Johnson Horizon Fitness T202 User manual

Issue date
Edition
01
Doc No.
SM-TM-AF-001
JOHNSON
Revision
Edition time
01
Page
37
date
Johnson Industries (Shanghai) Co.,Ltd
T202 Service Manual
Approval
Review
Editor
1

2

Contents
CHAPTER 1: SERIAL NUMBER LOCATION.............................................................................................................5
CHAPTER 2: PREVENTATIVE MAINTENANCE
2.1 Preventative Maintenance.................................................................................................................................... 6
2.2 Tension and Centering the Running Belt........................................................................................................... 8
CHAPTER 3: CONSOLE INSTRUCTION
3.1 Console Overview.................................................................................................................................................. 9
3.2 Display Window Indication..................................................................................................................................10
3.3 Getting Started & Program Information............................................................................................................ 11
CHAPTER 4: ENGINEERING MODE
4.1 Engineering Mode................................................................................................................................................ 13
4.2 Engineering Mode Overview.............................................................................................................................. 14
CHAPTER 5: TROUBLESHOTING
5.1 Electrical Diagram..............................................................................................................................................15
5.2 MCB Wiring Instructions................................................................................................................................... 16
5.3 Troubleshooting - No Power to the Console..................................................................................................17
5.4 Troubleshooting - No Function For Safety Key.............................................................................................18
5.5 Troubleshooting - No Response for Machine (Console & Motor).............................................................. 19
5.6 Troubleshooting - Incline Motor Issues.......................................................................................................... 20
5.7 Troubleshooting - Noise Issues....................................................................................................................... 21
5.8 Troubleshooting - Speaker / Audio Issues.....................................................................................................23
5.9 Troubleshooting - Heart Rate Function Issues..............................................................................................25
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CHAPTER 6: PART REPLACEMENT GUIDE
6.1 Motor Cover Replacement................................................................................................................................26
6.2 Rear Roller Replacement................................................................................................................................. 27
6.3 Side Rail Replacement......................................................................................................................................28
6.4 Running Deck Replacement............................................................................................................................ 29
6.5 Front Roller Replacement.................................................................................................................................30
6.6 Running Belt Replacement...............................................................................................................................31
6.7 Motor Control Board (MCB) Replacement..................................................................................................... 32
6.8 Motor Replacement........................................................................................................................................... 33
6.9 Drive Belt Replacement.................................................................................................................................... 34
6.10 Incline Motor Replacement............................................................................................................................ 35
6.11 Console Replacement.....................................................................................................................................36
6.12 Heart Rate Board Service.............................................................................................................................. 37
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CHAPTER 1: Serial Number Location
1.1 Serial Number Location
5

CHAPTER 2: Preventative Maintenance
2.1 PREVENTATIVE MAINTENANCE
Preventative maintenance is the key to smoothly operating equipment, as well as keeping the user’s liability
to a minimum. Equipment needs to be inspected at regular intervals. Defective components must be
replaced immediately. Improperly working equipment must be kept out of use until it is repaired. Ensure that
any person(s) making adjustments or performing maintenance or repair of any kind is qualified to do so.
EVERY DAY (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, stop using and contact Customer Technical
Support.
• 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.
• If any labels are damaged or illegible, contact Customer Technical Support for replacements.
EVERY WEEK (WEEKLY)
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 secured.
• 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.
• Remove the motor cover. Wait for ALL display screens to be off.
• Clean the motor and lower board area to eliminate any lint or dust particles that may have accumulated.
6

