Nustep TRS 4000 User manual

NuStepTRS 4000
Recumbent Cross Trainer
Service Manual Complete

TRS 4000
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ii
HOW TO OBTAIN CUSTOMER SUPPORT AND PARTS
Identify the problem.
Speak with the person who reported the problem to get a good understanding of the problem.
Verify the problem on the NuStep stepper.
Use this manual to verify and/or service the problem and/or determine what parts are required.
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.
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 [email protected]
Phone: [phone] or [phone] x 5
Fax: [phone]
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.
STEP 1
STEP 2
STEP 3
STEP 4

TRS 4000
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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.
This Service Manual - Complete covers NuStep TRS4000 products built beginning in 1999.
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 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 indicate direction of movement.
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.
Please match parts from the digital photos to the Schematic Drawings and Parts List to obtain
Item and Part Numbers.
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.
Service Manual Coverage
Service Instructions
iii
Part Names, Part Numbers, and Item Numbers
Directional References
Operating Instructions
This is the safety alert symbol. It is used
to call attention to instructions
concerning personal safety. Read and
obey all safety messages that follow
this symbol to avoid possible injury or
death resulting from misuse.
CAUTION
!CAUTION indicates a potentially
hazardous situation, which if not
avoided, may result in minor or
moderate injury. It may also be used to
alert against unsafe practices.
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.
CAUTION
!Do not operate this product unless all
covers, guards, and parts are in place
and securely fastened.
Do not operate this product if it appears
damaged or inoperable.
CAUTION
!

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Preventive Maintenance
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 depending on your actual use.
iv
Break-In Period, Preventive Maintenance Intervals
Preventive
Maintenance Usage Action Supplies
Clean covers,
arms, seat and
display. Wipe off
perspiration,
dirt and dust.
Monthly Weekly Daily Clean
Non-abrasive
spray cleaner
like Fantastik®
and a soft
cloth.
Check drive belts
for signs of wear.
Every 12
to 24
months
Every 6 to
12 months Every 3 to 6 months
Gently turn
NuStep onto side
and check.
None, if no
action required.
Parts, if action
required.
Replace
batteries. Every 12 months Every 3 months Every 1 month Replace
(4) AA alkaline
batteries.
Rechargeable
batteries are not
recommended
due to voltage
requirements of
the display.
Low
Less than 10
hours per week
(home)
Medium
10–40 hours
per week
(clinical)
High
More than 40
hours per week
(commercial)

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Contents
How to Obtain Customer Support..............................................................................................ii
About This Manual...................................................................................................................... iii
Preventive Maintenance
Break-in Period.......................................................................................................................iv
Preventive Maintenance Intervals..........................................................................................iv
Service Instructions (The Parts List item # is in parenthesis).
Arms - Upper
Foam Grip (55) Replacement.................................................................................... 1
Upper Arm (1 & 2)...................................................................................................... 2
Arm Lock (3) .............................................................................................................. 3
Arms - Lower
Arm Lock Knob (70) .................................................................................................. 4
Arm Lock Weldnut Repair Kit .................................................................................... 5
Arm Lock Knob Repair Kit ......................................................................................... 6
Lower Arm (4 & 5) & Bearings (8 & 9) & Pivot Shaft (129) ....................................... 7
Pivot Cam (158) Adjustment ................................................................................... 32
Pivot Cam Removal – see Lower Arm
CoverCover Removal/Installation (38 & 39 & 40)............................................................. 12
Seat Position Indicator Label (72) Replacement .................................................... 15
Display
Battery Changing..................................................................................................... 16
Display Removal/Installation (43) ........................................................................... 17
Display Accessory Kit Installation (181) .................................................................. 18
Polar Receiver (100) ............................................................................................... 19
Drivetrain
Bearings – Shaft (10) .............................................................................................. 20
Belt Idler Arm (18) ................................................................................................... 22
Belt Idler Spring (136) – see Poly-V Belt & Sheave
Belt Idlers (19) ......................................................................................................... 24
Connecting Link (37) ............................................................................................... 26
Flat Belt (189) & Belt Idler Spring (136) .................................................................. 28
Front Shaft Alignment.............................................................................................. 30
Magnet – EC & Pivot Disks ..................................................................................... 31
Pivot Casting Boot (23) – see Footpedal
Pivot Disk Assembly (99) – call Customer Support @ NuStep Inc
Pivot Shaft (129) – see Lower Arm
Pivot Shaft Alignment .............................................................................................. 33
Poly-V Belt (12) & Sheave (101) & Belt Idler Spring (136) ..................................... 34
Poly-V J6 Flex Belt (12) & Sheave Without Grooves (101) .................................... 36
Rear Shaft (130) & Timing Belt Sprockets (147)..................................................... 38
Rear Shaft Alignment .............................................................................................. 41
Timing Belt (13 & 14)............................................................................................... 42
Timing Belt Springs Replacement (139) ................................................................. 46
Timing Belt Sprocket – see Rear Shaft
v

