time, distance, and calories will all count up from zero. OR...
B) SELECT A WORKOUT OR TARGET
1) Select your USER by turning the workout knob and then pressing when your desired USER is displayed.
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.

CHAPTER 2: Console Instruction
9
2.4 WORKOUT PROFILES
1) MANUAL: Adjust your speed and incline manually during your workout.
2) INTERVALS: Improves your strength, speed and endurance by increasing and decreasing the
speed throughout your workout to
involve your heart and other muscles. Includes 10 levels.
Speed changes and segments repeat 90 seconds and 30 seconds
3) WEIGHT LOSS: A workout designed specifically to target fat.
Promotes weight loss by increasing and decreasing the speed and incline, while keeping you in your fat
burning zone. Includes 10 levels.
Speed and Incline changes, segments repeat every 30 seconds.
2.5 TARGET PROFILES
1) TARGET 1 – DISTANCE: Push yourself and go further during your workout with 13 distance workouts.
Choose from 1 mile, 2 miles,
5k, 5 miles, 10k, 8 miles, 15k, 10 miles, 20k, half marathon, 15 miles, 20 miles and marathon goals. User
sets starting speed and incline
levels.
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 speed and incline levels. Calories

CHAPTER 2: Console Instruction
10
burned are calculated using weight input of user profile.
2.6 RESET THE CONSOLE
Hold STOP key for 3 seconds.
2.7 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.
2.8 USING YOUR CD / MP3 PLAYER
1) Connect the included AUDIO ADAPTOR CABLE to the AUDIO IN JACK on the top right of the console
and the headphone jack on your CD / MP3 player.
2) Use your CD / MP3 player buttons to adjust song settings.
3) Remove the AUDIO ADAPTOR CABLE when not in use.
4) If you don’t want to use the SPEAKERS, you can plug your headphones into the AUDIO OUT JACK at
the bottom of the console.
2.9 AFG TABLET CONNECTED FITNESS SYSTEM (5.7AT & 5.9AT ONLY)
Your AFG machine is tablet ready, allowing you to use Bluetooth 4.0 technology to wirelessly connect your
tablet to your AFG sport treadmill. Using the free downloadable AFG Fitness app will enable you to control
your treadmill’s operating functions via your tablet. The app will also allow you to monitor your workout, track
your progress and view your workout history. The AFG Fitness app can be downloaded from either the
iTunes store for IOS devices or from the Google store for Android devices. Be sure to check your tablet
owner’s manual to ensure it is Bluetooth 4.0 compatiable.
For information about connecting your tablet to your AFG Sport treadmill, setting up the AFG
Fitness App and controlling and monitoring your workout with your tablet, see the AFG
Connected Fitness Manualincluded with your treadmill.

CHAPTER 3: Electrical Connection System
11
3.1 ELECTRICAL DIAGRAM
5.5AT Console Wire

CHAPTER 3: Electrical Connection System
12
5.5AT Console Wire
5.5AT USB Wire
Function
Function
1
VBUS1
8
IGND
2
GND
9
RIGHT
3
USB_DP
10
SEL
4
USB_DM
11
SW
5
LED CTL1
12
SIG
6
LED CTL2
13
SIG
7
LEFT

CHAPTER 3: Electrical Connection System
13
Console wire

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

CHAPTER 3: Electrical Connection System
15
3.3 MCB CIRCUIT BOARD INSTRUCTIONS
5.5AT MCB
CN1
Power line
CN2
Incline motor power connector
CN3
Console cable connector
CN4
Speed sensor connector
CN5
Drive motor connector

CHAPTER 3: Electrical Connection System
16
3.3 MCB CIRCUIT BOARD INSTRUCTIONS
5.9AT MCB
CN1
Power Line
CN2
Incline motor power cable
CN3
Speed sensor cable
CN4
Console set cable
CN5
Software burning cable
CN6
Drive motor cable
MCB LED Configure

CHAPTER4: Engineer Mode
17
Press incline ▲ and speed ▼3 seconds at the same time to enter ENG mode.
1) You can clockwise rotate “push to select” to select ENG mode;
2) You can press “▲/▼” to select ENG mode;

CHAPTER4: Engineer Mode
18

CHAPTER5: Troubleshooting
19
5.1 Error Code List
Mode Name
Error Code
Description
5.5AT
E1
RPM was not detect
E2
Sudden accelerate
5.9AT
NA
NA
5.2 TROUBLESHOOTING – NO POWER TO THE CONSOLE
1) SYMPTOM:
a. Turn on the power switch, but the console will not light up.
2) SOLUTION:
Please note the MCB in this model does NOT have an LED indicating the power is on. This means voltage
measurements must be taken to find the cause of a non-functioning console. Continue with each step below until the
problem is found.
a. Check power at the console. Measure power on pins 1 and 2 on the console cable where it connects to the console.
These are the same 2 wires labelled “12V and GND” on the console PCB as seen in the red circle below. If there is
approximately 12 VDC on pins 1 and 2, replace the console. If not, continue to step b.
b. Check the MCB is providing power to the console. Measure the pins in the yellow circle in the picture below. If
approximately 12 VDC is measured at these pins, replace the console cable.
c. Check that the MCB is receiving 120 VAC. Measure the black and white wires which connect to the MCB. If there is
approximately 120 VAC (+/- 15 VAC) on these wires, replace the MCB. As previously mentioned, this MCB has no
indicator LED to indicate the MCB is receiving power.
d. Check the outlet, power cord, breaker, switch, and internal wiring. If there was no AC voltage measured at the
MCB in step 3, then there is a problem with the AC voltage getting to the MCB. Carefully check the building breaker,
electrical outlet, power cord, treadmill breaker, treadmill power switch, and treadmill internal wiring to determine why AC
voltage is not being supplied to the MCB. The technician must verify what is not functioning with voltage and continuity
checks before ordering any parts to avoid sending unnecessary parts.

CHAPTER 3: Troubleshooting
20
5.3 TROUBLESHOOTING – NO FUNCTION FOR SAFETY KEY
1) SYMPTOM:
a. The safety key inserted in console, but display window still shows “safety key off”.
2) SOLUTION:
a. Check if the safety key totally inserted in the console.
- If no, take off and insert again.
b. Check if the safety key oxidized or not which will affect the conduction.
- If yes, please change a new one.
c. If the safety key is function, check the safety key sensor wires in console.
- Suggest to re-connect the wires or to change new wires.
5.4 TROUBLESHOOTING – NO RESPONSE FOR MACHINE (CONSOLE&MOTOR)
1) SYMPTOM:
The power is on and the console lights up, but the treadmill does not run when keys are pressed.
2) SOLUTION:
a. Check if the console beeps when all keys are pressed. If no, replace the keypads.
b. Enter Engineering Mode, and scroll to ENG 1 (Hardware Test).Press the key “ENTER” first and
then the key ”START”.
- When press the key “SPEED + / -“, if the data on windows “TIME” & “DISTANCE” is changed, the
console is ok. If not, replace the PCB.
c. Turn off the power switch, and open the motor upper cover. Remove the red & black wires of motor
from the MCB, and use a multi-meter to measure the resistance of drive motor.
If the resistance is bigger than 10 Ω, the drive motor is defective. Replace the drive motor.
If the resistance is lower than 10 Ω, the drive motor is ok. Then,
- Check the connection of the speed sensor (encoder disk group) at the MCB.
- Remove the speed sensor from the motor and clean it, then re-test.
- If the speed sensor is clean and has a good connection but still will not operate, replace the speed
sensor.
- Replace the MCB as the last step if machine does still not run after to take above actions.