CHAPTER 2: Preventative Maintenance
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.
2.1 PREVENTATIVE MAINTENANCE-CONTINUED
EVERY 6 MONTHS OR 150 MILES
It is necessary to lubricate your treadmill running deck every
six months or 150 miles (240 kilometers) to maintain optimal
performance. Once the treadmill reaches 150 miles (240
kilometers), the console will display the message “LUBE” or
“LUBE BELT”. The treadmill will not operate while the
message is showing. Hold „STOP‟ for 5 seconds to
suspend message for 5 miles.
Your treadmill came with a bottle of lubricant which
can be used for two applications.
● Turn off the treadmill with the on/off switch, then unplug
the power cord at the wall outlet.
● Loosen both the rear roller bolts. (for best results, place two
removable marks on both sides of the frame 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 Teflon based spray.
● Once lubrication is complete, hold “elevation ▲ & Stop” both keys 5 seconds then the message will be
clean.
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CHAPTER 2: Preventative Maintenance
2.2 TENSIONING & CENTERING 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. To
eliminate this slipping, turn the treadmill off and tension both the rear roller bolts using the supplied Allen
wrench, turning them ¼ turn to the right as shown. Turn the treadmill on and check for slipping. Repeat if
necessary, but never turn the roller bolts more than ¼ turn at a time. Belt is properly tensioned when the
slipping sensation is gone.
The running belt has been properly adjusted at the factory before it was shipped. At times the belt can move
off-center during shipment. Before operating the treadmill, make sure the belt is centered and remains
centered to maintain smooth operation.
If the running belt is too far to the right side: With the
treadmill running at 1 mph, turn the left adjustment bolt counter-
clockwise ¼ turn at a time (using the supplied Allen wrench).
Check the belt alignment. Allow belt to run a full cycle to gauge if
more adjustment is needed. Repeat if necessary, until the belt
remains centered during use.
If the running belt is too far to the left side: With the treadmill
running at 1 mph, turn the right adjustment bolt counter-
clockwise ¼ turn at a time (using the supplied Allen wrench).
Check the belt alignment. Allow belt to run a full cycle to gauge if
more adjustment is needed. Repeat if necessary, until the belt
remains centered during use.
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CHAPTER 3: Console Instruction
3.1 CONSOLE OVERVIEW
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) LCD DISPLAY WINDOWS: Incline, Speed, Time, Distance, Calories, Heart Rate
B) LED DISPLAY: Incline, Speed, Time, Distance, Calories, Heart Rate
C) WORKOUT QUICK KEYS: press to select your workout.
D) START: press to begin exercising, start your workout, or resume exercising after pause.
E) STOP: press to pause/end your workout. Hold for 3 seconds to reset the console.
F) INCLINE +/- KEYS: used to adjust incline in small increments (0.5% increments).
G) SPEED +/- KEYS: used to adjust speed in small increments (0.1 mph increments).
H) INCLINE QUICK KEYS: used to reach desired incline more quickly.
I) SPEED QUICK KEYS: used to reach desired speed more quickly.
J) FAN KEY: press to turn fan on and off.
K) FAN: personal workout fan.
L) SPEAKERS: music plays through speakers when your CD / MP3 player is connected to the console.
M) AUDIO IN JACK: plug your CD / MP3 player into the console using the included audio adaptor cable.
N) 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.
O) USB INPUT: 1A/5V USB output power.
P) WATER BOTTLE POCKETS: holds personal workout equipment.
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Q) TABLET/READING RACK: holds tablet or reading material.
R) BLUETOOTH INDICATOR LIGHT: informs user that the Bluetooth connection as been made.
S) HEART RATE PULSE GRIPS: used to measure heart rate.
DISPLAY WINDOWS
1) TIME: Shown as minutes : seconds. View the time remaining or the time elapsed in your workout.
2) DISTANCE: Shown as miles. Indicates distance traveled or distance remaining during your workout.