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Contents
Eddy Current (EC) Magnetic Resistance System
EC Ball Plunger (45) Replacement and Adjustment............................................... 47
EC Disk (46) & Bearings (7) .................................................................................... 48
EC Magnet (47) ....................................................................................................... 51
EC Magnet Gap Alignment (47) .............................................................................. 52
EC Plunger Plate (50) & EC Magnet Slide Bracket (49)......................................... 53
Load Lever (75) ....................................................................................................... 56
Workload Level PCB (94)........................................................................................ 57
Electronics
DC Power Cable (169) ............................................................................................ 58
Hall Effect Sensor (124) .......................................................................................... 60
Ribbon Cable (31) ................................................................................................... 62
VR Sensor (125)...................................................................................................... 63
Electronic Tube
Display Boot (21) – see Electronic Tube
Electronic Tube (52) ................................................................................................ 65
Electronic Tube Boot (22) – see Electronic Tube
Frame
Main Frame – call Customer Support @ NuStep Inc.
Step Through Support (140).................................................................................... 67
Wheel (156) & Axle (6) ............................................................................................ 68
Footpedal
Footpedal 1999 (56 & 57) ....................................................................................... 69
Footpedal 2000 (56 & 57) ....................................................................................... 71
Footpedal Bearing Replacement (8) ....................................................................... 73
Footpedal Bumper Upgrade.................................................................................... 74
Footpedal Stabilizer 2000 (161) .............................................................................. 75
Footpedal Support Tube 1999................................................................................. 78
Footpedal Support Tube Retaining Ring Removal 1999 (to reduce arm tension) .... 80
Seat Seat (110) & Swivel (141) & Seat Channel (116).................................................... 81
Seat Armrest (111) & Seat Armrest Bracket (112 & 113) ........................................ 85
Seat Assembly (115) Removal/Installation.............................................................. 86
Seat Locking Upgrade............................................................................................. 87
Seat Mounting Bracket Assembly (117) .................................................................. 89
Seat Mounting Bracket (117) & Seat Release Lever Bracket (122)
& Swivel Release Lever Bracket (142) & Springs (135 & 137) & Nyliners (93)...... 93
Seat Position Indicator (118) ................................................................................... 98
Seat Rail (119) & Seat Stop Pin (123) & Angle Cover Mount Bracket (24) ............ 99
Seat Release Bracket (120) & Seat Release Bracket Spring (138)
& Nyliners (93)....................................................................................................... 101
Seat Release Bracket With Stud (120) & Seat Release Spring (138) .................. 103
Seat Release Lever (121) ..................................................................................... 107
Seat Wheel (157) .................................................................................................. 109
Swivel Release Lever (143) ...................................................................................110
Appendix
Troubleshooting Guide ...........................................................................................................A
Parts List 1.4...........................................................................................................................C
Figure 1.4 NuStep Assembled View – Part Names ............................................................... E
Figure 2.4 NuStep Exploded Parts View – Outer Part Item Numbers ................................... F
Figure 3.4 NuStep Exploded Parts View – Inner Part Item Numbers....................................G
vi

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Foam Grip Replacement
Tools Required
Utility knife
Rubbing alcohol
Space heater
1. Cut off old grip.
2. Preheat grip till soft and warm,
pour or spray inside w/ rubbing
alcohol.
Shake grip to distribute alcohol and
shake out excess rubbing alcohol.
3. Push grip on.
A combination of mostly pushing and a
little pulling and twisting works best.
42037 Foam Grip Replacement 5-1-05
1
To avoid injury, use care when cutting
foam grip.
!CAUTION

