I have a treadmill (bodyguard Magellein) with a Pacific Scientific 2.3 hp motor that recently started making a fairly loud clicking sound. I took the cover off and I can see an LED indicating current limit flashing or solid red as speed increases, and I smell a burning smell from the motor. I took the motor apart and the brushes looked fine, but I saw a broken wire at one of the communicator contacts. I soldered it back on but this made no difference. The communicator surfaces on the armature near this wire were slightly carboned which I cleaned.
I am wondering if the motor is bad or if this clicking is from a defect in the controller board (some sort of electrical pulsing). Can you guys give me any advice as to how to proceed? Is there a way to test the motor without the controller card such as using a straight DC power supply? Nameplate says 124 vdc 16.8 amps.
Since the motor smells like it is overheating, I'm guessing something is wrong with it though. What are my options? I assume these are pretty darn expensive. Where can I buy a replacement? Can it be rebuilt? where? Is there a way to test the armature windings myself? I'd like to learn about this.
Please tell me about any links for parts, rebuilding info, etc. Also, where can these be purchased new/rebuilt?
Motor Info from nameplate.
Model: PWM 3636-5415-7
Prod Code: FGP1270
16.8A, 124 VDC
2.3 hp, 3590 RPM
Thanks for any help.