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41904B Service Manual Complete.pmd

1. For S N lt 428173 remove clamps that attach to timing belt springs and transfer to new belts For S N gt 428174 remove clamps that attach to flat belt and belt idler spring and transfer to new belts NOTE The clamp may be a two piece shown or one piece clamp 13 Route belts correctly attach timing belt springs for S N lt 428173 or flat belt and idler spring for S N gt 428174 test operation and install covers See reference photos on next page support nustep com 800 322 4434 42101 Timing Belt 5 1 05 gt TRS 4000 CNUSTEP Timing Belt R L REFERENCE PHOTO OF PIVOT DISK Tooth side of right belt is against pivot disk and has 4 teeth locked into teeth of casting as shown Backside of left belt is against pivot disk and has 4 teeth locked into slots of left clamp REFERENCE PHOTOS SHOWING CORRECT BELT PLACEMENT Left belt under low left idler Side view belts in proper position and under load lever tube ee Right belt under high right idler and over load lever tube Rear view belts wrapped Bottom view belts amp clamps around timing sprockets hooked to springs and frame e r T NOTE This photo applies only to units with S N lt 428173 support nustep com 800 322 4434 42101 Timing Belt 5 1 05 46 CNUSTEF ros 4000 lt NUSTER Timing Belt Springs Replacement NOTE This instruction applies only to units with S N lt 428173 Always replace bot
2. No photo support nustep com 800 322 4434 42011 Belt Idler Arm 5 1 05 TRS 4000 CNUSTEP Belt Idlers Poly V amp Right amp Left Timing Belt Idlers NOTE This instruction applies to all three belt idlers Tools Required 9 16 socket deep and ratchet 9 16 wrench 1 Remove covers See Cover Removal instruction Replace covers when steps are completed For Poly V Belt Idler 2 Remove poly v belt See Poly V 3 Remove and replace idler Install Belt instructions washer s on the side they were on No photo NOTE Units with S N gt 428327 do not have a poly v belt idler NOTE The idler pulley used for units with serial numbers 424793 428326 does not have flanges and is installed without washers For Left Timing Belt Idler 2 For S N lt 428173 unhook left 3 Remove and replace idler Install timing belt spring See Timing Belt all 8 washers on inside of frame Springs instructions e For S N gt 428174 unhook belt idler spring See Flat Belt amp Belt Idler Spring instructions CAUTION To avoid injury or damage to the product use caution when removing or installing Hold arm weldment when unhooking springs to prevent weldment from falling forward support nustep com 800 322 4434 42013 Belt Idlers 5 1 05 TRS 4000 CNUSTEP Belt Idlers Poly V amp Right amp Left Timing Belt Idlers For Right Timing Belt Idler 2 For S N lt 428173 unhook left 3 Remove
3. support nustep com 800 322 4434 42063 Pivot Shaft Alignment 5 1 05 34 CNUSTEF gt TRS 4000 NV STEER Poly V Belt amp Sheave amp Belt Idler Spring NOTE This instruction applies only to units with S N lt 428325 Units with serial numbers gt 424793 use a black plastic poly v sheave Units with serial numbers lt 424792 use a cast aluminum poly v sheave When replacing a cast aluminum poly v sheave with a plastic poly v sheave the idler pulley must be replaced as well the new idler pulley does not have flanges Tools Required 5 32 hex key 1 Remove covers See Cover Removal instructions 2 Remove belt idler spring NOTE If you are just replacing the spring do it now and replace covers CAUTION Springs are under tension To avoid injury or damage to the product use caution when removing or installing 3 To remove belt run belt off of poly v sheave starting with sheave first To install do the opposite 4 NOTE If you are just replacing the belt install new belt and tension belt and GOTO Step 8 No photo support nustep com 800 322 4434 42067 Poly V Belt amp Sheave 5 1 05 35 CNUSTEF gt rps 4000 NET Poly V Belt amp Sheave amp Belt Idler Spring 5 Note location of poly v sheave on shaft and loosen 2 set screws to remove poly v sheave 6 Install new poly v sheave on shaft in similar position as old one Do not tighten set screws No photo 7 Install belt
4. 64 1 65 6 66 4 67 8 68 10 69 1 70 2 71 1 12 1 73 2 74 2 75 1 76 4 77 1 78 12 80 2 81 2 82 16 83 10 84 6 85 1 86 2 88 1 not shown 89 6 91 2 92 4 93 5 94 1 95 2 96 2 97 7 ras 4o00 CNUSTEPD PN 4042A 4042 40410 40424 4043A 4043 41050 40140 41254 41052 41056 4083A 4083 4084A 4084 41214 41066 41210 41068 41202 41234 41218 41062 30104 41256 41200 41080 41076 41180 41078 4044 41082 41260 41222 30157 41216 30106 30109 41220 41088 40236 4100A 4100 30564 41096 41092 41094 40440 30162 41246 41100 Part Description EC MAGNET ASSY S N gt 412485 EC MAG ASSY S N 411001 412484 EC Mag Bracket S N 411001 412484 EC Magnet Slide Bracket EC PLUNGER PLATE ASSY S N gt 421096 EC PLUNGER PLATE ASSY S N lt 421095 EC Shoulder Pivot Electronic Tube FHPS 1 4 20x7 8 FHPS 1 4 20x3 4 Black Foam Grip Upper Arm FOOTPEDAL L S N gt 413368 FOOTPEDAL L S N 411001 413367 FOOTPEDAL R S N gt 413368 FOOTPEDAL R S N 411001 413367 HHCS G5 1 4 20x1 HHCS G5 1 4 20x3 8 HHCS G5 3 8 16x1 3 4 Black HHCS G5 3 8 16x2 1 4 HHCS G5 3 8 16x3 3 4 HHCS G5 5 16 18x1 2 Black HHCS G5 5 16 18x1 3 4 HHCS G5 5 16 18x3 4 HHCS G5 5 16 18x5 8 Insulator board Knob Arm Lock Knob Load Lever Label Seat Position Indicator Label NuStep Logo Leveler Foot LOAD LEVER ASSEMBLY Locknut NI G5 10 24 Locknut NI G5 1 2 13 Locknut NI G5 1 4 20 Black Locknut N
5. USS 5 16 108 1 41258 Retaining Ring Takeup 1 2 156 2 41170 Wheel Rear 109 2 41416 Roll Pin 1 8x1 1 8 157 10 41502 Wheel Seat 110 1 30120 Seat 158 2 41318 Pivot Cam 111 2 30624 Seat Armrest 159 6 41326 BHCS G8 1 4 20x3 4 112 1 30628 Seat Armrest Bracket Left 160 2 41324 Cap Arm Pivot Cam iis l 30626 Seat Armrest Bracket Right 161 2 4102 FP STABILIZER S N gt 413368 114 4 30625 Seat Armrest Spacer not shown 40220 FP Support Tube S N 411001 413367 LES 1 4050 SEAT ASSEMBLY not shown 41110 Ret Ring Ext 1 S N 411001 413367 116 1 40510 Seat Channel Weldment 162 2 41432 Shoulder Bolt 3 8x7 8 117 1 40500 Seat Mounting Bracket 163 2 41328 Shoulder Bolt 3 8x1 2 118 1 40524 Seat Position Indicator 164 4 41338 PHPSw ext washer 10 24x5 16 Blk 119 1 40550 Seat Rail 165 2 41116 Retaining Ring Takeup 1 120 1 4051 SEAT RELEASE BRACKET ASSY 166 3 41340 Shoulder Bolt 5 16x3 8 121 1 4053 SEAT RELEASE LEVER ASSY 167 2 41342 Wave Washer 5 16x5 8 122 1 4055 SEAT RELEASE LEVER BRKT ASSY 168 2 41336 Footpedal Bearing Spacer 123 1 40560 Seat Stop Pin Weldment 169 1 41805 AC Adapter amp Cable US amp Canada 110V 124 1 4064A SENSOR HALL EFFECT ASSY S N gt 422081 not shown 4150 AC Adapter amp Cable Europe 220V not shown 4064 SENSOR HALL EFFECT ASSY S N lt 422080 170 16 30119 Washer SAE 3 8 125 1 4062A SENSOR VR ASSEMBLY S N gt 422081 171 2 41027 Bumper Footpedal II Male not shown 4062 SENSOR VR AS
6. before removing third screw so it of connector to unlock cable doesn t fall connector 3 Hold onto cable connector and 4 To install align key on cable pull outward from display connector with slot on display connecior connector Slot 5 Push 2 locking tabs inward until 6 Hold onto display so it doesn t they snap in place to secure cable fall install three screws slide boot up Check display operation support nustep com 800 322 4434 42023 Display Removal 9 8 00 8 TRS 4000 CNUSTEP Installation Instructions for Water Bottle Holder Reading Rack and 123GO Instruction Panel This instruction applies to the Water Bottle Holder PN 4300 the Reading Rack PN 4305 and the 123GO Instruction Panel PN 4310 The three accessories may be ordered together as the Display Accessory Kit PN 4315 Note the water bottle shown below is not available Tools Required Phillips screwdriver Attach accessories to back of display using provided screws Note when the display accessory kit is shipped with a TRS4000 Recumbent Cross Trainer the screws are preinstalled in the back of the display Remove the screws and use them to attach the accessories 123GO Instruction Panel WK TE at AL oe kd e Vi Ki e Ki dy Se E e a an a lt Reading Rack Water Bottle Holder support nustep com 800 322 4434 42131 123GO RR H20 Instruction 2 6 04 19 S TRS 4000 NUSTEP Polar Receiver NOT
7. prevent scratching end of seat rail a CAUTION The TRS 4000 seat assembly is heavy it weighs 50 lbs 23 kg To avoid injury or damage to the product use caution when removing or installing Obtain assistance as required Use proper lifting technique Scratch awl use to align holes before screws 2 Remove seat rail bumpers gt e a 8 aa e ed 2 k e AA E ZZ eet 4 Remove 6 screws from top cover A sm ER Note In center of top cover 2 screws are only used in forward 2 holes support nustep com 800 322 4434 42017 Cover Removal 5 1 05 8 TRS 4000 CNUSTERD Cover Removal Installation 5 Remove top cover 6 Remove 2 screws Re A 7 Remove screw from front 8 Remove screw from rear i KE ge EI y Pull rear outward then nose Pull rear over wheel amp workload lever support nustep com 800 322 4434 42017 Cover Removal 5 1 05 TRS 4000 CNUSTEPD Cover Removal Installation 11 To install cover do previous steps in reverse order Note the following Hang side covers on bracket For top cover place awl in third hole directly below seat rail from front to align holes then insert 3 screws Repeat for opposite side support nustep com 800 322 4434 42017 Cover Removal 5 1 05 TRS 4000 Cum seat Position Indicator Label Replacement Tools Required Rubbing alcohol 1 Remove old label Clean label 2 Expos
8. 322 4434 42037 Foam Grip Replacement 5 1 05 2 e e TRS 4000 NUSTEP Upper Arm R or L NOTE This instruction applies to all variations of arm locks Make sure to use the screws that came with the kit if you are installing a complete arm assembly Tools Required Phillips screwdriver 1 Loosen knob A 3 Slide cap up arm and then pull upper arm out of lower arm tube INSTALLATION NOTES A Make sure components are properly installed before installing arm NOTE arm lock may be either white or black C The machine key always faces and comes in contact with the stud end of the knob and the holes indents align with the screws on the bottom of the tube R and L arms tilt inward 20 Reference Picture Pin Arm lock white or black support nustep com 800 322 4434 42003 Arm Upper 7 17 00 Grease or silicone white clear preferred 2 Remove 2 screws NOTE If you are installing a new arm assembly make sure to use the screws that came with the kit not the screws removed here 4 To install upper arm do above steps in reverse order B Wipe a little grease inside top 4 of lower arm tube before installing This prevents squeaking of arm lock amp tube D When tightening screws in Step 2 make sure screws go into the holes indents on the arm lock not against it The arm lock must float freely The screws keep arm lock from coming out Cap Machine Key may be rectangular or
9. Changing display windows instruction Not displaying WATTS Ribbon cable not installed correctly Verify cable is Refer to Ribbon Cable METS CALORIES or or cut installed correctly and instruction STEPS PER MINUTE does not have any cuts VR Sensor METS WATTS Lay unit on left side Refer to Hall Effect and CALORIES TIME and or Hall and inspect the sensor VR Sensor instructions Effect Sensor TOTAL STEPS cables VR sensor is STEPS PER MINUTE TIME gaps the black amp white wire are off or have cut wire and Hall Effect sensor Lis red white amp black missing on the EC disk VR Pivot Disks instruction sensor magnet and pivot disk Hall Effect sensor magneb Display PC board may be bad If facility has additional Refer to Display Removal The sensor magnet may be Check for the magnet Refer to Magnet EC A units install bad instruction display on another unit to verify that the display is bad Workload is not Ribbon cable not installed correctly Inspect the cable to Refer to Ribbon Cable displaying correctly or cut verify it is installed instruction correctly and does not Contact wipers of the EC plunger Remove cover and Refer to EC Plunger Plate plate not making contact with inspect wiper on EC instruction workload level PCB board plunger plate to verify it is touching the workload level PCB Remove display to Refer to Display investigate Installation instructi
10. Required L socket and ratchet 9 16 wrench 9 16 socket 1 Remove three bolts that attach 2 Remove bolt that attaches armrest bracket to seat left side shown to armrest bracket D r g T f 2 i G i j Ra Z 3 Replace armrest or armrest bracket at this time No photo 4 To install spacers go on each 5 Tighten nut until armrest moves side of bracket inside armrest Slide smoothly but not too tight or loose bolt through from outside in Compare feel with other side armrest and match it 6 Attach bolts that hold armrest and tighten to 200 in Ibs J To avoid injury and to ensure safe operation of this product fasteners must be tightened to the proper torque support nustep com 800 322 4434 42079 Seat Armrest and Bracket 5 01 05 86 ONUSTEF ros 4000S NYSTER seat Assembly Removal Installation NOTE These instructions are usually the first step if you have to work on or replace the seat assembly Tools Required Phillips screwdriver 3 8 wrench CAUTION The TRS 4000 seat assembly is heavy it weighs 50 Ibs 23 kg To avoid injury or damage to the product use caution when removing or installing Obtain assistance as required Use proper lifting technique 1 Remove seat rail cap 2 Remove seat rail bumpers Deg ae aw e E SCH SN j 5 P eee 3 Roll seat off of seat rail 4 lf you are going to work on the seat turn seat upside d