3) SPEED: Shown as MPH. Indicates how fast your walking or running surface is moving.
4) INCLINE: Shown as percent. Indicates the incline of your walking or running surface.
5) 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)
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:
2) QUICK START UP
Simply press the START key to begin working out.
Time, distance, and calories will all count up from zero. OR...
1.1 SELECT A WORKOUT OR TARGET
1) Select the USER with the +/- buttons and press ENTER when the desired USER is displayed.
2) Select your WEIGHT with the +/- buttons and press ENTER when your desired WEIGHT is displayed.
3) Select your PROGRAM with the +/- buttons and press ENTER when your desired PROGRAM is displayed.
4) Adjust the SETTING with the +/- buttons and press ENTER when your desired SETTING is displayed.
5) Press START to begin.
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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.
Segment
Warm Up
1
2
Cool Down
Time
4:00 Mins
90 sec
30 sec
4:00 Mins
Level 1
0.5
1.5
2
4
1.5
1
Level 2
0.5
1.5
2
4.5
1.5
1
Level 3
0.5
1.9
2.5
5
1.9
1.3
Level 4
1
1.9
2.5
5.5
1.9
1.3
Level 5
1
2.3
3
6
2.3
1.5
Level 6
1
2.3
3
6.5
2.3
1.5
Level 7
1.4
2.6
3.5
7
2.6
1.8
Level 8
1.4
2.6
3.5
7.5
2.6
1.8
Level 9
1.4
3
4
8
3
2
Level 10
1.4
3
4
8.5
3
2
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.
Segment
Warm Up
1
2
3
4
5
6
7
8
Cool Down
Time
4:00 Mins
30 sec
30 sec
30 sec
30 sec
30 sec
30 sec
30 sec
30 sec
4:00 Mins
Level 1
Incline
0
0.5
1.5
1.5
1
0.5
0.5
0.5
1
1.5
0.5
0
Speed
0.5
1.5
2
2.5
3
3.5
4
3.5
3
2.5
2.3
1.5
Level 2
Incline
0
0.5
1.5
1.5
1
0.5
1
0.5
1
1.5
0.5
0
Speed
0.5
1.9
2.5
3
3.5
4
4.5
4
3.5
3
2.6
1.8
Level 3
Incline
0.5
1
2
2
1.5
1
1
1
1.5
2
1
0.5
Speed
0.5
2.3
3
3.5
4
4.5
5
4.5
4
3.5
3
2
Level 4
Incline
0.5
1
2
2
1.5
1
1
1
1.5
2
1
0.5
Speed
1
2.6
3.5
4
4.5
5
5.5
5
4.5
4
3.4
2.3
Level 5
Incline
1
1.5
2.5
2.5
2
1.5
1.5
1.5
2
2.5
1.5
1
Speed
1
3
4
4.5
5
5.5
6
5.5
5
4.5
3.8
2.5
Level 6
Incline
1
1.5
2.5
2.5
2
1.5
1.5
1.5
2
2.5
1.5
1
Speed
1
3.4
4.5
5
5.5
6
6.5
6
5.5
5
4.1
2.8
Level 7
Incline
1.5
2
3
3
2.5
2
2
2
2.5
3
2
1.5
Speed
1.4
3.8
5
5.5
6
6.5
7
6.5
6
5.5
4.5
3
Level 8
Incline
1.5
2
3
3
2.5
2
2
2
2.5
3
2
1.5
Speed
1.4
4.1
5.5
6
6.5
7
7.5
7
6.5
6
4.9
3.3
Level 9
Incline
2
2.5
3.5
3.5
3
2.5
2.5
2.5
3
3.5
2.5
2
Speed
1.4
4.5
6
6.5
7
7.5
8
7.5
7
6.5
5.3
3.5
Level 10
Incline
2
2.5
3.5
3.5
3
2.5
2.5
2.5
3
3.5
2.5
2
Speed
1.4
4.9
6.5
7
7.5
8
8.5
8
7.5
7
5.6
3.8
TARGET PROFILES
2) 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
levels.
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3) TARGET 2 – CALORIES: Set goals for burning calories. Calories burned are calculated using weight input of user
profile.
TO RESET THE CONSOLE
Hold STOP key for 3 seconds.
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.
USING YOUR CD / MP3 PLAYER/BLUETOOTH SPEAKERS
- 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.
- Use your CD / MP3 player buttons to adjust song settings.
- 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 on the
right side of the console.
1) To connect to the Bluetooth speakers open your Bluetooth settings, turn on Bluetooth, scan for new devices, look
for Horizon T202 and select connect.
AFG TABLET CONNECTED FITNESS SYSTEM
Your AFG machine is tablet ready, allowing you to use Bluetooth 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.
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
Manual included with your treadmill.
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CHAPTER 4: Engineering Mode
4.1 ENGINEERING MODE
1. The key combination to enter engineering menu and eng8 menu is different regarding to different machine
types.
1.2 TM with powered elevation motor: incline up + speed down
1.3 TM without powered elevation motor: speed up + speed down
1.4 BK,EP and ascent trainer without powered elevation motor: resistance up + resistance down
1.5 EP and ascent trainer with powered elevation motor: incline up + resistance down.
4. Some of machine may not have certain engineer menu. Display “NA” or “NOT AVAILABLE” when certain
engineer menu is selected.
4.2 ENGINEERING MODE OVERVIEW
13

