Section 5 - National Gym Supply, Inc
Section 5 - National Gym Supply, Inc
Section 5 - National Gym Supply, Inc
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STAIRMASTER<br />
STAIRMASTER 4000 PT<br />
4000 PT Alternator<br />
Troubleshooting<br />
If you suspect your StairMaster has a faulty alternator,<br />
perform the following tests to pinpoint the problem.<br />
(When ordering an alternator, be sure to identify its<br />
make and model number.)<br />
1. Test continuity of grey cable. Disconnect the grey<br />
cable from the back of the console. Using a paper<br />
clip formed into a “U” shape, insert the ends of<br />
the paper clip in the pin sockets # 2 and # 4. Then<br />
start stepping. You should experience full pedal<br />
resistance. If there is no pedal resistance, either<br />
the grey cable or the alternator is bad.<br />
2. Check alternator brushes. The brushes should be<br />
seated squarely on the commutator and should be<br />
worn evenly. Check for cracks and excessive wear.<br />
The brushes should be at least 3/8" long.<br />
3. Check the commutator. Look for excessive wear on<br />
the copper commutator. If it is excessively grooved,<br />
the alternator should be replaced.<br />
4. Check all wiring harnesses for wear. Bad electrical<br />
connections can cause alternator malfunction.<br />
With a continuity tester, check the continuity of all<br />
grey cable wires.<br />
5. Check the alternator. Disconnect the black wire<br />
from the right side of the load resistor. (It is the<br />
same wire that connects to the “positive output”<br />
terminal of the alternator.) Remove the brown wire<br />
from the “field terminal.” Hold the black wire you<br />
have disconnected to the spade connector of the<br />
field terminal. Start stepping. Resistance in the<br />
alternator should increase steadily. If the resistance<br />
does not increase, the alternator is bad.<br />
MOTOROLA OR PRESTOLITE<br />
WITH BLACK CAP<br />
c SME01.4, Exchange<br />
g SME02, Repair<br />
BOSCH<br />
f SME01.3, Exchange<br />
g SME02, Repair<br />
PRESTOLITE<br />
d SME01.1, Exchange<br />
(Yellow Label)<br />
e SME01.2, Exchange<br />
(White Label, Not Shown)<br />
g SME02, Repair<br />
b SMA07, Purchase<br />
Brush Assembly<br />
h SM011<br />
Brush Assembly<br />
i SM013<br />
Brush only<br />
j PBC01<br />
Brush Assembly<br />
1! SM078<br />
Brush only<br />
1) SM023<br />
WIRING DIAGRAMS ONLINE<br />
AT WWW.GYMPART.COM!<br />
BLACK CAP WIRING DIAGRAM<br />
BOSCH WIRING DIAGRAM<br />
COMMUTATOR STONE<br />
When replacing alternator brushes,<br />
don’t forget to resurface<br />
the commutator.<br />
MCT035.1, $3.90<br />
PRESTOLITE WHITE LABEL<br />
WIRING DIAGRAM<br />
PRESTOLITE YELLOW LABEL<br />
WIRING DIAGRAM<br />
56 PARTS RESOURCE BOOK 2009<br />
NATIONAL GYM SUPPLY 1-800-496-7278 FAX: 310-280-0937
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