11. Required Phillips screwdriver long 52 CNUSTEF rus 4000 lt NUSTER 1 Remove top and left side cover See Cover Removal instruction 2 Slightly loosen 3 screws holding magnet assembly Insert long screwdriver as shown 4 Ride test and make sure disk does not hit magnets in all 10 loads No photo 3 Set gap between magnet and disk 1 8 gap this side 1 16 gap this side Spin disk by hand to check but do Step 4 ride test 5 Install covers No photo support nustep com 800 322 4434 42031 EC Magnet Gap Align 9 10 00 gt TRS 4000 CNUSTEP EC Plunger Plate amp EC Magnet Slide Bracket NOTE These parts come off sequentially Once you get to the part you need to replace replace that part and skip to the other steps as the instruction tells you Tools Required Channel lock pliers 3 4 deep socket and new locking ring 3 16 hex key Hammer Sllicone grease white or clear Safety glasses 2 x4 wood CAUTION To avoid injury wear safety glasses 1 Remove covers See Cover Removal instructions 2 Remove poly v belt or poly v J6 flex belt For S N lt 428325 remove poly v belt See Poly V Belt instructions For S N gt 428326 remove poly v J6 flex belt see Poly V J6 Flex Belt instructions 3 Remove load lever See Load Lever instructions 4 Remove self locking ring Ring 5 Pull plunger plate out of frame will be destroyed during this step NOTE
12. Safety glasses To avoid injury wear safety glasses 1 Remove covers See Cover Removal instruction 2 Loosen load lever nut until justa 3 Tap gently on nut to disengage few threads are holding nut on load lever then remove nut completely 4 Remove load lever 5 Reinstall load lever and tighten nut just enough to draw roll pin into groove and remove play Do not overtighten nut 6 Check operation of load lever and Workload on display Install covers No photo support nustep com 800 322 4434 42057 Load Lever 5 01 05 57 CNUSTEF rus 4000 NUSTER Workload Level PCB Tools Required Parts Required Scratch awl 4 1 8 diameter by 5 16 length pop rivets Hammer Safety glasses Pop rivet gun 1 Remove covers See Cover Removal instruction 2 Put workload lever in load 1 3 Disconnect wires from back of 4 From outside of frame pound out rivets using scratch awl amp hammer 5 Remove PCB and insulator board 6 Carefully install new PCB and from frame insulator board between wiper and frame using pop rivets see No photo reference photo below before proceeding 7 Reconnect wires shown in Step 3 8 Test all electronics before installing covers Reference Photo Workload PCB e NOTE EC Plunger shown removed from frame for clarity It is not necessary to remove plunger to install PCB but you must be careful when installing PCB Insulator board Wiper support
13. T shaped Holes indents in arm lock that screws go into they do not screw into here 3 Leg eege Trs 4000 JN USTEP Arm Lock Note This instruction applies to all units but units with S N gt 411092 use part number 4087 Arm Lock and units with S N lt 411091 use part number 4088 Arm Lock Part number 4088 has a T shaped machine key Tools Required Hammer Pliers Nail punch Safety glasses 1 Remove upper arm See Upper Arm instruction 2 Tap roll pin through first hole 3 Pull pin from second hole k aope i a a 4 Ge b Ce e S T TA 4 CA 1 E ii C L d Ca i H A d z 4 Remove arm lock and slide new arm lock onto upper arm i ae To ensure the new arm lock is not installed backwards note the machine key s posi 6 Install upper arm tion relative to the upper arm groove while removing the arm lock support nustep com 800 322 4434 42257 Arm Lock 5 1 05 4 Ki TRS 4000 CNUSTEP Arm Lock Knob NOTE Units with S N gt 411924 do not have a snap ring on the end of the knob stud Units lt 411924 do but it is not necessary to reinstall it once removed Tools Required Needle nosed pliers Ah CAUTION Grease silicone white clear Safety glasses To avoid injury wear safety glasses 1 Remove upper arm See Upper Arm instruction 2 Remove snap ring from end of 3 Thread old knob out It may be knob stud if it has one If n
14. To avoid injury wear safety glasses 1 Remove covers See Cover Removal instructions 2 Remove poly v belt or poly v J6 flex belt For S N lt 428325 remove poly v belt See Poly V Belt instructions For S N gt 428326 remove poly v J6 flex belt See Poly V J6 Flex Belt instructions 3 Remove belt idler arm S N lt 428325 only See Belt Idler Arm instructions 4 Remove snap ring shown or 5 Using the puller remove disk nut NOTE On earlier models there is from shaft NOTE If you are just a nut instead of the snap ring replacing the complete EC Disk assem bly GOTO Step 10 support nustep com 800 322 4434 42027 EC Disk amp Bearings 5 01 05 TRS 4000 CNUSTERD EC Disk amp Bearings 6 Remove flywheel side bearing 7 Remove belt side bearing s Bearings will be destroyed during NOTE Early models have 1 bearing removal DO NOT REUSE here while later ones have 2 e a l al r e d v 5 CR ts oe lt bl F a 3 e Le Ki Knock out with blunt object or use Knock out with deep socket or use arbor press to press bearing out arbor press to press bearings out s SS 8 Clean bores on EC Disk Place small amount of Loctite 680 on bores a CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material saf
15. To avoid injury wear safety glasses 9 16 socket and ratchet 9 16 wrench 9 16 12 tap Safety glasses 1 Remove upper arm See Upper Arm instruction 2 Remove arm lock knob See Arm Lock Knob instruction 3 Drill out arm lock knob hole using 4 Tap hole using 9 16 12 tap 31 64 drill bit 5 Using the repair kit thread the 3 8 6 Use the bolt to thread threaded 24 nut all the way onto the bolt then insert into hole until 1 16 1 8 of thread the threaded insert on the bolt the insert sticks out of the end of make sure slot on threaded insertis hole Remove bolt leaving threaded f bolt insert in place 7 Install upper arm See Upper Arm instruction 8 Install arm lock knob See Arm Lock Knob instruction support nustep com 800 322 4434 42261 Arm Lock Knob Repair Kit 5 1 05 7 Ki TRS 4000 uerge Lower Arm R L amp Bearings amp Pivot Shaft NOTE This instruction applies to all units but units with S N gt 412137 have the cam shown in Steps 7 amp 25 and those lower do not Tools Required LG socket and ratchet Loctite 242 Large flat head screwdriver Grease silicone white clear 5 32 hex key Torque wrench 3 2x4 blocks of wood Very helpful Scratch awl Long Phillips screwdriver Safety glasses Hard rubber or plastic hammer 1 Remove covers See Cover Removal instruction A CAUTION To avoid injury wear safety glasses 2 Disconnect stabilizers or 3
16. accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 support nustep com 800 322 4434 42001 Arm Lower 5 1 05 11 Ferme TRS 4000 NUSTEP Lower Arm R L amp Bearings amp Pivot Shaft 22 Place rod ends onto shoulder 23 Wipe grease on both sides of rod bolts and tighten nuts to 200 inch ends into spaces between rod end Ibs and washer and rod end and nut 24 Attach footpedals stabilizers or 25 Set cams to eliminate play footpedal tubes and then attach from arms Insert scratch awl into springs hole with slight pressure While No photo keeping pressure on awl tighten screws with hex key e Ni NOTE Cams are set correctly when olay is removed from arms but cam is not set too tightly which can increase arm resistance 26 Insert plugs install covers and slide boots back in place No photo support nustep com 800 322 4434 42001 Arm Lower 5 1 05 Cover Removal Installation TRS 4000 use NOTE Removing the covers is the first step for every service issue under them Once service is completed all covers must be installed again for safe operation Tools Required Phillips screwdriver 3 8 wrench 1 Remove seat rail cap Keep upward pressure on front of seat to
17. footpedal tubes to reduce operating tension See Retaining Ring Removal instructions Tools Required Snap ring pliers Quick clamp maybe Safety glasses a CAUTION a CAUTION The TRS 4000 is very heavy it weighs To avoid injury wear safety glasses 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique 1 Turn NuStep gently onto the side 2 Remove lower retaining ring from that you want to remove the tube footpedal support tube inside frame from left side is shown 3 With NuStep upright remove 4 With equal pressure pull tube out upper retaining ring near footpedal of frame and footpedal support nustep com 800 322 4434 42051 Footpedal Support Tube 7 25 00 TRS 4000 CNUSTEP Footpedal Support Tube 1999 R or L 5 To install tube push with equal 6 Install upper ring to secure tube pressure at top and bottom to footpedal Lock ring in place If hard to insert use quick clamp Do not install lower retaining ring shown at top and bottom Remove opposite lower ring also support nustep com 800 322 4434 42051 Footpedal Support Tube 5 01 05 80 ONUSTEF rRs 4000 X NYSTER Footpedal Support Tube Retaining Ring Removal Note This only applies to units with serial numbers of 411001 411943 Removing both lower retaining rings helps reduce the overall operating tension of the NuStep After removal there
18. nustep com 800 322 4434 42111 Workload Level PCB 5 01 05 TRS 4000 CNuSTERD DC Power Cable Tools Required 11mm socket and wrench Aa CAUTION The TRS 4000 is very heavy it weighs 1 Gently turn NuStep onto its left 205 Ibs 93 kg To avoid injury or side damage to the product always obtain assistance to move this product Use proper lifting technique 2 Remove power cable Remove nut and lockwasher with 11mm socket from the outside of the cover not shown Push jack through the hole in the frame on the inside of the cover as shown Jack hole Power cable jack 3 Remove wiring from clips there may be more clips than shown Unsnap connector end of power cable from connector pins on PCB board support nustep com 800 322 4434 42019 DC Power Cable 5 01 05 gt TRS 4000 CNUSTERD DC Power Cable 5 To install plug power cable into board Snap connector end of power cable into connector pins on PCB board Make sure connector is installed with cable wires exiting from the top of connector and that connector is securely snapped in place Remove nut and lockwasher from the end of the jack Push jack through the hole in the frame on the inside of the cover as shown Now from the outside not shown place lockwasher and nut onto end of jack Tighten nut with 11mm socket wrench while holding jack from inside Jack hole Power cable jack 7 Route wiring through clip s e
19. over load lever tube Rear view belts wrapped around timing sprockets Side view belts in proper position and names of parts Timing sprocket Pivot disk Bottom view belts amp clamps hooked to springs and frame PRRPPPP PDI Miebdda elitr ieee Note This photo applies only to units with S N lt 428173 The NuStep will not work correctly without proper belt placement If you have any questions about proper belt placement please call us support nustep com 800 322 4434 42069 Rear Shaft amp Sprockets 5 1 05 41 PAG Se TRS 4000 NUSTEP Rear Shaft Alignment NOTE This instruction only applies to units with S N lt 411630 and will help prevent shaft from sliding axially in bearings Later models have a grooved shat ponder oma a CAUTION Loctite 290 wicking see Rawhide hamim r To avoid injury wear safety glasses Safety glasses 1 Remove covers See Cover Removal instruction 2 Loosen all 4 set screws on left 3 Tap shaft with hammer until right and right side bearings end of shaft aligns with end of right side bearing shown 4 Remove both right side set screws and pour a few drops of 290 Loctite down into set screw holes Tighten all 4 set screws back down CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Mater
20. sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 For S N gt 415412 the lever is attached with nuts Torque Setting 80 inch lbs support nustep com 800 322 4434 42083 Seat Mounting Brkt amp Levers 5 1 05 i TRS 4000 CNUSTEP seat Mounting Bracket amp Seat Release Lever Bracket amp Swivel Release Lever Bracket amp Springs amp Nyliners 12 To install either release bracket 13 Tighten all shoulder bolts to 80 place Loctite on shoulder bolts in lbs Swivel bracket shown Don t get Loctite on Nyliners 14 To install seat channel place 15 Swivel assembly 45 to install Loctite on swivel bolts two bolts through cutouts support nustep com 800 322 4434 42083 Seat Mounting Brkt amp Levers 5 1 05 97 TRS 4000 uerge Seat Mounting Bracket amp Seat Release Lever Bracket amp Swivel Release Lever Bracket amp Springs amp Nyliners 16 Swivel assembly 90 to install 17 Tighten all four bolts to 200 in next two bolts through cutouts Ibs 18 Check swivel and release lever operation Swivel seat left and right and check that swivel locks in place 19 Install seat release bracket For S N lt 428341 see Seat Release Bracket instructions For S N gt 428342 see Seat Release Bracket With Stud instructions 20 Check seat locking operation Install seat assembly onto NuStep see Seat Assembly Remo
21. will need to complete the job Please follow the Steps in order The major instruction steps are above the photos while others are directly below the photos Please read NOTES and GOTO instructions carefully They contain important information to save you time and direct you to the next applicable step Finally solid arrows Usually point toward the part action described while dotted line arrows ssnnnne gt indicate direction of movement Directional References All directional references left right front back side top bottom are from a user s perspective as if sitting on the seat of the NuStep unless noted Please note that these directional references still refer back to the original reference even when the NuStep is placed on its side Part Names Part Numbers and Item Numbers Please match parts from the digital photos to the Schematic Drawings and Parts List to obtain ltem and Part Numbers Operating Instructions This service manual does not include operating instructions The NuStep TRS4000 Operating Manual is sent with each NuStep Additional copies can be obtained from NuStep Inc a CAUTION a CAUTION This is the safety alert symbol It is used CAUTION indicates a potentially to call attention to instructions hazardous situation which if not concerning personal safety Read and avoided may result in minor or obey all safety messages that follow moderate injury It may also be used to this symbol to av
