Stairmaster FreeClimber, Service Manual

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Page 9
4600/4400/4200/4000 PT
®
- ELECTRICAL TROUBLESHOOTING
Please refer to your owner’s manual for detailed instructions. If you do not have an owner’s manual please call
our Customer Service phone number to order one.
1. Verify AC voltage at wall outlet (110 - 120 VAC).
2. Verify AC voltage at end of AC cord (110 - 120 VAC).
3. Verify DC voltage from the power supply. You should get 12-17 VDC if your DC cable detaches from the
power supply, and 10-12 VDC if your DC cable does not detach from the power supply and is prior to
10/27/97. If the power supply is a newer style and has part number 24379 (PS-5), or part number
24381(PS-7), you should get 12-19 VDC.
4. Verify DC voltage at the end of DC cable (shake cable during test).
5. Verify DC voltage at power connector (are wires firmly attached to molex connector?).
6. Check all wiring connections on alternator.
7. Verify DC voltage drop under load by measuring voltage at the white wires, using the alternator casing
as a ground. Use leads with alligator clips to eliminate the need for an assistant. Voltage under load
should be between 9-12 VDC on the older style, and no less than 12 VDC on the newer style power
supply.
8. Verify DC voltage on the grey cable (pins 4 & 5 - 4000 PT, pins 1 & 9 - 4600/4400/4200 PT).
9. Test diode – Remove the diode from the alternator. Place the leads from your voltmeter on either side
of the diode touching the wire. Place your voltmeter selector switch on the diode check setting. Your
digital voltmeter should read 0.5 Volts. Now reverse your leads. You should get overload (O.L.).
10. Test continuity of the grey cable/cross check.
11. Test load resistor (0.7 Ohms-for the gold metal resistor and 0.5 Ohms for the ceramic resistor).
12. Perform the 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 the alternator.
Place alligator clips on the B+ terminal and on the field terminal of alternator.
Run on the machine for 15-20 seconds.
If full resistance is achieved during this time, your alternator has correct current flow it is
accepting current (field) and producing current (B+).
13. Swap consoles, power supply and cables to verify problem stays with machine.