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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.
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 & 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.
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: Cap
Machine Key (may be rectangular or
T shaped)
Holes/indents in arm lock that screws
go into (they do not screw into here)
Pin Arm lock (white or black)
42003 Arm - Upper 7-17-00
2

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3
42257 Arm Lock 5-1-05
Arm Lock
Tools Required
Hammer
Pliers
Nail punch
Safety glasses
2. Tap roll pin through first hole.
1. Remove upper arm. See Upper Arm instruction.
3. Pull pin from second hole.
4. Remove arm lock and slide new
arm lock onto upper arm. 5. Install roll pin.
Note: This instruction applies to all units, but units with S/N > 411092 use part number 4087
Arm Lock and units with S/N < 411091 use part number 4088 Arm Lock. Part number 4088 has
a “T” shaped machine key.
6. Install upper arm.
To ensure the new arm lock is not installed
backwards, note the machine key’s posi-
tion relative to the upper arm groove while
removing the arm lock.
To avoid injury, wear safety glasses.
!CAUTION

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Arm Lock Knob
NOTE: Units with S/N > 411924 do not have a snap ring on the end of the knob stud.
Units < 411924 do, but it is not necessary to reinstall it once removed.
Tools Required
Needle-nosed pliers
Grease/silicone (white/clear)
Safety glasses
2. Remove snap ring from end of
knob stud if it has one. If not,
continue.
3. Thread old knob out. It may be
hard to thread out if it had a snap
ring on it.
No photo.
4. Lubricate threads on new knob
and thread into arm. Wipe up
excess lube. You do not have to
install snap ring back on.
No photo.
5. Install upper arm per instructions.
No photo.
42005 Arm Lock Knob 5-1-05
4
1. Remove upper arm. See Upper Arm instruction.
To avoid injury, wear safety glasses.
!CAUTION

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42259 Arm Lock Weldnut Repair Kit 5-1-05
Arm Lock Weldnut Repair Kit
Tools Required
Hammer Torque wrench
Cold chisel Safety glasses
Phillips screwdriver
3. Remove remaining weldnut from
underside of arm weldment (both
weldnuts must be removed to install
the nut plate).
1. Remove upper arm. See Upper
Arm instruction.
2. Install new arm lock. See Arm
Lock instruction.
4. Insert nut plate into arm weldment
and align threads with arm
weldment holes. Thread screws into
nut plate until the tip of the screw is
flush with the surface of the nut
plate.
Note: This instruction applies to units with S/N < 412391. For S/N 411001 - 411091, use part
number 4112. For S/N 411092 - 412391, use part number 4114.
5. Install upper arm. (See Upper Arm
instruction.) Do not over tighten
screws - maximum torque = 7.5 in-
lbs.
For S/N 411092 - 412391, note the
direction reference written on the nut
plate.
5
To avoid injury, wear safety glasses.
!CAUTION

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42261 Arm Lock Knob Repair Kit 5-1-05
Arm Lock Knob Repair Kit
Tools Required
Drill
31/64” drill bit
Tap wrench
9/16” socket and ratchet
9/16” wrench
9/16” - 12 tap
Safety glasses
3. Drill out arm lock knob hole using
31/64” drill bit.
1. Remove upper arm. See Upper Arm instruction.
2. Remove arm lock knob. See Arm Lock Knob instruction.
4. Tap hole using 9/16” - 12 tap.
5. Using the repair kit, thread the 3/8”
- 24 nut all the way onto the bolt, then
thread the threaded insert on the bolt
(make sure slot on threaded insert is
facing the nut and head of bolt).
6. Use the bolt to thread threaded
insert into hole until 1/16” - 1/8” of
the insert sticks out of the end of
hole. Remove bolt leaving threaded
insert in place.
7. Install upper arm. See Upper Arm instruction.
8. Install arm lock knob. See Arm Lock Knob instruction.
6
To avoid injury, wear safety glasses.
!CAUTION