22. with large screwdriver CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 8 Place a few drops of Loctite 242 and do the same on rear Don t on front shoulder bolt and threads get Loctite on rod end balls 9 Place rod ends onto shoulder 10 On both rod ends wipe grease bolts and tighten nuts to 200 inch on both sides of rod end into spaces Ibs between rod end and washer and rod end and nut 11 Slide boots down test operation and install covers No photo support nustep com 800 322 4434 42015 Connecting Link 5 1 05 28 NUSTER S TRS 4000 TE Flat Belt amp Belt Idler Spring NOTE This instruction applies only to units with S N gt 428173 Tools Required 5 16 wrench or nut driver Aa CAUTION Measuring tape or yard stick Safety glasses To avoid injury wear safety glasses 1 Remove covers See Cover Removal instruction 2 Remove step through support assembly See Step Through Support instruction 3 Pull flat belt off front pulley Belt is under tension To avoid injury or damage to the product use caution when removing or installing Spring is under tension To avoid injury or damage
23. 046 4041A 4041 Part Description ARM UPPER L S N gt 412392 ARM UPPER L S N 411092 412391 ARM UPPER L S N 411001 411091 ARM UPPER R S N gt 412392 ARM UPPER R S N 411092 412391 ARM UPPER R S N 411001 411091 ARM LOCK EXTRUSION ARM ASSY L S N gt 412137 ARM ASSY L S N 411001 412136 ARM ASSY R S N gt 412137 ARM ASSY R S N 411001 412136 Axle Bearing EC Disk Roller Bearing Pivot amp Footpedal Polymer Bearing Pivot Casting Polymer Bearing Shafts Roller Bearing Timing Sprocket Thrust Belt Poly V J 6 Flex gt 428326 Belt Poly V S N lt 428325 Belt Timing Left Belt Timing Right Belt Clamp Left Belt Clamp Right Belt Idler Pulley BHCS G8 1 4 20x1 1 4 Boot Display Boot Electronic Tube Boot Pivot Casting BRACKET ASSY ANGLE COVER BRACKET ASSY SIDE COVER Bumper Footpedal Stop Bumper Large Bumper Seat Rail Bumper Small Cable Ribbon Cap Frame Crosstube Cap Lower Arm Cap Seat Rail Clamp Ribbon Cable CONNECTING LINK ASSY COVER ASSY L COVER ASSY R COVER ASSY TOP Battery Access Panel S N gt 421388 Battery Access Panel S N lt 421387 Display Bracket Assembly DISPLAY ASSY REV 2 1 EC Ball Detent Plate EC Ball Plunger EC DISK ASSY S N gt 411115 EC DISK ASSY S N 411001 411114 Item Qty 47 1 not shown not shown 49 1 50 1 not shown 51 1 52 1 53 1 54 4 J9 2 56 1 not shown 57 1 not shown 59 1 60 4 62 2 63 1
24. 147 2 4070 TIMING BELT SPROCKET ASSY support nustep com 800 322 4434 734 769 3939 x 5 42117 Parts List 1 4 4 1 05 1004 7 UA 143l Wav ai ONILSVD LOAId LOOE WY LUAId A4ZPWaVis Wdsdll0s 1441 Wd4dl004 a3A09 duly ZUN 3 M301 Wale TANNVHO IN A3A41 ASV 14d LVS 1441 3A A03 ACIS L431 WaV ddd 14481 d3alsn Lad LaAnWIVad LSAadWAay NIdWNG TVA LVS dvd Iva Luis IVa us LSJYWX LVAS Vb 207 bk p s CR d d N E di ji A h aY d e j E EA W 4 y j L LHOIA Wdsdl004 AJdDWNE WOsd L004 1H9IJ JAD JAIS JEN1L ND 2 1004 A d AS Ing WY Y3MO1 Lp 3aNl JINOYLII13 GON CVO TAHOM PL i VA Gy AST IH JILLOd aslvA AIVA MI UN Widss LHDIA WAY d iddi AW IdSId 1004 TANVd SS S99V AdSLLVa JANVd NOLLONALSNI DI Eel AN dsId dat WVO4 ONIGV JY 42119 Figures 4 1 05 d i ve HIEL Ee SNN Ve danla 42119 Figures 4 1 05 NuStep I nc 5111 Venture Drive Suite 1 Ann Arbor MI 48108 800 322 2209 www nustep com We Transform Lives NuStep is a registered trademark of NuStep Inc US Patent Nos 5 356 356 6 042 518 6 361 479 6 666 799 Design Patent Nos D359 777 D421 075 and other patents pending Made in USA Copyright May 2005 by NuStep Inc PN 41904B All rights reserved The information in this manual is the most current at the time of printing Due to our commitment toward continuous improvemen
25. 2263 Seat Mounting Bracket Assembly 5 01 05 TRS 4000 CNUSTEP Seat Mounting Bracket Assembly 10 Transfer old seat release lever to new bracket and tighten nuts to 80 in Ibs CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 12 Swivel assembly 45 to install two bolts through cutouts support nustep com 800 322 4434 42263 Seat Mounting Bracket Assembly 5 01 05 8 TRS 4000 CNUSTEP Seat Mounting Bracket Assembly 13 Swivel assembly 90 to install next two bolts through cutouts To avoid injury and to ensure safe operation of this product fasteners must be tightened to the proper torque 15 Check swivel lever operation Swivel seat left and right and check that swivel locks in place 16 Install seat release bracket For S N lt 428341 see Seat Release Bracket instructions For S N gt 428342 see Seat Release Bracket With Stud instructions 17 Check seat locking operation Install seat assembly onto NuStep See Seat Assembly Removal instructions support nustep com 800 322 4434 42263 Seat Mounting Bracket Assembly 5 01 05 93 CNUSTEF rrs 4000 X NET Seat Mounting Bracket amp Seat Release Lever B
26. 800 322 4434 42041 Footpedal 2000 5 01 05 73 e c TRS 4000 NUJSTEE Footpedal Bearing Replacement NOTE NuStep Inc can supply the bearings inserted into a new footpedal see Parts List Units with S Ns 411001 413367 have Footpedal 1999 with 4 bearings total while S Ns gt 413368 have Footpedal 2000 with 2 bearings total This instruction shows Footpedal 2000 We recommend using an arbor press to insert bearings If you don t have one use the wood technique below Tools Required Large flat head screwdriver A CAUTION Hammer e Blocks of wood To avoid injury wear safety glasses Safety glasses 1 Remove footpedal See Footpedal 1999 or Footpedal 2000 instructions 2 Insert screwdriver against end of 3 To insert outside bearing s bearing wall and gently tap out Be carefully tap into bore using a block careful not to scar footpedal bore of wood and hammer Make sure bearing goes in equally and does not get skewed 4 To insert inside bearing s use 5 Install footpedal wood to press bearing into bore with downward pressure y 4 No photo Make sure bearing presses in equally and does not get skewed support nustep com 800 322 4434 42043 Footpedal Bearing Replacement 5 01 05 TRS 4000 CNUSTERD Footpedal Bumper Upgrade Tools Required Phillips screwdriver long and or magnetic preferred 1 Remove 2 screws and current 2 Align new bracket over existing bumper and discard holes a
27. 8180 Address NuStep Inc 5111 Venture Dr Ste 1 Ann Arbor MI 48108 1654 International customers may obtain customer support by contacting their local NuStep distributor NuStep is a registered trademark of NuStep Inc United States Patent Nos 5 356 356 6 361 479 B1 6 042 518 6 666 799 D359 777 D421 075 and other patents pending TRS4000 Service Manual P N 41904B Copyright May 2005 by NuStep Inc All rights reserved The information in this manual is the most current at the time of printing Due to our commitment toward continuous improvement specifications and descriptions are subject to change without notice No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of NuStep Inc support nustep com 800 322 4434 N iii TRS 4000 NUSTEP ABOUT THIS MANUAL Your NuStep is made with high quality components designed for long life and durability In the event the NuStep needs service this manual provides some information for a mechanically qualified person to service it The following important items tell more about the manual Service Manual Coverage This Service Manual Complete covers NuStep TRS4000 products built beginning in 1999 Service Instructions We hope you like the digital photos that show how to perform the service Each instruction begins with a helpful list of required tools that you
28. Do not tighten nut so that it preloads the bearings Spin the disk and if disk slows rapidly when tightening nut back off so that disk spins freely instead Any bearing preload due to the nut will shorten bearing life Loctite will hold disk in place No photo support nustep com 800 322 4434 42027 EC Disk amp Bearings 5 01 05 51 e c TRS 4000 NUSTEP EC Magnet NOTE Units with S N gt 412485 have 3 screws and no separate bracket to attach the magnet assembly while those with lower S Ns have 2 screws and a separate bracket This instruction applies to both but a lower S N unit is shown Tools Required Phillips screwdriver long 1 Remove top and left side cover See Cover Removal instruction 2 Remove 2 or 3 screws holding 3 On older models remove screws magnet assembly holding this separate bracket to EC Magnet bracket shown On newer models there is no separate bracket mg Insert screwdriver as shown Lower magnet assembly downward and out 4 To install do above steps in re 5 Ride test and make sure disk verse order Set magnet and disk does not hit magnets in all 10 loads gap alignment per instructions before installing covers below For Gap Alignment between magnet and disk 1 8 gap this side 1 16 gap this side Ride test to make sure disk does not hit magnets in all 10 loads support nustep com 800 322 4434 42029 EC Magnet 9 10 00 EC Magnet Gap Alignment Tools
29. E It is a good idea to change batteries during this instruction also Tools Required Phillips screwdriver 1 Remove battery access panel 2 Remove Polar receiver from jack 8 DH 1 e mge a 3 Install new Polar receiver into 4 Make sure receiver is fully jack inserted into jack 5 Replace battery access panel No photo support nustep com 800 322 4434 42065 Polar Receiver Replacement 9 8 00 20 CNUSTEF rrs 4000 lt NV STEL Bearings Shaft NOTE This instruction applies to any 1 roller bearing front left shown Tools Required 1 8 hex key a CAUTION L socket and ratchet Flat head screwdriver Torque wrench Safety glasses To avoid injury wear safety glasses 1 Remove covers See Cover Removal instructions 2 For S N lt 428173 unhook timing belt springs see Timing Belt Springs instructions For S N gt 428174 unhook belt idler spring See Flat Belt amp Belt Idler Spring instructions 3 For S N lt 428326 remove poly v belt See Poly V Belt instructions For S N gt 428327 remove poly v J6 flex belt see Poly V J6 Flex Belt instructions 4 lf removing either left side bearing remove EC disk and or poly v sheave see EC Disk and or applicable Poly V Sheave instructions 5 Loosen set screws 6 Remove nuts support nustep com 800 322 4434 42009 Bearings Shaft 5 1 05 TRS 4000 CNUSTEPD Bearings Shaft 7 Pry bearing off 8 Replac
30. I G5 3 8 16 Locknut NI G5 3 8 16 Black Locknut NI G5 5 16 18 Lockwasher Split 5 16 Lockwasher Split 5 16 Black Machine Key 1 4x1 4x1 1 2 Machine Key 3 16x3 16x2 1 2 MAIN FRAME ASSY S N gt 413368 M FRAME ASSY S N411001 413367 Nut Serrated Flange G5 5 16 18 Nyliner 3 4 Nyliner 3 8 Nyliner 5 16 PCBoard Workload PHPS T S Typ B 8x3 8 Black PHPS Typ F 10 24x3 8 Black PHPS w ext washer 10 24x3 8 Blk support nustep com 800 322 4434 734 769 3939 x 5 42117 Parts List 1 4 4 1 05 D ON Se TRS 4000 amp NUSTEP NuStep TRS 4000 Parts List 1 4 Note Most parts are available individually but to simplify installation ASSEMBLIES in CAPS only come fully assembled Items noted as not shown were replaced with current revision parts and are available as service parts but are not shown in the Figures Item Qty PN Part Description Item Qty PN Part Description 99 1 4072 PIVOT DISK ASSEMBLY 148 16 41156 Unut 10 24 100 1 41801 Polar Receiver 149 1 41158 User Manual 101 1 41407A Poly V Sheave S N gt 428326 150 10 41168 Washer 1 4 External Star Black not shown 41407 Poly V Sheave S N 424793 428325 151 1 41270 Washer M6 4x12 not shown 40332 Poly V Sheave S N lt 424792 152 3 30333 Washer Nylon 75x1 102 D 41182 Poprivet 1 8x3 16 153 14 41166 Washer Seat Wheel Black 103 2 30141 Pushnut 3 8 154 4 30613 Washer Swivel 5 16 107 1 41114 Retaining Ring Selflocking 3 4 155 22 30126 Washer
31. NuStep TRS 4000 Recumbent Cross Trainer Service Manual Complete d NUSTEP A We Transform Lives TRS 4000 Ces HOW TO OBTAIN CUSTOMER SUPPORT AND PARTS STEP 1 Identify the problem Speak with the person who reported the problem to get a good understanding of the problem STEP 2 Verify the problem on the NuStep stepper Use this manual to verify and or service the problem and or determine what parts are required STEP 3 Record the serial number of the NuStep stepper and the cumulative steps taken The serial number is located at the top end of the electronic tube directly behind the display The display has a stepmeter that shows cumulative steps To show the steps press and hold the reset button and then press the up arrow while continuing to hold the reset button Read the cumulative steps across the HEART RATE METS WATTS and WORKLOAD LCD screens There will be a total of 9 digits and the value is displayed for 5 seconds Repeat if necessary STEP 4 Contact Customer Support at NuStep Inc To support our customers better you must have the serial number cumulative steps complete description of the problem and part or item number s required to service the problem for our product specialists Our Product Specialists are ready to help you 8 00 a m 4 30 p m EST Email Call or Fax Customer Support at Email Support nustep com Phone 800 322 4434 or 734 769 3939 x 5 Fax 734 769
