Nustep TRS 4000 Service Manual
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Nustep TRS 4000 Service Manual

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NuStep
TRS 4000
Recumbent Cross Trainer
Service Manual Complete

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Summary of Contents for Nustep TRS 4000

  • Page 1 ® NuStep TRS 4000 Recumbent Cross Trainer Service Manual Complete...
  • Page 3 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.

  • Page 4: About This Manual

    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.

  • Page 5: Preventive Maintenance

    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.

  • Page 6: Table Of Contents

    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) &...
  • Page 7 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 9: Foam Grip (55) Replacement

    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) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42037 Foam Grip Replacement 5-1-05...

  • Page 10: Upper Arm (1 & 2)

    Machine Key (may be rectangular or T shaped) Holes/indents in arm lock that screws go into (they do not screw into here) Arm lock (white or black) support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42003 Arm - Upper 7-17-00...

  • Page 11: Arm Lock (3)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42257 Arm Lock 5-1-05...

  • Page 12: Arm Lock Knob (70)

    Wipe up excess lube. You do not have to No photo. install snap ring back on. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42005 Arm Lock Knob 5-1-05...

  • Page 13: Arm Lock Weldnut Repair Kit

    5. Install upper arm. (See Upper Arm instruction.) Do not over tighten screws - maximum torque = 7.5 in- lbs. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42259 Arm Lock Weldnut Repair Kit 5-1-05...

  • Page 14: Arm Lock Knob Repair Kit

    7. Install upper arm. See Upper Arm instruction. 8. Install arm lock knob. See Arm Lock Knob instruction. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42261 Arm Lock Knob Repair Kit 5-1-05...

  • Page 15: Lower Arm (4 & 5) & Bearings (8 & 9) & Pivot Shaft (129)

    4. For S/N < 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42001 Arm - Lower 5-1-05...
  • Page 16 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42001 Arm - Lower 5-1-05...
  • Page 17 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42001 Arm - Lower 5-1-05...
  • Page 18 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42001 Arm - Lower 5-1-05...
  • Page 19 26. Insert plugs, install covers and slide boots back in place. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42001 Arm - Lower 5-1-05...

  • Page 20: Cover Removal/Installation (38 & 39 & 40)

    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. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42017 Cover Removal 5-1-05...
  • Page 21 Slide boot up out of way. 9. Remove left side cover. 10. Remove right side cover. Pull rear outward, then nose. Pull rear over wheel & workload lever. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42017 Cover Removal 5-1-05...
  • Page 22 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42017 Cover Removal 5-1-05...

  • Page 23: Seat Position Indicator Label (72) Replacement

    See Seat Position Indicator bubbles and creases may develop. instructions. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42087 Seat Position Indicator Label 9-18-00...

  • Page 24: Display

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42007 Battery Changing 5-1-05...

  • Page 25: Display Removal/Installation (43)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42023 Display Removal 9-8-00...

  • Page 26: Display Accessory Kit Installation (181)

    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 Reading Rack Water Bottle Holder support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42131 123GO/RR/H20 Instruction 2-6-04...

  • Page 27: Polar Receiver (100)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42065 Polar Receiver Replacement 9-8-00...

  • Page 28: Bearings - Shaft (10)

    4. If 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42009 Bearings - Shaft 5-1-05...
  • Page 29 No photo. 9. Tighten nuts to 200 inch-lbs. Torque Setting: 200 inch-lbs 10. Install components and covers. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42009 Bearings - Shaft 5-1-05...

  • Page 30: Belt Idler Arm (18)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42011 Belt Idler Arm 5-1-05...
  • Page 31 10. Check belt alignment per Poly-V down smoothly, then install sheave Belt instructions. and belt. No photo. 11. Install covers. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42011 Belt Idler Arm 5-1-05...

  • Page 32: Belt Idlers (19)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42013 Belt Idlers 5-1-05...
  • Page 33 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42013 Belt Idlers 5-1-05...

  • Page 34: Connecting Link (37)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42015 Connecting Link 5-1-05...
  • Page 35 Torque Setting: inch-lbs 11. Slide boots down, test operation and install covers. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42015 Connecting Link 5-1-05...

  • Page 36: Flat Belt (189) & Belt Idler Spring (136)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42273 Flat Belt & Belt Idler Spring 5-1-05...
  • Page 37 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42273 Flat Belt & Belt Idler Spring 5-1-05...