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Lower Arm (R / L) & Bearings & Pivot Shaft
NOTE: This instruction applies to all units, but units with S/N > 412137 have the
cam shown in Steps 7 & 25 and those lower do not.
Tools Required
½” socket and ratchet
Large flat head screwdriver
5/32" hex key
(3) 2x4 blocks of wood (Very helpful!)
Long Phillips screwdriver
Hard rubber or plastic hammer
Loctite 242
Grease/silicone (white/clear)
Torque wrench
Scratch awl
Safety glasses
2. Disconnect stabilizers or
support tubes from footpedals.
Remove both footpedals.
See Footpedal 1999 and Footpedal
Support Tube 1999 or Footpedal
2000 and Footpedal Stabilizer 2000
instructions depending on your
model.
3. Remove step through support.
4. For S/N < 428173, disconnect
timing belt springs. See Timing Belt
Springs instruction.
42001 Arm - Lower 5-1-05
7
5. Remove left and right side nuts
that attach rod ends to arms.
1. Remove covers. See Cover
Removal instruction. To avoid injury, wear safety glasses.
!CAUTION

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Lower Arm (R / L) & Bearings & Pivot Shaft
7. Remove plug and loosen (don’t
remove) (6) screws on both sides.
NOTE: Early models don’t have this
assembly, so GOTO Step 8.
8. Loosen setscrews that hold pivot
shaft. There may be (2) or (4) total
on both sides.
9. Place one 2x4 under main shaft
pivot and one 2x4 on end under
each arm.
10. Place Phillips screwdriver into
hole on end of shaft (most models)
and drive carefully out right to left.
NOTE: If you are just replacing the
shaft do Step 10, then GOTO 17.NOTE: You will have to wiggle arms when driving shaft out.
8
42001 Arm - Lower 5-1-05
6. Pry off both rod ends with large
screwdriver. Let arms rotate
forward against footpedal bumper.
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.
!CAUTION

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Lower Arm (R / L) & Bearings & Pivot Shaft
13. If you are just replacing either
lower arm, do it now. Transfer parts
from old to new. GOTO Step 16.
No photo.
14. To replace bearings, insert
screwdriver against end of bearing
wall and gently tap out. Be careful
not to scar bore.
15. To insert bearings, carefully tap
into bore using a block of wood and
hammer.
16. Place arm assemblies back into
the frame and back onto wood
blocks.
42001 Arm - Lower 5-1-05
9
11. Carefully lift left arm out. 12. Carefully lift right arm out.
No photo.

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Lower Arm (R / L) & Bearings & Pivot Shaft
19. Remove top right setscrew and
tap shaft into position so that
groove aligns with setscrews.
20. Tighten all setscrews securely.
Right side setscrews must lock into
groove to prevent shaft movement.
21. Place a few drops of Loctite 242
on shoulder bolt threads and
shoulder.
42001 Arm - Lower 5-1-05
10
17. Shaft direction. Radius end in
first, groove end last. NOTE: Early
models may not have the groove.
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.
Radius end Groove end
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.
!CAUTION

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Lower Arm (R / L) & Bearings & Pivot Shaft
42001 Arm - Lower 5-1-05
25. Set cams to eliminate “play”
from arms. Insert scratch awl into
hole with slight pressure. While
keeping pressure on awl, tighten
screws with hex key.
26. Insert plugs, install covers and slide boots back in place. No photo.
NOTE: Cams are set correctly when
“play” is removed from arms, but cam is
not set too tightly, which can increase
arm resistance.
11
22. Place rod ends onto shoulder
bolts and tighten nuts to 200 inch-
lbs.
23. Wipe grease on both sides of rod
ends into spaces between rod end
and washer and rod end and nut.
24. Attach footpedals, stabilizers (or
footpedal tubes) and then attach
springs.
No photo.
200 inch-lbs
Torque Setting:

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Cover Removal / Installation
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 Scratch awl (use to align holes before screws)
1. Remove seat rail cap.
2. Remove seat rail bumpers.
3. Roll seat off of seat rail. 4. Remove 6 screws from top cover.
Keep upward pressure on front of seat to
prevent scratching end of seat rail. Note: In center of top cover, 2 screws are only used in forward 2 holes.
42017 Cover Removal 5-1-05
12
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.
CAUTION
!