32. Remove step through support support tubes from footpedals Remove both footpedals See Footoedal 1999 and Footpedal Support Tube 1999 or Footpedal 2000 and Footoedal Stabilizer 2000 instructions depending on your model 4 For S N lt 428173 disconnect 5 Remove left and right side nuts timing belt springs See Timing Belt that attach rod ends to arms Springs instruction support nustep com 800 322 4434 42001 Arm Lower 5 1 05 i TRS 4000 CNUSTERD Lower Arm R L amp Bearings amp Pivot Shaft 6 Pry off both rod ends with large screwdriver Let arms rotate CAUTION To avoid injury or damage to the product use caution when removing or forward against footpedal bumper installing Hold arm weldment before prying rod end off bolt to prevent weldment from falling forward 7 Remove plug and loosen don t 8 Loosen setscrews that hold pivot remove 6 screws on both sides shaft There may be 2 or 4 total NOTE Early models dont have this on both sides assembly so GOTO Step 8 9 Place one 2x4 under main shaft 10 Place Phillips screwdriver into pivot and one 2x4 on end under hole on end of shaft most models each arm and drive carefully out right to left NOTE If you are just replacing the NOTE You will have to wiggle arms shaft do Step 10 then GOTO 17 when driving shaft out support nustep com 800 322 4434 42001 Arm Lower 5 1 05 i TRS 4000 CNUSTERD Lowe
33. SEMBLY S N lt 422080 174 4 41433 1 4 20 Prevailing Torque Flange Nut 126 4 41122 Set Screw 5 16 18x1 2 175 2 41246 10 24x3 8 PHPS Type F Blkzinc 127 8 na Set Screw 1 4 28x1 4 177 1 41464 Spacer Pivot Disk Belt 128 4 na Set Screw 5 16 24x1 4 178 1 4300 Water Bottle Holder 129 1 40600 Shaft Pivot Arm 179 1 4305 Reading Rack 130 1 40604 Shaft Rear 180 1 4310 123G0 Instruction Panel isk 2 41230 Shoulder Bolt 3 8x1 181 1 4315 Display Accessory Kit 132 2 41232 Shoulder Bolt 3 8x1 3 4 182 2 41414 Washer Shim 375x 563x 030 133 2 41134 Shoulder Bolt 3 8x2 1 2 183 1 40156 Boot Display 134 2 41136 Shoulder Bolt 5 16x1 4 184 1 41467 3 8x3 4x 090 Thrust Washer 135 l 41140 Spring Front Seat Lever 185 1 41469 5 16x3 8x1 4 Flange Bearing 136 1 41138 Spring Belt Idler 186 1 41470 5 16 18 Locknut Black Zinc 137 2 41142 Spring Rear Seat Lever 187 2 40368 10 32x5 16 HXMS Zinc 138 1 41144 Spring Seat Release Bracket 188 1 40362 Timing Belt Clamp Top R 140 1 4099 SUPPORT ASSY STEP THROUGH 189 1 40374 Belt Flat 141 1 41148 Swivel 190 2 40364 Timing Belt Clamp Bottom Assy 142 1 4056 SWIVEL REL LEVER BRKT ASSY 191 1 40370 Bracket Flat Belt Pulley Assy 143 1 4054 SWIVEL RELEASE LEVER ASSY 192 1 40376 Pulley Flat Belt Idler 3 38 144 9 41152 THPS 10 24x1 2 Black 193 1 30153 3 8 16x1 3 4 HHCS G5 Zinc 145 16 41154 THPS 10 24x3 4 Black 194 1 40366 Flat Belt Clamp L 146 8 41252 THPS 6 32x1 4 195 1 40363 Timing Belt Clamp Top L
34. Sensor 7 To install do above steps in reverse order Set gap alignment To Set Gap Alignment Set gap at 1 8 3 16 between sensor and magnet on pivot disk Additional Installation Notes 1 Make sure all wires are secured in cable clips on frame and out of path of timing belts 2 Make sure wire exits from top of connector when installing into PCB connector in step 3 above 3 Before installing covers it s a good idea to test the sensor to make sure everything is working correctly support nustep com 800 322 4434 42055A Hall Effect Sensor 5 01 05 62 CNUSTEF rus 4000 X NUSTER Ribbon Cable NOTE This is the main cable forall M A APIA electronics Aa CAUTION The TRS 4000 is very heavy it weighs Tools Required 205 Ibs 93 kg To avoid injury or Tape damage to the product always obtain assistance to move this product Use proper lifting technique 1 Remove covers See Cover Removal instruction 2 Remove display See Display Removal instruction Keep old ribbon cable hanging out of top end of electronic tube for pulling new cable up through tube 3 Disconnect ribbon cable 4 Remove ribbon cable from clips KK Note Bottom view shown 5 Remove cable from clips then tape new cable to end of old cable and pull it up through the electronic tube at this point Make sure newly installed cable is out of way of pivot casting boot during operation Be gentle pulling
35. and replace idler timing belt spring See Timing Belt E Springs instructions For S N gt 428174 unhook belt idler spring See Flat Belt amp Belt Idler Spring instructions a CAUTION To avoid injury or damage to the product use caution when removing or installing Hold arm weldment when unhooking springs to prevent weldment from falling forward support nustep com 800 322 4434 42013 Belt Idlers 5 1 05 26 CNUSTEF rus 4000 X NUSTER Connecting Link Tools Required Flat head screwdriver long 2 9 16 wrenches LG socket and wrench Loctite 242 Socket extension short Grease silicone white or clear preferred Torque wrench 1 Remove covers See Cover Removal instructions 2 Remove step through support 3 For S N lt 428173 unhook timing belt springs See Timing Belt Springs instructions CAUTION To avoid injury or damage to the product use caution when removing or installing Hold arm weldment when unhooking springs to prevent weldment from falling forward 5 Push right NuStep arm forward to gain access and remove rear nut a CAUTION To avoid injury or damage to the product use caution when removing or installing Hold arm weldment before prying rod end off bolt to prevent weldment from falling forward support nustep com 800 322 4434 42015 Connecting Link 5 1 05 TRS 4000 CNUSTER Connecting Link 7 Pry rear rod end off shoulder bolt CAUTION
36. and tension belt See photos for Steps 3 amp 2 8 Spin poly v sheave Belt should track directly on center of belt idler If not move poly v sheave in or out on shaft until belt tracks true No photo 9 Tighten 2 set screws of poly v sheave securely Install covers See photo above for Step 5 support nustep com 800 322 4434 42067 Poly V Belt amp Sheave 5 1 05 i TRS 4000 Custer STEP Poly V J6 Flex Belt amp Sheave Without Grooves Note This instruction only applies to units with S N gt 428326 Tools Required 5 32 hex key 2 zip ties PN 30586 Diagonal cutters or tin snips 1 Remove covers See Cover Removal instructions 2 To remove belt run belt off poly v sheave a CAUTION Belt is under tension To avoid injury or damage to the product use caution when removing or installing 3 Note If you are just replacing the belt GO TO Step 6 No photo 4 Note location of poly v sheave on _ 5 Install new poly v sheave on shaft shaft and loosen 2 set screws to in similar position as old one Do remove poly v sheave not tighten set screws support nustep com 800 322 4434 42068 Poly V J6 Flex Belt amp Sheave Without Grooves 5 1 05 TRS 4000 Cer ce Poly V J6 Flex Belt amp Sheave Without Grooves 6 To install new belt secure belt to 7 Place the front of the belt onto the sheave using 2 zip ties Install zip hub of the EC disk and rotate the ties in front of and behind spoke sh
37. arge flange out 8 Transfer old lever to new bracket Place Loctite on bolts if applicable Tighten bolts or nuts to 80 in lbs GOTO Step 12 Note for S N lt 415411 the lever is attached with bolts For S N gt 415412 the lever is To avoid injury and prevent adverse attached with nuts health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 support nustep com 800 322 4434 42083 Seat Mounting Brkt amp Levers 5 1 05 TRS 4000 CNUSTEP Seat Mounting Bracket amp Seat Release Lever Bracket A owivel Release Lever Bracket amp Springs amp Nyliners 9 Remove shoulder bolts and remove seat release lever bracket assembly e CAUTION Insert Nyliners Springs are under tension To avoid with large flange injury or damage to the product use out caution when removing or installing 11 Transfer old lever to new bracket Place Loctite on bolts if applicable Tighten bolts or nuts to 80 in Ibs Note For S N lt 415411 the lever is attached A CAUTION with bolts To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data
38. ase Lever Bracket 122 amp Swivel Release Lever Bracket 142 amp Springs 135 amp 137 amp Nyliners 93 93 Seat Position Indicator 118 NEE 98 Seat Rail 119 amp Seat Stop Pin 123 amp Angle Cover Mount Bracket 24 99 Seat Release Bracket 120 amp Seat Release Bracket Spring 138 RK et EEN 101 Seat Release Bracket With Stud 120 amp Seat Release Spring 138 103 Seat Release Lever a KE NEE 107 DC aE VC ONL eege 109 Swivel Release Lever A2 110 Appendix Troubleshooting AMNG Cs x soccseeatencnaseccumennaseaecetccedecvetesiiens EAA EENI ETETE E EE A Se E a E EE C Figure 1 4 NuStep Assembled View Part Names cccccceeceeeeeeeeeeeeeeeeeeeeeeeeeesaaeeeesenaaes E Figure 2 4 NuStep Exploded Parts View Outer Part Item Numbers cccceseeeeeeees F Figure 3 4 NuStep Exploded Parts View Inner Part Item Numbers annaannnnnnnnannnnnnnnnnneannn G support nustep com 800 322 4434 TRS 4000 IST Foam Grip Replacement Tools Required Utility knife Rubbing alcohol Space heater 1 Cut off old grip a CAUTION To avoid injury use care when cutting foam grip 2 Preheat grip till soft and warm 3 Push grip on pour or spray inside w rubbing alcohol Shake grip to distribute alcohol and A combination of mostly pushing and a shake out excess rubbing alcohol little pulling and twisting works best support nustep com 800
39. cable through tube 6 To install remainder of lower portion of ribbon cable do above steps in reverse order No photo Additional Installation Notes 1 Make sure all wires are secured in cable clips on frame and out of path of timing belts 2 Make sure ribbon cable is fastened securely to board connector in step 3 above 3 Before installing covers its a good idea to test the display to make sure everything is working correctly support nustep com 800 322 4434 42073 Ribbon Cable 5 01 05 o TRS 4000 CNUSTER VR Sensor NOTE The VR sensor and the magnet that passes by it are responsible for indicating WATTS METS CALORIES and TIME on the display Tools Required Phillips screwdriver 1 Remove covers See Cover Removal instruction 2 Disconnect ribbon cable 3 Disconnect VR sensor wire e It makes it easier to access wire The black amp white wire on left 4 Unscrew sensor bracket from frame z 4 i me il zl The photo above shows the sensor bracket The photo above shows the sensor bracket used for serial numbers 411001 422080 used for serial numbers gt 422081 5 Remove sensor wiring from cable clips along frame The TRS 4000 is very heavy it weighs 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique ee Note Bottom view shown support nustep com 800 322 4434 42107A VR S
40. ce with the manufacturer s material safety data sheets including 2 Locate the round indent on the the use of safety glasses and left side of the Pivot Disk or right impermeable gloves Material safety side of the EC Disk If there is data sheets are available via the residual glue or pieces of magnet internet at www loctite com or by clean out as best as possible for a calling Henkel Corporation at 800 562 good mounting surface 8483 3 Wipe spray activator into the 4 Place Loctite 324 adhesive onto indent and let evaporate 10 seconds the side with the red or black dot minimum ee 5 Press red dot side of magnet into 6 Check gap Gap should be 1 8 indent The sensors will not work if 3 16 from magnet to sensor Test red dot is out display to verify operation support nustep com 800 322 4434 42059 Magnet EC and Pivot 5 1 05 TRS 4000 CNusTERD Pivot Cam Adjustment Note This instruction only applies to units with serial numbers 412137 The cams serve the purpose to eliminate play from the arms by their outward position and by removing clearance between their bearings and the shaft they rotate on However if too much pressure is placed on the bearing this can affect the amount of resistance to move the arms Tools Required 5 32 hex key Scratch awl 1 Loosen don t remove 6 screws 2 Set cams to eliminate play from on both sides Lower arms should arms Insert scratc
41. com 800 322 4434 42091A Seat Release Bracket Instruction 5 1 05 TRS 4000 Cem seat Release Bracket With Stud amp Seat Release Spring 12 Tighten front locknut until the 13 Test seat relese bracket opera bracket is tight and then back off tion by depressing the seat release until the bracket rotates freely from lever the pull of the spring 14 Install seat assembly on NuStep See Seat Assembly Removal instruc tions support nustep com 800 322 4434 42091A Seat Release Bracket Instruction 5 1 05 107 CNUSTER ros 4000 X NYSTER Seat Release Lever NOTE Follow Steps 1 2 amp 4 if you are only tightening the bolts that hold this lever Tools Required 7 16 socket and ratchet 242 Loctite Torque wrench 1 Swivel seat to the side and locate two bolts 6l F g SLE th 1a wy 2 Remove bolts and lockwashers from bracket D aam WH 2 hw 3 Remove lever support nustep com 800 322 4434 42093 Seat Release Lever 5 1 05 TRS 4000 CnusTERD Seat Release Lever 4 To install do steps in reverse order Place Loctite on both bolts before installing them then tighten to 80 in Ibs CAUTION To avoid injury and to ensure safe operation of this product fasteners must be tightened to the proper torque Torque Setting 80 inch lbs CAUTION M To avoid injury and prevent adverse ake sure no oere health effects use Loctite in positioned accordance with the manufactur
42. e bearing CN NOTE If replacing right side bearings most shafts have a groove that the set screws must engage in D gt No photo 10 Install components and covers No photo support nustep com 800 322 4434 42009 Bearings Shaft 5 1 05 TRS 4000 NS A Belt Idler Arm NOTE This instruction applies only to units with S N lt 428326 Tools Required Parts Required Channel lock pliers Le self locking ring 9 16 deep socket W Bien of wood BO CAUTION Safety glasses To avoid injury wear safety glasses 1 Remove covers See Cover Removal instructions 2 Remove poly v belt and sheave see Poly V Belt amp Sheave instructions 3 Remove self locking ring from 4 Remove belt idler arm from seat right side of idler arm shaft rail assembly s Ring will be destroyed during removal 5 Transfer pulley Keep the 6 Install belt idler arm Make sure washer s on the side they were on Nyliners don t push out of holes support nustep com 800 322 4434 42011 Belt Idler Arm 5 1 05 TRS 4000 CNUSTEPD Belt Idler Arm 7 Reference photo Close up 8 Lean into 2x4 on left side pound showing right Nyliner in hole with new self locking ring onto end of shaft sticking out shaft with deep socket amp hammer 9 Make sure idler moves up and 10 Check belt alignment per Poly V down smoothly then install sheave Belt instructions and belt No photo 11 Install covers