  • Page 38: Front Shaft Alignment

    5. Realign EC Magnet and disk before installing covers. See EC Magnet Gap Alignment instructions. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42053 Front Shaft Alignment 5-1-05...

  • Page 39: Magnet - Ec & Pivot Disks

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42059 Magnet - EC and Pivot 5-1-05...

  • Page 40: Pivot Cam (158) Adjustment

    NOTE: Cams are set correctly when “play” is removed from arms, but cam is not set too tightly, which can increase arm resistance. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42061 Pivot Cam Adjustment 9-18-00...

  • Page 41: Pivot Shaft Alignment

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42063 Pivot Shaft Alignment 5-1-05...

  • Page 42: Poly-V Belt (12) & Sheave (101) & Belt Idler Spring (136)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42067 Poly-V Belt & Sheave 5-1-05...
  • Page 43 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42067 Poly-V Belt & Sheave 5-1-05...

  • Page 44: Poly-V J6 Flex Belt (12) & Sheave Without Grooves (101)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42068 Poly-V J6 Flex Belt & Sheave Without Grooves 5-1-05...
  • Page 45 If not, move poly-v sheave in or out on shaft until belt tracks true. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42068 Poly-V J6 Flex Belt & Sheave Without Grooves 5-1-05...

  • Page 46: Rear Shaft (130) & Timing Belt Sprockets (147)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42069 Rear Shaft & Sprockets 5-1-05...
  • Page 47 10. Tighten 4 set screws; install poly-v belt and sheave; install timing belt springs (S/N < 428173) or belt idler spring (S/N > 428174). support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42069 Rear Shaft & Sprockets 5-1-05...
  • Page 48 Note: This photo applies only to units with S/N < 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 49: Rear Shaft Alignment

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42071 Rear Shaft Alignment 5-1-05...

  • Page 50: Timing Belt (13 & 14)

    Clamp secures belt to pivot disk – Do not bend clamp up too far, just 4 teeth of belt are in contact. enough to loosen belt. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42101 Timing Belt 5-1-05...
  • Page 51 See reference photos on last page of these instructions. L side pivot disk should be rotated rearward to allow clamp to come off. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42101 Timing Belt 5-1-05...
  • Page 52 13. Route belts correctly, attach timing belt springs (for S/N < 428173) or flat belt and idler spring (for S/N > 428174), test operation, and install covers. See reference photos on next page. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42101 Timing Belt 5-1-05...
  • Page 53 Bottom view – belts & clamps around timing sprockets. hooked to springs and frame. NOTE: This photo applies only to units with S/N < 428173. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42101 Timing Belt 5-1-05...

  • Page 54: Timing Belt Springs Replacement (139)

    Tools Required None 1. Turn NuStep gently onto its left side (from rider’s perspective). 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.

  • Page 55: Ec Ball Plunger (45) Replacement And Adjustment

    “play.” 5. Test that all 10 Workload Levels show on display. No photo. 6. Install covers. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42025 EC Ball Plunger 9-10-00...

  • Page 56: Ec Disk (46) & Bearings (7)

    TRS 4000 EC Disk & 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 > 411115 have 3 bearings and a snap ring. This instruction applies to either.
  • Page 57 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42027 EC Disk & Bearings 5-01-05...
  • Page 58 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42027 EC Disk & Bearings 5-01-05...

  • Page 59: Ec Magnet (47)

    ~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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42029 EC Magnet 9-10-00...

  • Page 60: Ec Magnet Gap Alignment (47)

    4. Ride test and make sure disk 5. Install covers. does not hit magnets in all 10 loads. No photo. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42031 EC Magnet Gap Align 9-10-00...

  • Page 61: Ec Plunger Plate (50) & Ec Magnet Slide Bracket (49)

    5. Pull plunger plate out of frame. will be destroyed during this step. NOTE: if you are just replacing plunger GOTO Step 9. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42033 EC Plunger & Slide Brkt 5-01-05...
  • Page 62 If it doesn’t, slightly bend shoulder ball plunger loose (not shown). bolts to make bracket slide easily on Nyliners. Washers EC Shoulder pivot Stud support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42033 EC Plunger & Slide Brkt 5-01-05...
  • Page 63 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42033 EC Plunger & Slide Brkt 5-01-05...

  • Page 64: Load Lever (75)

    Do not overtighten nut. 6. Check operation of load lever and “Workload” on display. Install covers. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42057 Load Lever 5-01-05...

