Stairmaster FreeClimber, Service Manual

Page: 34 / 113

Page 35
GAUNTLET ELECTRICAL TROUBLESHOOTING
*For machines with a mechanical relay
1. Check positive output to field using the following test:
Positive output to field test on the alternator:
Turn the power off.
Remove the black wire from the B+ terminal on alternator.
Remove the brown wire from the field terminal on alternator.
Place alligator clips on the B+ terminal and the field terminal of alternator.
Run on machine for 10-15 seconds.
If full resistance is achieved during this time, your alternator has correct current build up from residual
magnetism to field coil.
2. Test diode – Remove the diode from the alternator. Place the leads from your voltmeter on either side
of the diode touching the wire. Your digital voltmeter should read 1.5 Ohms. Now reverse your leads.
You should get O.L. Your analog meter should read 15 Ohms or less, and 10.000 or infinity in the other
direction.
3. Test continuity on the following wires using your voltmeter set on Ohms: Disconnect the main cable
from the console before testing. All tests should read < 1.0 Ohms:
A. Disconnect the DC cable. Test between Pin #4 of the main cable connector and Pin #1 (positive) of
the DC connector.
B. Test between Pin #5 of the main cable and Pin J1-2 of the 3-pin connector at the relay box.
C. Disconnect the blue wire from the alternator. Test between Pin #3 of the main cable and at the end
of the blue wire at the alternator.
D. Disconnect the black wire from the left side of the load resistor. Remove the white wire from the
alternator. Test between the white wire and the black wire while holding the relay down. This will
check continuity from the white wire through the relay to the resistor.
E. Disconnect the brown wire from the alternator. Test between Pin #2 of the main cable and the end
of the brown wire while holding the relay down.
4. Test for continuity in the main cable – Pin #2 is the brown wire, Pin #3 is blue wire, Pin#4 is the white
wire, and Pin #5 is the black wire. If the main cable passes this test upgrade the mechanical relay to
an electrical relay.