43. e one inch of new label area with rubbing alcohol and let Attach this edge to forward bottom dry corner of non textured area on left side of cover No photo 3 Remove remainder of adhesive 4 Carefully align label along bottom backing while holding front edge of edge of non textured area NOTE label down Do not pull hard on label while doing this otherwise it will stretch No photo Decrees z H il 15 kd d A AN el 71 ab al et 21 121 131 e sl d Si J l AE 5 Gently smooth label down Don t 6 Align Seat Position Indicator if press down too hard the first time or needed See Seat Position Indicator bubbles and creases may develop instructions No photo gpupeeee peepee SC io 11 13 140 15 a support nustep com 800 322 4434 42087 Seat Position Indicator Label 9 18 00 16 FM Wes TRS 4000 NUSTEP Battery Changin Tools Required Phillips screwdriver 1 Remove 2 screws that attach battery access panel 2 Replace batteries Use 4 AA alkaline batteries Rechargeable batteries are not recommended due to voltage requirements of the display 3 Replace battery access panel No photo support nustep com 800 322 4434 42007 Battery Changing 5 1 05 TRS 4000 CNUSTER Display Removal Installation Tools Required Phillips screwdriver 1 Slide boot down tube and remove 2 On back of display push 2 three screws Hold onto display locking tabs outward on each side
44. eave counter clockwise until the positioned at 4 o clock belt is completely on the sheave and EC disk hub Se EE EE d 5 ed So L tie LP UE a o D K ns bh bie 2 eat A Ben el E D ds ayy becht SA AIEE Du Gees Ka el CAUTION Belt is under tension To avoid injury or damage to the product use caution when removing or installing 9 Spin poly v sheave Belt should 10 Tighten 2 set screws of poly v track directly on center of sheave If Sheave securely Install covers not move poly v sheave in or out on shaft until belt tracks true No photo support nustep com 800 322 4434 42068 Poly V J6 Flex Belt amp Sheave Without Grooves 5 1 05 38 CNUSTEF rRs 4000 XN STER Rear Shaft amp Timing Belt Sprockets NOTE We recommend replacing both the shaft and sprockets if either wear out For S N lt 427184 it is necessary to replace the poly v sheave when replacing the rear shaft Tools Required 1 8 hex key LG socket and ratchet Torque wrench 1 Remove covers See Cover Removal instruction 2 Remove poly v belt and sheave For S N lt 428325 see Poly V Belt amp Sheave instructions For S N gt 428326 see Poly V J6 Flex Belt amp Sheave instructions 3 For S N lt 428173 unhook timing A CAUTION belt springs a CAUTION See Timing Belt Springs To avoid injury or damage to the instructions product use caution when removing or installing Hold arm weldment w
45. echnique 1 Turn NuStep gently onto the side 2 Remove lower retaining ring from that you want to remove the footpedal support tube inside frame footpedal from left side is shown as MA 2 i di eh asf e K bm This ring may already be removed 3 With NuStep upright remove 4 With equal pressure pull pound upper retaining ring near footpedal tube out of frame and footpedal Arm must be all the way forward support nustep com 800 322 4434 42039 Footpedal 1999 5 01 05 TRS 4000 CNUSTEP Footpedal 1999 R or L 5 Remove upper footpedal retaining 6 To install continue by sliding ring and remove footpedal footpedal onto shaft No photo 7 Install upper footpedal retaining 8 Install tube push pound with ring Lock ring in place equal pressure at top and bottom lf hard to insert a quick clamp shown usually works better than the mallet 9 Install upper ring to secure tube to footpedal To reduce operating tension do not install lower retaining ring on footpedal tube Remove opposite side lower ring also support nustep com 800 322 4434 42039 Footpedal 1999 5 01 05 71 Ne TRS 4000 NUSTEP Footpedal 2000 R or L Note This only applies to units with serial numbers gt 413368 For serial numbers 411001 413367 see Footpedal 1999 instructions Left side instructions are shown Tools Required 3 16 hex key Loctite 242 L wrenc
46. ed to ribbon carefully spread covers to access bolts cable The support nustep com 800 322 4434 42035 Electronic Tube 5 01 05 66 ONUSTEF ros 4000 X NYSTER Electronic Tube 7 Attach tube to frame and tighten 8 Make sure ribbon cable is secured bolts to 160 in Ibs in clips and does not hit boot on the footpedal tube during operation Electronic tube and footpedal bumper removed from picture for clarity 9 Slide boots onto tube plug cable into connector and install display i BS 3 j Align key of cable with slot of connector on display support nustep com 800 322 4434 42035 Electronic Tube 5 01 05 67 CUSTER i rars 4000 C TE Step Through Support NOTE Removing the step through support is helpful when working on the drivetrain and especially when unhooking and hooking timing belt springs to remove tension on the drivetrain Tools Required L socket and ratchet 1 Remove covers See Cover Removal instruction 2 Remove step through support Ja aj d One piece step through support shown Two piece step through support shown above applies to serial numbers above applies to serial numbers gt 411001 423601 423602 3 To install do above steps in reverse order No photo support nustep com 800 322 4434 42097 Step Through Support 5 01 05 TRS 4000 CNUSTEP Wheel amp Axle Tools Required Parts Required 2 blocks of wood 3 8 pushnut s Channel lock pli
47. eeeeceeseeeeeeeeseseeeeeeseeeaeeeseseeeeeeeaas 32 Pivot Cam Removal see Lower Arm Cover Cover Removal Installation 38 amp 39 amp A0 12 Seat Position Indicator Label 72 Replacement ccccccecseeeeeeeseeeeseeeeeeseeeeeens 15 Display Battery CMAN GUNG BE 16 Display Removal Installation A2 17 Display Accessory Kit Installation 81 18 Polar Receiver TOO E 19 Drivetrain B arings Shat WO tee 20 Belt Idler Arm 18 22 Belt Idler Spring 136 see Poly V Belt amp Sheave Segel 19 E 24 CONMECING MINK 387 EE 26 Flat Belt 189 amp Belt Idler Spring 3261 28 Front Shaft Alignment eege 30 Magnet EC amp Pivot DISKS 00 0 0 ccccccccceecceceeeeeeeeeceeeeeeeseeeeceseeeeueeeeseaeeeeeseaaeeeeseaaaes 31 Pivot Casting Boot 23 see Footpedal Pivot Disk Assembly 99 call Customer Support NuStep Inc Pivot Shaft 129 see Lower Arm Pivot Shaft le nn EE ER Poly V Belt 12 amp Sheave 101 amp Belt Idler Spring 26 34 Poly V J6 Flex Belt 12 amp Sheave Without Grooves 01 36 Rear Shaft 130 amp Timing Belt Sprockets A7 38 Rear Shaft Alignment naannnaannnannnnennnnsnnnonnnnosnnnsrnnrnrnnrnnnnrosnrensrrrnsnrrnsnrrrnnnrrnnneennnee 41 lo 1 3 Ce UA TEE 42 Timing Belt Springs Replacement 291 46 Timing Belt Sprocket see Rear Shaft support nustep com 800 322 4434 TRS 4000 Cer Contents Eddy Current EC Magnetic Resistance System EC Ball Plunger 45 R
48. ensor 5 01 05 64 Ne e TRS 4000 NUSTEP VR Sensor 6 Replace old VR sensor with new sensor No Photo 7 To install do above steps in reverse order Set gap alignment To Set Gap Alignment mee i Set gap at 1 8 3 16 between sensor and magnet on disk Additional Installation Notes 1 Make sure all wires are secured in cable clips on frame and out of path of timing belts 2 Make sure wire exits from top of connector when installing into PCB connector in step 3 above 3 Before installing covers its a good idea to test the sensor to make sure everything is working correctly support nustep com 800 322 4434 42107A VR Sensor 5 01 05 gt TRS 4000 Cer Electronic Tube Tools Required Phillips screwdriver Wood block Yo wrench Torque wrench 1 Remove three screws and hold 2 Release 2 locking tabs on each onto display so it doesn t fall side of connector Slide boot down tube then remove Snap tabs of connector outward 1 screw each side 1 on bottom 3 Pull out cable from connector 4 Slide both rubber boots up and off electronic tube No photo 5 Remove 4 bolts that attach 6 To install tie washers on end of electronic tube and remove tube string and drop from top through from frame carefully letting ribbon tube Tie ribbon cable to string and cable come out end carefully pull up through tube bech PS Remove front cover screw and String with washers attach
49. eplacement and Adjustment ccccsseeeeeseeeeeeeeeeeesaeees 47 EC Disk 46 amp Bearings 7 48 EG Magnet E EE 51 EC Magnet Gap Alignment 471 52 EC Plunger Plate 50 amp EC Magnet Slide Bracket 49 cccccecsseeeeseeeeeesaeeees 53 Oa CW ER E E E E E 56 Workload Level PCB 94 sssseesescectascces ceonsstegesad sedacceehessvdeueriiebesesbeiccteeesbivelasstegenctesds 57 Electronics DO Power Cable e NEE 58 Hall Effect Sensor 24 60 RIDDON Cable E KE 62 En Ee E EN 63 Electronic Tube Display Boot 21 see Electronic Tube Electroni TUDO 92 EE 65 Electronic Tube Boot 22 see Electronic Tube Frame Main Frame call Customer Support NuStep Inc Siep TiO SUPPO AO E 67 Wheel 1 5G amp Axle EE 68 Footpedal Footpedal 1999 56 amp DI 69 Footpedal 2000 56 amp bn 71 Footpedal Bearing Replacement 91 73 Footpedal Bumper Upgrade nn0annnannnannoannnannonnnnnnnonnrnnninnnrennrrnnrennrrnnnrrnrrenrennnnne 74 Footpedal Stabilizer 2000 61 75 Footpedal Support Tube 1900 78 Footpedal Support Tube Retaining Ring Removal 1999 to reduce arm tension 80 Seat Seat 110 amp Swivel 141 amp Seat Channel ei 81 Seat Armrest 111 amp Seat Armrest Bracket 12112 85 Seat Assembly 115 Removal Installation cccccccccccceesseeeeeseseeeeeeeeeseeeeeeeaaeeeeens 86 Sear LOCKING leie Ee 87 Seat Mounting Bracket Assembly 171 89 Seat Mounting Bracket 117 amp Seat Rele
50. er mount brackets remove belt idler arm from seat rail assembly See Belt Idler Arm instructions No photo support nustep com 800 322 4434 42089 Seat Rail 5 1 05 100 TRS 4000 use Seat Rail amp Seat Stop Pin amp Angle Cover Mount Bracket 7 Replace applicable parts and 8 Install seat rail onto frame transfer old parts to new Tighten nuts securely Install cov ers IL E Geen Seat Rail ut A e T WW P P 7 b T he l j F CG r i 5 BR via support nustep com 800 322 4434 42089 Seat Rail 5 1 05 TRS 4000 Cum seat Release Bracket amp Seat Release Spring amp Nyliners NOTE This instruction applies to units with S N lt 428341 Tools Required 5 32 hex key Aa CAUTION Aa CAUTION SE peie To avoid injury wear safety To avoid injury and to 242 Loctite glasses ensure safe operation of Silicone or white grease this product fasteners must Safety glasses be tightened to the proper torque 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket by 3 Remove seat release spring removing front and rear shoulder bolts rear shown d a CAUTION Springs are under tension To avoid injury or damage to the product use caution when removing or installing 4 Replace seat release bracket or spring or Nyliners now not shown Before installing lubricate bracket along slots and where lever pin contacts brack
51. er s with flats material safety data sheets including of lever the use of safety glasses and against the impermeable gloves Material safety bracket data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 REFERENCE PHOTO support nustep com 800 322 4434 42093 Seat Release Lever 5 1 05 TRS 4000 Cum Seat Wheel Tools Required 5 32 hex key A CAUTION To avoid injury and to ensure safe 7 16 socket and ratchet Torque wrench operation of this product fasteners must be tightened to the proper torque 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove wheel s 3 Install new wheel s and tighten bolts to 80 in Ibs No photo NOTE For units with S N lt 420357 discard the washer between the seat wheel and the seat channel New seat wheels do not require the washer support nustep com 800 322 4434 42095 Seat Wheel 5 1 05 TRS 4000 CNusTERD Swivel Release Lever Tools Required T 5 32 hex key CAUTION EE To ensure safe operation of this Needle nosed pliers LG socket and ratchet Long socket extension 7 16 socket and ratchet 3 8 wrench Torque wrench 242 Loctite product fasteners must be tightened to the proper torque 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket For S N lt 428341 see Seat Release Bracket instructions Fo
52. ers Rubber hammer Safety glasses CAUTION The TRS 4000 is very heavy it weighs 205 Ibs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique 1 Prop rear of NuStep on block of 2 Remove wheel s and or axle wood and remove pushnut with pliers Tem oe Fe Pushnut will be destroyed during re moval 3 To install place wheels and axle back on and balance pushnut onto end of axle Hold block of wood gently against pushnut on opposite side With one direct hit hit pushnut on Continue to hit pushnut on until there are slight gaps between pushnuts and wheels on both ends Do not hit pushnut on too tight as damage may occur and or wheels may not roll support nustep com 800 322 4434 42109 Wheel and Axle Removal 5 01 05 69 CNUSTEF ros 4000 X NYSTER Footpedal 1999 R or L Note This only applies to units with serial numbers of 411001 413367 For serial numbers gt 413368 see Footpedal 2000 instructions You may want to remove both lower retaining rings from the footpedal tubes to reduce operating tension See Retaining Ring Removal instructions Tools Required Snap ring pliers 90 tip Rubber mallet Quick clamp maybe Safety glasses a CAUTION The TRS 4000 is very heavy it weighs 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting t