  • Page 65: Workload Level Pcb (94)

    It is not necessary to remove plunger to install PCB, but you must be careful when installing PCB. Insulator board Wiper support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42111 Workload Level PCB 5-01-05...

  • Page 66: Dc Power Cable (169)

    DC Power Cable Tools Required 11mm socket and wrench CAUTION The TRS 4000 is very heavy; it weighs 1. Gently turn NuStep onto its left 205 lbs (93 kg). To avoid injury, or side. damage to the product, always obtain assistance to move this product.
  • Page 67 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42019 DC Power Cable 5-01-05...

  • Page 68: Hall Effect Sensor (124)

    > 422081. 5. Remove sensor wiring from cable clips along frame. 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.
  • Page 69 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42055A Hall Effect Sensor 5-01-05...

  • Page 70: Ribbon Cable (31)

    TRS 4000 Ribbon Cable NOTE: This is the main cable for all CAUTION electronics. The TRS 4000 is very heavy; it weighs Tools Required 205 lbs (93 kg). To avoid injury, or Tape damage to the product, always obtain assistance to move this product. Use proper lifting technique.

  • Page 71: Vr Sensor (125)

    > 422081. 5. Remove sensor wiring from cable clips along frame. 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.
  • Page 72 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42107A VR Sensor 5-01-05...

  • Page 73: Electronic Tube

    Remove front cover screw and String with washers attached to ribbon carefully spread covers to access bolts. cable support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42035 Electronic Tube 5-01-05...

  • Page 74: Frame

    160 inch-lbs 9. Slide boots onto tube, plug cable into connector and install display. Align key of cable with slot of connector on display. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42035 Electronic Tube 5-01-05...

  • Page 75: Step Through Support (140)

    > 411001 - 423601. 423602. 3. To install, do above steps in reverse order. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42097 Step Through Support 5-01-05...

  • Page 76: Wheel (156) & Axle (6)

    Rubber hammer Safety glasses 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. 1. Prop rear of NuStep on block of 2.

  • Page 77: Footpedal 1999 (56 & 57)

    Safety glasses CAUTION CAUTION To avoid injury, wear safety glasses. 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.
  • Page 78 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42039 Footpedal 1999 5-01-05...

  • Page 79: Footpedal 2000 (56 & 57)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42041 Footpedal 2000 5-01-05...
  • Page 80 / bolt. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42041 Footpedal 2000 5-01-05...

  • Page 81: Footpedal Bearing Replacement (8)

    TRS 4000 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 > 413368 have Footpedal 2000 with 2 bearings total. This instruction shows Footpedal 2000. We recommend using an arbor press to insert bearings.

  • Page 82: Footpedal Bumper Upgrade

    3. Install new bumpers onto the footpedal bumper bracket and tighten snugly with finger pressure. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42127 Footpedal Bumper Upgrade 6-12-01...

  • Page 83: Footpedal Stabilizer 2000 (161)

    2. Remove lower shoulder bolt from frame. 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42049 Footpedal Stabilizer 2000 5-01-05...
  • Page 84 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42049 Footpedal Stabilizer 2000 5-01-05...
  • Page 85 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42049 Footpedal Stabilizer 2000 5-01-05...

  • Page 86: Footpedal Support Tube 1999

    Quick clamp (maybe) Safety glasses CAUTION 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.
  • Page 87 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42051 Footpedal Support Tube 5-01-05...

  • Page 88: Footpedal Support Tube Retaining Ring Removal 1999 (To Reduce Arm Tension)

    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 may be a slight gap between the footpedal support tube and the frame, and this is normal.

  • Page 89: Seat (110) & Swivel (141) & Seat Channel (116)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42077 Seat & Swivel & Seat Channel 5-01-05...
  • Page 90 GOTO Step 13 if you are done. Make sure springs operate properly. Torque Setting: 200 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42077 Seat & Swivel & Seat Channel 5-01-05...
  • Page 91 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42077 Seat & Swivel & Seat Channel 5-01-05...
  • Page 92 For S/N < 428341, see Seat Release Bracket instructions. For S/N > 428342, see Seat Release Bracket With Stud instructions. 19. Test seat locking operation. Install seat assembly onto NuStep. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 93: Seat Armrest (111) & Seat Armrest Bracket (112 & 113)

    To avoid injury, and to ensure safe operation of this product, fasteners must be tightened to the proper torque. Torque Setting: 200 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42079 Seat Armrest and Bracket 5-01-05...

