Mechanical Troubleshooting - Stairmaster FreeClimber 4600 PT Owner's Manual

If you hear a grinding or clicking noise, or experience excessive vibration during
exercise, or if the pedals are not functioning properly, you probably have a prob-
lem in the drive train. Attempt to isolate the problem area by performing the fol-
lowing tests in precisely the order listed below. Refer to the "Parts Removal and
Replacement" section for all disassembly and assembly instructions.
1. Unplug the machine and remove the bottom side covers.
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE
WHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE PEDALS WHILE
2. Noise can be generated by a Poly-V or HTD belt that is either too tight
or too loose. Check the condition and the tension of the belts. Replace
worn belts. Adjust the belt tension according to the instructions in the
"Parts Removal and Replacement" section.
3. Remove the Poly-V belt and move the pedal arms. If the noise no longer
exists, check the condition of the alternator. If the noise is still present,
go to step #4.
• Disconnect the DC power cable if you have a 4600/4400/4200 PT or
unplug the connector from position J4 on the power supply circuit
board if you have a 4600/4400 CL. Spin the alternator pulley with
your fingers. It should spin freely and remain spinning for at least
two revolutions. If it does not, the alternator should be replaced.
• If the alternator does spin freely, check the alternator for noise,
roughness, or the presence of an excessive amount of black powder
inside the alternator or near the outside of the case. If any of these
conditions exist, the brushes might be bad and the alternator
should be replaced.
• Do not reinstall the Poly-V belt if performing step #4. Plug in the
connector at position J4 or reconnect the DC power cable,
as applicable.

MECHANICAL TROUBLESHOOTING

!
WARNING
ANYONE'S HANDS ARE INSIDE THE MACHINE.
Page 45