53. et see old bracket support nustep com 800 322 4434 42091 Seat Release Brkt amp Spring 5 1 05 102 ONUSTEF Trs 4000 TN Seat Release Bracket amp Seat Release Spring amp Nyliners 5 Install seat release bracket Loctite front and rear shoulder bolt threads CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by Don t get Loctite on Nyliners calling Henkel Corporation at 800 562 8483 6 On front wave washer goes on 7 On rear washer goes on inside of shoulder bolt peak against bolt channel Tighten both shoulder bolts head washer on inside of channel to 80 in Ibs Torque Setting 80 inch lbs NOTE If your model does not have a NOTE The shoulder bolt may extend wave washer install without out from end of Nyliner 8 Install spring 9 Test seat locking operation Install seat assembly onto NuStep See Seat Assembly Removal instruc tions support nustep com 800 322 4434 42091 Seat Release Brkt amp Spring 5 1 05 103 CNUSTEF rus 4000 X NUSTER seat Release Bracket With Stud amp Seat Release Spring NOTE This instruction applies to units with S N gt 428342 Tools Required 5 32 hex key Needle nosed pliers 1 2 socket and ratchet P
54. ety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 NOTE Early models have 1 bearing on belt 8483 side while most have 2 bearings shown 9 Press in bearing s using arbor press Spin disk to make sure bearings are OK after installation NOTE NuStep uses a custom bearing installation tool However a thick heavy washer pressing only on the bearing races can work shown support nustep com 800 322 4434 42027 EC Disk amp Bearings 5 01 05 50 CNUSTEF rRs 4000 XN STER EC Disk amp Bearings 10 Clean shaft and apply small 11 Place small amount of Loctite on amount of Loctite on shaft at 1 2 exterior bearing race inch from the tapered end near S We wy H rE ZS Cy Vi E d r Ce d b d i Y OH H 12 Carefully install EC disk onto Ar CAUTION shaft and install snap ring Snap To avoid injury and prevent adverse ring will slightly preload the bearing health effects use Loctite in and Loctite will hold disk in place accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 13 NOTE If you are installing the 14 Install covers nut instead of the snap ring nut should only bottom out against No photo shaft shoulder
55. g on your actual use Preventive Maintenance Action Supplies Low Medium High Less than 10 10 40 hours More than 40 hours per week per week hours per week home clinical commercial Clean covers Non abrasive arms seat and spray cleaner ii lac Monthly Daily Clean ike Fantastike pe p and a soft dirt and dust cloth 4 AA alkaline batteries Replace Every 12 Every 3 Every 1 Rechargeable batteries months months month Replace batteries are not l recommended due to voltage requirements of the display None if no action required Parts if action required Check drive belts SC a Every 6 to Every 3 to 6 EEN for signs of wear 12 months months BUEP ONIO sae months and check support nustep com 800 322 4434 TRS 4000 Cem i Contents How to Obtain Customer Support cssceecccsnsseececnnsseeeecnnseeeeecnasseseecnnsseseeonasseseeensseesesenaes i ADOLTA Map ee lil Preventive Maintenance Break in Period EE iV Preventive Maintenance Internvale iV Service Instructions The Parts List item is in parenthesis Arms Upper Foam Grip 55 Replacement ccccccssseeccseseeeeseeeeceeeeeeeseseeeseueeesseeeeseeesessaeeeess 1 UEA ER WEE 2 len COCK EE 3 Arms Lower Arm Lock KNOB 70 E 4 Arm Lock Weldnut Repair Ki 5 Arm Lock Knob Repair kt 6 Lower Arm 4 amp 5 amp Bearings 8 amp 9 amp Pivot Shaft 20 7 Pivot Cam 158 Adjustment ccccccccccceeceeeeeeeec
56. h Large flat head screwdriver Snap ring pliers 90 tip Safety glasses CAUTION To avoid injury wear safety glasses 1 Remove upper nut from stabilizer Prevent shoulder bolt from turning Shoulder bolt is locked to footpedal Don t turn it If it loosens then Loctite it back in during installation below 2 Pry rod end off shoulder bolt with 3 Remove upper footpedal retaining large flat head screwdriver ring and remove footpedal support nustep com 800 322 4434 42041 Footpedal 2000 5 01 05 TRS 4000 CNUSTEP Footpedal 2000 R or L 5 Install upper footpedal retaining 4 To install slide footpedal ring Lock ring in place onto shaft No photo H 6 Place a little Loctite 242 onto shaft and threads of shoulder bolt Don t let any get into rod end ball To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by If upper shoulder bolt loosened in Step 1 rl EES place a little Loctite on shoulder bolt shaft and install into footpedal 8 On both rod ends wipe grease on both sides of rod end into spaces between rod end and washer and rod end and nut bolt 7 Tighten nut securely Prevent shoulder bolt from turning support nustep com
57. h awl into hole have some play in them with slight pressure While keeping pressure on awl tighten screws with hex key NOTE Cams are set correctly when olay is removed from arms but cam is not set too tightly which can increase arm resistance support nustep com 800 322 4434 42061 Pivot Cam Adjustment 9 18 00 33 CNUSTEP ros 4000 lt NUSTER Pivot Shaft Alignment NOTE This instruction only applies to units with S N lt 411609 and will help prevent shaft from sliding axially in bearings Later models have a grooved shaft Tools Required 5 32 hex key A CAUTION ee ee To avoid injury wear safety glasses Rawhide hammer Safety glasses 1 Rotate right arm forward to work on right side left arm forward to work on left side 2 Remove caps loosen and remove _ 3 Tap shaft with hammer until right set screws from both collars end of shaft aligns with end of right collar shown Note Right side shown 4 With set screws removed from both sides pour a few drops of 290 A CAUTION Loctite down into set screw holes To avoid injury and prevent adverse Tighten set screws back down and health effects use Loctite in replace caps accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483
58. h springs Before replacing springs please review how the current springs and belts are positioned on the unit and then unhook and replace one spring at a time Tools Required None 1 Turn NuStep gently onto its left side from rider s perspective The TRS 4000 is very heavy it weighs 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique Springs are under tension To avoid injury or damage to the product use caution when removing or installing Move right arm rearward shown to reduce tension on right spring then replace right spring Move left arm rearward to reduce tension on left spring then replace it J 3 Review current spring and belt position then unhook and replace one spring at a time Keep spring hooks facing up Make sure springs are hooked through rubber grommet in frame and engaged into belt clamps aa n Fire pa SI TTT ea 3S m e Right belt must be around higher idler TZ and above workload lever tube Left belt must be around lower idler and below workload lever tube Make sure belts are in correct position as shown above after replacing springs support nustep com 800 322 4434 42103 Timing Belt Springs Replacement 9 1 00 47 Ne SC TRS 4000 NUSTEP EC Ball Plunger Replacement Adjustment Tools Required Flat head screwdriver 1 Remove covers See Cover Removal i
59. hen For S N gt 428174 unhook belt unhooking springs to prevent weldment idler spring from falling forward see Flat Belt amp Belt Idler Spring instructions 4 Loosen 4 set screws on left and 5 Loosen 4 nuts of bearings right side rear bearings Remove right bearing only support nustep com 800 322 4434 42069 Rear Shaft amp Sprockets 5 1 05 39 ONUSTEF TRS 4000 X NET Rear Shaft amp Timing Belt Sprockets 6 Slide rear shaft toward poly v side 7 To install slide new shaft from and remove plastic spacers and poly v side Install parts in order 3 sprockets and shaft spacers sprocket 2 spacers sprocket 3 spacers See Figure 3 1 IMPORTANT NOTE Lock A and printing on roller clutches must face poly v side The drivetrain will not operate properly if sprockets are installed backwards 8 Attach right side bearing and slide 9 Tighten 4 nuts on bearings to 200 shaft until shaft is flush with end of inch lbs bearing Set screws will tighten into No photo groove on shaft 10 Tighten 4 set screws install poly v belt and sheave install timing belt springs S N lt 428173 or belt idler spring S N gt 428174 support nustep com 800 322 4434 42069 Rear Shaft amp Sprockets 5 1 05 40 FM SC TRS 4000 NUSTEP Rear Shaft amp Timing Belt Sprockets Reference photos showing correct belt placement Left belt under low left idler and under load lever tube and
60. hillips screwdriver Silicone or white grease Safety glasses CAUTION To avoid injury wear safety glasses 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket by removing front locknut front flange bearing and rear shoulder bolt keep rear washer and bolt 3 Remove and keep seat release 4 Remove old thrust washer from spring seat release bracket a CAUTION Springs are under tension To avoid injury or damage to the product use caution when removing or installing support nustep com 800 322 4434 42091A Seat Release Bracket Instruction 5 1 05 a TRS 4000 Custer seat Release Bracket With Stud amp Seat Release Spring 5 Lubricate new seat release 6 Place thrust washer on bracket bracket along slots on bottom and stud on tab on top where the lever pin contacts the bracket see old bracket 7 Slide bracket stud into the front 8 Slide flange bearing onto bracket seat channel hole stud and ensure that the bearing slides inside the thrust washer support nustep com 800 322 4434 42091A Seat Release Bracket Instruction 5 1 05 TRS 4000 CNUSTERD seat Release Bracket With Stud amp Seat Release Spring 9 Thread locknut onto stud but do 10 Install spring not tighten nut yet 11 Slide shoulder bolt through rear seat channel hole and washer thread bolt into bracket and tighten to 80 in Ibs support nustep
61. ial safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 Due to Loctite strength it is only necessary to use Loctite on right side set screws and shaft to prevent shaft from sliding axially 5 Moving shaft back in alignment should also align poly v sheave and belt If it doesn t realign them See Poly V Belt and Sheave instructions Install covers support nustep com 800 322 4434 42071 Rear Shaft Alignment 5 1 05 Timing Belt R L 42 NUS TRS 4000 NUSTEP NOTE We recommend replacing both belts at the same time The right side belt is an 8M20x944 mm long while the left is an 8M20x1040 mm long Do right belt first then left to avoid mistakes Tools Required Phillips screwdriver long Flat head screwdriver long 1 Remove covers See Cover Removal instructions 3 For S N lt 428173 unhook timing belt springs see Timing Belt Springs instructions For S N gt 428174 unhook belt idler spring see Flat Belt amp Belt Idler Spring in structions 4 Remove right nut and bolt using wrench and Phillips screwdriver Ae x ya a Clamp secures belt to pivot disk 4 teeth of belt are in contact L socket and ratchet 7 16 socket ratchet extension amp wrench 2 Remove step through support CAUTION To avoid injury or damage to the product use caution when removing or installing Hold arm weldmen
62. if you are just replacing plunger GOTO Step 9 support nustep com 800 322 4434 42033 EC Plunger amp Slide Brkt 5 01 05 TRS 4000 Cer EP EC Plunger Plate amp EC Magnet Slide Bracket 6 Remove EC magnet 7 Remove shoulder bolts and remove slide bracket 8 Install slide bracket and lube and 9 Install plunger plate through tighten shoulder bolts Bracket Nyliners in frame Three washers on should slide easily back and forth tube stud into shoulder washer and If it doesn t slightly bend shoulder ball plunger loose not shown bolts to make bracket slide easily on Nyliners Washers EC Shoulder pivot support nustep com 800 322 4434 42033 EC Plunger amp Slide Brkt 5 01 05 TRS 4000 CAS EC Plunger Plate amp EC Magnet Slide Bracket 10 Leaning into a 2x4 against the 11 Install load lever and set ball plunger on left side lean over and plunger pound ring onto end of plunger tube with socket until it just contacts see Load Lever instructions Nyliner Make sure plunger stud does not come out of shoulder see Ball Plunger Adjustment washer see Step 9 instructions No photo 12 Test Check Workload on 13 Install poly v components and display install covers No photo No photo support nustep com 800 322 4434 42033 EC Plunger amp Slide Brkt 5 01 05 56 ONUSTEF ras 4000 SN STER Load Lever Tools Required 3 socket ratchet and extension A CAUTION Hammer
63. ivel amp Seat Channel 5 01 05 n TRS 4000 Cum Seat amp Swivel amp Seat Channel 11 Replace swivel now not shown Replace seat channel now Transfer wheels from old channel to new Tighten bolts to 80 in lbs 12 Install swivel with keyhole slots against seat bottom Tighten bolts to 200 in lbs Lubricate round flat area on channel see old channel To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 support nustep com 800 322 4434 42077 Seat amp Swivel amp Seat Channel 5 01 05 TRS 4000 CNUSTEP Seat amp Swivel amp Seat Channel 14 Swivel assembly 45 to install 15 Swivel assembly 90 to install two bolts through cutouts next two bolts through cutouts 17 Check swivel and release lever Ibs operation 18 Install seat release bracket For S N lt 428341 see Seat Release Bracket instructions For S N gt 428342 see Seat Release Bracket With Stud instructions 19 Test seat locking operation Install seat assembly onto NuStep support nustep com 800 322 4434 42077 Seat amp Swivel amp Seat Channel 5 01 05 85 ONUSTEF TRS 4000 amp NET Seat Armrest R L amp Seat Armrest Bracket R L Tools
