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