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Stairmaster Stepper 4000PT Alternator Belt Replacement WARNING: The belts must be properly tensioned. A belt that is too loose will cause slow and sluggish operation. A belt that is too tight will cause excessive noise and belt wear.
Remove side covers.
Loosen the adjustment screw that mounts the alternator to the alternator brace and the pivot adjusting bolt that mounts the alternator to the frame.
Pivot the alternator down and remove the belt.
Make sure the is centered on the pulleys during installation.
Pivot the alternator up or down as necessary to allow 1/4" (0.6 cm) of belt deflection with fingertop pressure at the midpoint between the two pulleys.
Tighten the alternator adjustment bolt. Verify 1/4" (0.6) deflection in the belt.
Preform this test if you are having trouble entering data into the console. If you cannot enter the DIAGNOSTIC code due to an inoperable keypad, replace the console.
Press  to start the test.
The display LEDs will light up in an L-shaped formation, representing the keypad matrix. Pressing a button on either the exercise program keypad or the function keypad will light an LED within the outline on the display that corresponds to that button's position on the console.
Firmly press each button. If the LED corresponding to the button you pushed does not light up, the keypad is bad and the console should be replaced.
Press [CLEAR] to test the LED and then end the test 10 seconds later.
Reinstall the drive chain, ensuring the master link is properly installed.
Check the drive chain tension. There should be a total of 1" to 1-1/2" (2.5 to 4.0 cm) of play, up and down, at the slackest point in the chain. If the drive chain tension needs adjustment, refer to the "Drive Hub Assembly" section.
WARNING: If the drive chain is too tight, the drive train will wear excessively, shortening the life of the drive hub assembly. If the chain is too loose, the machine will be noisy and will operate at less than peak efficiency.
Lubricate the chain with 30W motor oil and wipe off the excess.
" * Read all maintenance instructions thoroughly before beginning work.
* In some cases, an assistant is required to perform the necessary tasks, use all precautions.
* The safety level given by the design of this equipment can only be maintained when the equipment is regularly examined for damage and wear.
* Inoperable components should be replaced immediately or the equipment should be put out of use until it is repaired."
Remove the side covers. WARNING: TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE PEDALS WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE.
Remove the Poly-V belt and inspect the belt for cracks, fraying or any other unusual or excessive wear.
Spin the alternator pulley to check the bearings. Replace the alternator if any clicking or grinding noises are heard.
Inspect the alternator pulley for wear.
Tighten the transmission pulley set screw to the flat side of the transmission output shaft.
Remove the drive chain and inspect the chain for frozen links. Replace a chain with frozen links.
Tighten the transmission drive sprocket set screw to the keyway in the transmission input shaft.
Spin the transmission drive sprocket input 1 complete revolution. The transmission pulley output should turn 19 revolutions. Replace the transmission if any clicking or grinding noises are heard during rotation or the drive ratio is not 19 to 1.
Remove the step chains and return springs from the main frame of the machine.
Inspect the step chains for frozen links and the springs for corrosion. Replace a chain with frozen links and replace a corroded spring.
Make sure that the step chain connection points pivot freely and have no vertical play.
Remove the pedals, pedal arms, and leveling arms and lubricate according to the maintenance section of the manual.
Verify that the clutch sprockets of the hub assembly spin freely in the forward direction and lock in the reverse direction.
Inspect the hub assembly for wear. The drive shaft sprocket should not move up and down or side to side.
Clean and lubricate the drive and step chains with 30W motor oil.
Reinstall all parts, ensuring the proper tension of the Poly-V belt and the drive chain.