64. ket and ratchet Torque wrench 242 Loctite Silicone or white grease 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket For S N lt 428341 see Seat Release Bracket instructions For S N gt 428342 see Seat Release Bracket With Stud instructions 3 Swivel seat channel assembly 45 4 Remove four bolts and washers to access four bolts that attach seat channel to seat support nustep com 800 322 4434 42077 Seat amp Swivel amp Seat Channel 5 01 05 82 Seat amp Swivel amp Seat Channel 5 Lift seat channel assembly off NOTE If you are replacing the seat channel or swivel GOTO Step 10 7 Replace seat Lubricate seat bottom lightly where it contacts mounting bracket see old seat Transfer armrests to new seat Lubrication prevents squeaking be tween the two parts 9 Align 6 mounting holes install front two bolts tighten to 200 in Ibs GOTO Step 13 if you are done Make sure KR springs operate properly TRS 4000 ue 6 Remove seat mounting bracket Remove front two bolts below and lift assembly off seat 8 Position springs with larger diameter coil against seat Install mounting bracket over both springs Springs go through holes in bracket Springs shown in holes other parts re moved for clarity 10 Remove four bolts that attach swivel to channel support nustep com 800 322 4434 42077 Seat amp Sw
65. may be a slight gap between the footoedal support tube and the frame and this is normal Tools Required Snap ring pliers Safety glasses for removing ring a CAUTION a CAUTION The TRS 4000 is very heavy it weighs To avoid injury wear safety glasses 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique 1 Turn NuStep gently onto its left 2 Remove lower retaining ring from side from rider s perspective left footpedal support tube inside frame Do not remove upper ring near footpedal WT may snap into the frame and there may now be a gap on the outside between the tube and the frame This is normal 3 Turn NuStep gently onto its right 4 Remove lower retaining ring from side right footpedal support tube inside frame Do not remove upper ring near footpedal No photo No photo support nustep com 800 322 4434 42047 FP Support Tube Retaining Ring Removal 5 01 05 81 NUS Bee TRS 4000 NUSTEP Seat amp Swivel amp Seat Channel NOTE Follow NOTE and GOTO instructions carefully They tell what Steps to do and what to skip for specific parts Tools Required 5 32 hex key Aa CAUTION To avoid injury and to ensure safe Needle nosed pliers VS socket and ratchet an 4 Get Long socket extension operation ot this product fasteners 1 2 wrench must be tightened to the proper torque 7 16 soc
66. mm Loop extra cable back and forth and insert into a clip to keep it out of the way of moving parts Make sure power cable is out of the way of the ribbed timing belt 8 Turn NuStep upright and test power with AC adapter support nustep com 800 322 4434 42019 DC Power Cable 5 01 05 60 ONUSTEF rps 4000 INTE Hall Effect Sensor NOTE This sensor and the magnet that passes by it are responsible for indicating STEPS PER MINUTE STEPS TIME and for turning the display on from its sleep mode Tools Required Phillips screwdriver long 1 Remove covers See Cover Removal instruction 2 Disconnect ribbon cable 3 Disconnect hall sensor wire d fy A P i j J F It makes it easier to access wire The red black amp white wire on right 4 Unscrew sensor bracket from inside of frame L e Tihi The photo above shows the sensor bracket The photo above shows the sensor bracket used for serial numbers 411001 422080 used for serial numbers gt 422081 5 Remove sensor wiring from cable clips along frame a CAUTION The TRS 4000 is very heavy it weighs 205 lbs 93 kg To avoid injury or damage to the product always obtain assistance to move this product Use proper lifting technique NOTE Bottom view shown l 6 Replace old sensor with new sensor No Photo support nustep com 800 322 4434 42055A Hall Effect Sensor 5 01 05 TRS 4000 NS A Hall Effect
67. nd install 2 new flat head fasteners and tighten Pay Mind Shy l d a gt S Sa y i d CS D Dee Push right footpedal forward to remove left screw left footoedal forward to remove right screw or center footpedals and remove both screws 3 Install new bumpers onto the footpedal bumper bracket and tighten snugly with finger pressure support nustep com 800 322 4434 42127 Footpedal Bumper Upgrade 6 12 01 TRS 4000 CNUSTEP Footpedal Stabilizer 2000 R or L Note This only applies to units with serial numbers 413368 For serial numbers 411001 413367 see Footpedal Support Tube 1999 instructions Left side instructions are shown Tools Required 3 16 hex key A CAUTION L wrench Snap ring pliers Loctite 242 Large flat head screwdriver Hammer Grease silicone white or clear preferred Torque wrench Safety glasses To avoid injury wear safety glasses 1 Remove upper nut from stabilizer Prevent shoulder bolt from turning Shoulder bolt is locked to footpedal Don t turn it If it loosens then Loctite it back in during installation below 2 Remove lower shoulder bolt from frame Aw A Shoulder bolt is locked to rod end ball Remove rod end from shoulder bolt by lightly tapping with a hammer support nustep com 800 322 4434 42049 Footpedal Stabilizer 2000 5 01 05 TRS 4000 CNUSTEP Footpedal Stabilizer 2000 R or L 3 Pry upper rod end off
68. ngs end of shaft aligns with end of right 4 Remove right side set screws and pour a few drops of 290 Loctite down into set screw holes Tighten all 4 set screws back down CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 NOTE Due to Loctite strength it is only 8483 necessary to use Loctite on right side set screws and shaft to prevent shaft from sliding axially 5 Realign EC Magnet and disk before installing covers see EC Magnet Gap Alignment instructions support nustep com 800 322 4434 42053 Front Shaft Alignment 5 1 05 TRS 4000 CNUSTEPD Magnet EC amp Pivot Disks NOTE This magnet is located on both the EC amp Pivot Disks and activates the VR amp Hall Effect Sensors If the magnet was installed correctly it will not come off This instruction is for the unlikely event that the magnet was incorrectly attached and did come off The instruction shows the Pivot Disk but the same steps apply for the EC Disk Tools Required Loctite 324 adhesive BO CAUTION To avoid injury and prevent adverse Loctite 7075 or 7387 Activator 1 Remove covers See Cover health effects use Loctite in Removal instruction accordan
69. nstruction 2 Place workload lever in position 4 3 NOTE If you are just adjusting ball plunger GOTO Step 4 If replacing remove old one and replace with new one 4 Tighten ball plunger until ball just seats into each hole on plate W IE NOTE Move workload lever back and forth and then adjust ball plunger If workload lever is too tight lever moves hard and body of ball plunger scrapes plate loosen ball plunger by turning a little to the left If workload lever is too loose there is a little play in each position tighten ball plunger by turning a little to the right The right feel is achieved when the workload lever hits each position but is not too hard to move or has excessive play JJ 5 Test that all 10 Workload Levels show on display No photo 6 Install covers No photo support nustep com 800 322 4434 42025 EC Ball Plunger 9 10 00 TRS 4000 CNUSTEP EC Disk amp Bearings NOTE NuStep Inc can supply this part fully assembled see parts list Units with S N 411001 411114 have only 2 bearings in the disk and a nut on the end of the shaft while S N gt 411115 have 3 bearings and a snap ring This instruction applies to either Tools Required Snap ring pliers Arbor press Mechanical puller 2 jaw with 4 spread Loctite 680 for cylindrical parts and 3 1 4 reach Safety glasses L socket and ratchet oe of wood Aa C AUTI ON Flat head screwdriver 9 16 deep socket
70. nting Bracket Assembly Tools Required 5 32 hex key A CAUTION To avoid injury and to ensure safe Needle nosed pliers LG socket and ratchet i Long socket extension operation of this product fasteners 7 16 socket and ratchet must be tightened to the proper torque Torque wrench 242 Loctite 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket For S N lt 428341 see Seat Release Bracket instructions For S N gt 428342 see Seat Release Bracket With Stud instructions 3 Swivel seat channel assembly 45 4 Remove four bolts and washers to access four bolts that attach seat channel to seat support nustep com 800 322 4434 42263 Seat Mounting Bracket Assembly 5 01 05 90 ONUSTEF ras 4000 SN STER Seat Mounting Bracket Assembly 5 Lift seat channel assembly off 6 Remove the two remaining bolts Remove seat release lever and that attach seat mounting bracket to swivel release lever seat and remove seat mounting bracket Note leave rear seat lever springs in place on seat bottom 7 Align holes of new seat mounting _ 8 Transfer old swivel release lever bracket assembly with seat to new bracket and tighten nuts to weldnuts and rear seat lever 80 in lbs springs Place bracket on seat and thread two bolts with lockwashers into front weldnuts Tighten bolts to 200 in Ibs Torque Setting 200 inch lbs support nustep com 800 322 4434 4
71. o NuStep see Seat Assembly Removal instructions support nustep com 800 322 4434 42099 Swivel Release Lever 5 1 05 TRS 4000 Cause Troubleshooting Guide PROBLEM POTENTIAL CAUSE VERIFY CAUSE CORRECTIVE ACTION There is no resistance Timing belt spring break Lay unit on left side Refer to Timing Belt and inspect the spring Springs Replacement instruction Poly v belt may have come off Remove covers and Refer to Poly V Belt inspect poly v belt instruction Resistance feels too Retaining rings on the Footpedal Lay unit gently on left Refer to Footpedal hard Support Tube may be causing side and see if there Support Tube Retaining resistance on S N 411001 411943 are retaining rings Ring Removal instruction A belt may be out of alignment Inspect all belts to Refer to Poly V Belt amp verify they are not Timing Belt instructions misaligned Jerky arm movement A newer user getting used to the Is there a slight jerky This is normal operation feel of the motion feeling in arms at and most users will higher Workloads develop a smoother motion over time DISPLAY amp ELECTRONICS For all problems start A low battery Low battery indicator Refer to Battery Changing with fresh batteries may be illuminated _ instruction 8 s appear in all LCD A low battery Replace batteries Refer to Battery
72. oid possible injury or alert against unsafe practices death resulting from misuse a CAUTION a CAUTION The TRS 4000 is very heavy it weighs Do not operate this product unless all 205 lbs 93 kg To avoid injury or covers guards and parts are in place damage to the product always obtain and securely fastened assistance to move this product Do not operate this product if it appears Use proper lifting technique damaged or inoperable support nustep com 800 322 4434 IV e e TRS 4000 NUSTEP Preventive Maintenance Break In Period Preventive Maintenance Intervals Break in Period Most mechanical products break in after which bearings roll more freely bushings rotate better belts stretch and parts loosen up a little This is normal Your TRS4000 is designed to accommodate this break in with no adjustment on your part The resulting effect is that there is a little less friction and the unit may feel a little easier but this is normal and the unit needs no calibration Preventive Maintenance Intervals Your TRS4000 is designed to be maintenance free We recommend just a few items that will increase the useful life of the NuStep Please follow the recommended preventive maintenance intervals in months according to the amount of usage that the NuStep receives hours per week These are estimated intervals and you may need to increase or decrease the time period between preventive maintenance dependin
73. oise will be Refer to Bearing Shaft may be bad slow and consistent _ instruction EC disk bearing bad listen that noise is consistent with speed Spin disk rapidly and Refer to EC Disk amp Bearings instruction The seat jumps to the next position The seat lock wasn t fully engaged support nustep com 800 322 4434 734 769 3939 x 5 Make sure the seat is fully locked in place NuStep TRS 4000 Parts List 1 4 Note Most parts are available individually but to simplify installation ASSEMBLIES in CAPS only come fully assembled Items noted as not shown were replaced with current revision parts and are available as service parts but are not shown in the Figures Item Qty 1 1 not shown not shown 2 1 not shown not shown 3 2 4 1 not shown 5 1 not shown 6 1 7 8 9 10 11 12 1 not shown 13 1 14 15 16 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 36 37 38 39 40 41 1 not shown 42 43 44 45 46 not shown O BN CO W NFP FP Pe PFNONFUBNFTNNNF RF FA oO m N Pr k Fb me me me Eech Kc PN 4085B 4085A 4085 4086B 4086A 4086 4087 4081A 4081 4080A 4080 40128 41002 41004 41208 41006 41008 41462 41010 41014 41012 40322 40320 41016 41018 40156 40148 40210 4091 4093 41024 41028 41030 41026 41184 41036 41038 40552 30267 4074 4090 4092 4094 40154A 40154 40150 4800 40132 41
74. on The button doesn t The button may be broken Replace the display operate the functions support nustep com 800 322 4434 734 769 3939 x 5 PROBLEM POTENTIAL CAUSE VERIFY CAUSE TRS 4000 Cem CORRECTIVE ACTION Heart Rate not showing in the display Polar receiver may be missing or defective Open battery access panel and look Is the user wearing the Polar transmitter belt correctly Install a Polar receiver Make sure chest amp belt contacts are moistened belt is well positioned The Watts aren t reading similar to the NuStep TRS3000 This is normal TRS4000 is more accurate Clicking clanking clunking noise linked to each step taken squeaking noise linked Metal to metal to each step taken Ps high pitched squeak Nut loose on the connecting especially wl left foot forward Footpedal tube is compressing bumper and causing the connecting link to hit pivot disk Take shorter steps and visually check if bumper is being hit Move arms without sitting on seat If noise is not there then patient is not set up properly Seat rocking Are front and rear shoulder bolts tight on seat release bracket Inspect bearing set shaft screws to verify that _ they are tight Belt clamp hitting the workload Lay unit on left side and lever tube check if belt clamp is hitting tube Set screw loose on the pivot shaft Ins