CHAPTER 4: Engineering Mode
14

CHAPTER 5: Troubleshooting
5.1 Electrical Diagram
15

CHAPTER 5: Troubleshooting
5.2 MCB WIRING INSTRUCTIONS
Cn4
Cn1
Cn2
Cn3
CN1------- AC power cable socket
CN2------- Elevation motor cable socket
CN3------- Console set cable socket
CN4------- AC motor cable socket
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CHAPTER 5: Troubleshooting
5.3 TROUBLESHOOTING – NO POWER TO THE CONSOLE
NO POWER TO THECONSOLE
1) SYMPTOM:
a. Turn on the power switch, but the console will not light up.
4) SOLUTION:
a. Check if the power cord connected well.
- If the power cord connected well but console doesn’t turn on, try another one.
b. Check if the outlet is well.
- If no, please try another functional outlet.
c. Check if the MCB has power. There is a red power LED on the MCB that should be lit.
d. If the MCB does not have power, check the connection of the power wiring from the power receptacle
to the MCB. Use a multi-meter to measure AC1 & AC2, AC voltage shall be same as local’s standard
voltage (110V-240V)
- If AC voltage value is standard, replace the MCB as it shall be defective.
e. If the MCB does have power, check the connection of the console cable wire at the MCB and UCB.
- Remove the console cable from MCB, and use a multi-meter to measure the DC voltage between the
“GND pin” (Pin 1&2) and the ” + 12V Pin” (Pin7 & 8)-. DC output is normally around DC 12V. If no
output, replace the MCB.
- If output is around DC 12V, check the console cable. If it is defective, replace the console cable.
- If the console cable connections are all good, replace the PCB.
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CHAPTER 5: Troubleshooting
5.4 TROUBLESHOOTING – NO FUNCTION FOR SAFETY KEY
NO FUNCTION FOR SAFETY KEY
2) SYMPTOM:
a. The safety key inserted in console, but display window still shows “safety key off”.
3) 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.
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CHAPTER 5: Troubleshooting
5.5 TROUBLESHOOTING – NO RESPONSE FOR MACHINE (CONSOLE&MOTOR)
THEPOWER IS ON, BUT MACHINE HAS NO RESPONSE
1) SYMPTOM:
a. 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.
19

CHAPTER 5: Troubleshooting
5.6 TROUBLESHOOTING - INCLINE MOTOR ISSUES
INCLINE MOTOR ISSUES
1) SYMPTOM:
a. The incline motor does not lift up or down.
2) SOLUTION:
a. Enter Engineering Mode, and scroll to ENG 1 (Hardware Test). Press the key “ENTER” first and then
the key ”START”.
- Press the key “INCLINE ▲/▼”.
If can hear click from two relays at the MCB, the MCB is ok. Then check the connection of
the elevation motor at the MCB first, try to unplug and re-plug these two pins. If can not resolve
the issue, replace the elevation motor.
If there is no beeps from these two relays, MCB is defective and replace the MCB.
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