75. ot hard to thread out if it had a snap continue ring on it No photo 4 Lubricate threads on new knob 5 Install upper arm per instructions and thread into arm Wipe up excess lube You do not have to No photo install snap ring back on No photo support nustep com 800 322 4434 42005 Arm Lock Knob 5 1 05 i TRS 4000 Cer EP Arm Lock Weldnut Repair Kit Note This instruction applies to units with S N lt 412391 For S N 411001 411091 use part number 4112 For S N 411092 412391 use part number 4114 Tools Required Hammer Torque wrench Cold chisel Safety glasses Phillips screwdriver 1 Remove upper arm See Upper Arm instruction A CAUTION To avoid injury wear safety glasses 2 Install new arm lock See Arm Lock instruction 3 Remove remaining weldnut from 4 Insert nut plate into arm weldment underside of arm weldment both and align threads with arm weldnuts must be removed to install weldment holes Thread screws into the nut plate nut plate until the tip of the screw is flush with the surface of the nut plate pu For S N 411092 412391 note the direction reference written on the nut plate 5 Install upper arm See Upper Arm instruction Do not over tighten screws maximum torque 7 5 in Ibs support nustep com 800 322 4434 42259 Arm Lock Weldnut Repair Kit 5 1 05 i TRS 4000 CNUSTERD Arm Lock Knob Repair Kit o CAUTION 31 64 drill bit Tap wrench
76. own and lay it across rear of NuStep The horizontal position keeps parts from prevent scratching end of seat rail Sliding out of position 5 To install do steps in reverse order No photo support nustep com 800 322 4434 42081 Seat Assembly Removal 5 01 05 87 CNUSTEP TRS 4000 lt NET Seat Locking Upgrade NOTE This instruction applies to units with S N lt 428343 Tools Required 7 16 socket and ratchet A CAUTION 7 16 wrench sacs Drill To avoid injury wear safety glasses Shop vac Long socket extension Philips screwdriver 1 2 or 15 32 drill bit Safety glasses 1 Remove seat assembly See Seat Assembly Removal instruction 2 Replace seat release bracket See Seat Release Bracket With Stud instruc tion 3 Remove covers See Cover Removal instruction 4 Remove old seat stop pin weldment and discard screws e k 5 Enlarge 2 seat stop pin holes on seat rail and remove all metal shavings from the unit after drilling support nustep com 800 322 4434 42058 Seat Locking Upgrade Instruction 5 01 05 TRS 4000 Cer Seat Locking Upgrade 6 Install new seat stop pin weldment using new screws EH e Pe KA GE Note install seat stop pin weldment WK with notch toward the front of the unit 7 Install covers and seat assembly See Cover Removal instruction support nustep com 800 322 4434 42058 Seat Locking Upgrade Instruction 5 01 05 i TRS 4000 CNUSTEP Seat Mou
77. pect pivot shaft to verify the shaft is not rotating Noise is a Lay unit on left side to verify nuts holding the connecting link are tight at the pivot disk amp arms link bracket are worn Instruct patient to take smaller steps and move seat back one notch Position user one notch closer with more weight against seat back and adjust arms so shoulders rotate less Refer to Seat Release Bracket instruction Set screw loose on the rear Refer to Bearings Shaft instruction Spring Replacement instruction Refer to Pivot Shaft Alignment Instruction Refer to Timing Belt Refer to Connecting Link instruction Nyliners for the seat release Refer to Seat Release Bracket instruction linked to each step Vibrating or groaning taken Metal to metal clicking noise continues after stopped stepping Other noises continue after stopped stepping Rod ends on the connecting Noise ends when links are bad movement is stopped Is the noise a metal to metal sound Poly v belt may have become Remove covers and misaligned inspect poly v belt stops moving not rubbing on frame Front or rear shaft bearings Verify belt idler arm is Refer to Connecting Link instruction Refer to EC Magnet Gap Alignment instruction Refer to Rear Shaft Alignment instruction Squeaking present until disk Refer to Belt Idler Arm instruction Bearing n
78. r Arm R L amp Bearings amp Pivot Shaft 11 Carefully lift left arm out 12 Carefully lift right arm out S No photo De ARI gt ra ee mc mmm Ki Krich 5 DG Get s 13 If you are just replacing either 14 To replace bearings insert lower arm do it now Transfer parts screwdriver against end of bearing from old to new GOTO Step 16 wall and gently tap out Be careful not to scar bore No photo 15 To insert bearings carefully tap 16 Place arm assemblies back into into bore using a block of wood and the frame and back onto wood hammer blocks support nustep com 800 322 4434 42001 Arm Lower 5 1 05 10 TRS 4000 CNUSTERD Lower Arm R L amp Bearings amp Pivot Shaft 17 Shaft direction Radius end in first groove end last NOTE Early models may not have the groove Groove end Radius end 19 Remove top right setscrew and tap shaft into position so that groove aligns with setscrews a A i J KT o A G E TN Cel 21 Place a few drops of Loctite 242 on shoulder bolt threads and shoulder 18 Carefully tap shaft through bear ings but do not force You must wiggle arms as you go otherwise bearings will be damaged Work shaft through one bearing at a time 20 Tighten all setscrews securely Right side setscrews must lock into groove to prevent shaft movement mg am A CAUTION To avoid injury and prevent adverse health effects use Loctite in
79. r S N gt 428342 see Seat Release Bracket With Stud instructions 3 Swivel seat channel assembly 45 to access four bolts that attach seat channel to seat support nustep com 800 322 4434 42099 Swivel Release Lever 5 1 05 R TRS 4000 use Swivel Release Lever 5 Lift seat channel assembly off Remove swivel release lever Note for S N s 415412 421171 install lever using flange nuts provided with new lever Do not install lever with washers and jam locknuts 7 To install seat channel place Loctite on swivel bolts CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 support nustep com 800 322 4434 42099 Swivel Release Lever 5 1 05 TRS 4000 CNusTERD Swivel Release Lever 8 Swivel assembly 45 to install two 9 Swivel assembly 90 to install next two bolts through cutouts bolts through cutouts 10 Tighten all four bolts to 200 in 11 Check swivel and release lever Ibs operation Swivel seat left and right and check that swivel locks in place 12 Install seat release bracket See Seat Release Bracket Installation instruc tions 13 Check seat locking operation Install seat assembly ont
80. racket amp Swivel Release Lever Bracket amp Springs amp Nyliners en A CAUTION Needle nosed pliers To avoid injury wear safety glasses LG socket and ratchet Long socket extension T 7 16 socket and ratchet CAUTION DEENEN To avoid injury and to ensure safe 242 Loctite e operation of this product fasteners Safety glasses must be tightened to the proper torque 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket 3 Swivel seat channel assembly 45 to access four bolts that attach seat For S N lt 428341 see Seat Release channel to seat Bracket instructions 4 For S N gt 428342 see Seat Release Bracket With Stud instructions 4 Remove four bolts and washers 5 Lift seat channel assembly off NOTE To remove swivel release lever bracket or springs or Nyliners GOTO Step 6 To remove seat release lever bracket or springs or Nyliners GOTO Step 9 support nustep com 800 322 4434 42083 Seat Mounting Brkt amp Levers 5 1 05 94 Nu TRS 4000 NUSTEP Seat Mounting Bracket amp Seat Release Lever Bracket amp Swivel Release Lever Bracket amp Springs amp Nyliners 6 Remove shoulder bolts and 7 Replace springs or Nyliners now remove swivel release lever bracket Lubricate and install springs with assembly larger diameter coil against seat in holes If only replacing springs or Nyliners GOTO Step 12 E Insert Nyliners with l
81. shoulder bolt with large flat head screwdriver 4 To install place a little Loctite 242 onto shaft and threads of shoulder bolt and tighten to 200 in lbs Don t get any Loctite into rod end ball CAUTION To avoid injury and prevent adverse health effects use Loctite in accordance with the manufacturer s material safety data sheets including the use of safety glasses and impermeable gloves Material safety data sheets are available via the internet at www loctite com or by calling Henkel Corporation at 800 562 8483 5 Place a little Loctite 242 onto shaft and threads of shoulder bolt Don t let any get into rod end ball If upper shoulder bolt loosened in Step 1 place a little Loctite on shoulder bolt shaft and install into footpedal support nustep com 800 322 4434 42049 Footpedal Stabilizer 2000 5 01 05 TRS 4000 Custer STEP Footpedal Stabilizer 2000 R or L 6 Tighten nut securely Prevent shoulder bolt from turning 7 On both rod ends wipe grease on both sides of rod end into spaces between rod end and washer and rod end and nut bolt support nustep com 800 322 4434 42049 Footpedal Stabilizer 2000 5 01 05 78 CNUSTEF rus 4000 lt NUSTER Footpedal Support Tube 1999 R or L Note This only applies to units with serial numbers of 411001 413367 For s n gt 413367 see Footpedal Stabilizer instructions You may want to remove both lower retaining rings from the
82. t specifications and descriptions are subject to change without notice No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of NuStep Inc
83. t when unhooking springs to prevent weldment from falling forward 5 Pry up bottom edge of clamp about 1 2 up to loosen belt Do not bend clamp up too far just enough to loosen belt support nustep com 800 322 4434 42101 Timing Belt 5 1 05 Timing Belt R L 6 With both hands slide clamp and belt off disk then rotate by bracket kk Ad Rer Der Er D s 8 E ja St R side pivot disk should be rotated rearward so that clamp can come off 8 Remove left nut and bolt using ratchet and wrench Km 0 di 10 Rotate clamp down and toward front to remove from pivot disk L side pivot disk should be rotated rearward to allow clamp to come off TRS 4000 CNUSTEP 7 Install new right belt by doing Steps 6 5 4 in reverse order See reference photos on last page Installation note some units may have a shim on the interior side of the pivot disk where the left timing belt clamp is attached Reuse this shim when installing the new belt if applicable 9 Pry down top edge of clamp about WG out from disk to loosen belt Do not bend clamp down too far just enough to loosen belt 11 Install new left belt by doing Steps 10 9 8 in reverse order See reference photos on last page of these instructions support nustep com 800 322 4434 42101 Timing Belt 5 1 05 TRS 4000 CNUSTERD Timing Belt R L 12 Remove clamps from old belts and transfer to new belts
84. to the product use caution when removing or installing Note If replacing belt idler spring only go to step 8 5 Remove timing belt clamp from right timing belt support nustep com 800 322 4434 42273 Flat Belt amp Belt Idler Spring 5 1 05 TRS 4000 CNUSTEPD Flat Belt amp Belt Idler Spring 6 Before installing new flat belt verify length To ensure proper drive train operation the length from the end of the flat belt clamp to the end of the timing belt clamp must be 27 inches 7 Attach flat belt to right timing belt 8 Hook belt idler spring to left using the belt timing clamp timing belt clamp and to flat belt clamp 9 Install flat belt on front pulley 10 Adjust position of timing belts so they ride on the center of the timing belt sprockets Verify that belts are properly routed on sprockets and pulleys 11 Install step through support assembly and replace covers support nustep com 800 322 4434 42273 Flat Belt amp Belt Idler Spring 5 1 05 30 CNUSTEF rus 4000 fJ Front Shaft Alignment NOTE This instruction only applies to units with S N lt 411617 and will help prevent shaft from sliding axially in bearings Later models have a grooved shaft Tools Required 1 8 hex key Loctite 290 wicking Rawhide hammer Safety glasses 1 Remove covers See Cover Removal instructions 2 Loosen all 4 set screws on left 3 Tap shaft with hammer until right and right side beari
85. val instructions support nustep com 800 322 4434 42083 Seat Mounting Brkt amp Levers 5 1 05 8 TRS 4000 Cum Seat Position Indicator Tools Required Phillips screwdriver long and magnetic if possible 1 Roll seat back to position 15 2 Remove 2 screws holding seat position indicator eg ot 138 141 151 3 To install place indicator in position and tighten screws just to hold indicator in position 4 Make sure seat is locked in position 15 Shift indicator left or right to align point with bar stripe then fully tighten screws oe 121 13h 141 151 support nustep com 800 322 4434 42085 Seat Position Indicator 8 7 00 99 CNUSTEF gt rps 4000 NET Seat Rail amp Seat Stop Pin amp Angle Cover Mount Bracket Tools Required LG socket and ratchet Large Phillips screwdriver 7 16 socket and ratchet and extension 1 Remove covers See Cover Removal instructions 2 Remove poly v belt and spring For S N lt 428325 see Poly V Belt instructions For S N gt 428326 see Poly V J6 Flex Belt instructions 3 Remove 4 bolts washers and 4 Lift seat rail off of frame nuts that attach seat rail to frame 5 To replace seat stop pin remove 4 bolts Install new seat stop pin weldment using new screws GOTO step 8 if replacing seat stop pin only Reference Photo Note install seat stop pin weldment with notch toward the front of the unit 6 To replace seat rail or angle cov

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