  • Page 94: Seat Assembly (115) Removal/Installation

    Phillips screwdriver 3/8" wrench 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.

  • Page 95: Seat Locking Upgrade

    4. Remove old seat stop pin weldment and discard screws. 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42058 Seat Locking Upgrade Instruction 5-01-05...
  • Page 96 Note: install seat stop pin weldment with notch toward the front of the unit. 7. Install covers and seat assembly. See Cover Removal instruction. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42058 Seat Locking Upgrade Instruction 5-01-05...

  • Page 97: Seat Mounting Bracket Assembly (117)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42263 Seat Mounting Bracket Assembly 5-01-05...
  • Page 98 Tighten bolts to 200 in-lbs. Torque Setting: 80 inch-lbs Torque Setting: 200 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42263 Seat Mounting Bracket Assembly 5-01-05...
  • Page 99 Henkel Corporation at (800) 562- 8483. 12. Swivel assembly 45° ° ° ° ° to install two bolts through cutouts. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42263 Seat Mounting Bracket Assembly 5-01-05...
  • Page 100 16. Install seat release bracket. For S/N < 428341, see Seat Release Bracket instructions. For S/N > 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 101: Seat Mounting Bracket (117) & Seat Release Lever Bracket (122) & Swivel Release Lever Bracket (142) & Springs (135 & 137) & Nyliners (93)

    Nyliners, GOTO Step 6. To remove seat release lever bracket or springs or Nyliners, GOTO Step 9. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42083 Seat Mounting Brkt & Levers 5-1-05...
  • Page 102 Henkel Corporation at (800) 562- 8483. Torque Setting: 80 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42083 Seat Mounting Brkt & Levers 5-1-05...
  • Page 103 Henkel Corporation at (800) 562- 8483. Torque Setting: 80 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42083 Seat Mounting Brkt & Levers 5-1-05...
  • Page 104 15. Swivel assembly 45° ° ° ° ° to install 14. To install seat channel, place Loctite on swivel bolts. two bolts through cutouts. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42083 Seat Mounting Brkt & Levers 5-1-05...
  • Page 105 For S/N > 428342, see Seat Release Bracket With Stud instructions. 20. Check seat locking operation. Install seat assembly onto NuStep. See Seat Assembly Removal instructions. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42083 Seat Mounting Brkt & Levers 5-1-05...

  • Page 106: Seat Position Indicator (118)

    4. Make sure seat is locked in position 15. Shift indicator left or right to align point with bar stripe, then fully tighten screws. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42085 Seat Position Indicator 8-7-00...

  • Page 107: Seat Rail (119) & Seat Stop Pin (123) & Angle Cover Mount Bracket (24)

    6. To replace seat rail or angle cover mount brackets, remove belt idler arm from seat rail assembly. See Belt Idler Arm instructions. No photo. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42089 Seat Rail 5-1-05...
  • Page 108 7. Replace applicable parts and 8. Install seat rail onto frame. transfer old parts to new. Tighten nuts securely. Install cov- ers. Idler arm Bracket(2) Seat Rail support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42089 Seat Rail 5-1-05...

  • Page 109: Nyliners (93)

    4. Replace seat release bracket or spring or Nyliners now (not shown). Before installing, lubricate bracket along slots and where lever pin contacts bracket (see old bracket). support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091 Seat Release Brkt & Spring 5-1-05...
  • Page 110 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091 Seat Release Brkt & Spring 5-1-05...

  • Page 111: Seat Release Bracket With Stud (120) & Seat Release Spring (138)

    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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091A Seat Release Bracket Instruction 5-1-05...
  • Page 112 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091A Seat Release Bracket Instruction 5-1-05...
  • Page 113 11. Slide shoulder bolt through rear seat channel hole and washer; thread bolt into bracket and tighten to 80 in-lbs. Torque Setting: 80 inch-lbs support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091A Seat Release Bracket Instruction 5-1-05...
  • Page 114 14. Install seat assembly on NuStep. See Seat Assembly Removal instruc- tions. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42091A Seat Release Bracket Instruction 5-1-05...

  • Page 115: Seat Release Lever (121)

    Torque wrench 1. Swivel seat to the side and locate two bolts. 2. Remove bolts and lockwashers from bracket. 3. Remove lever. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42093 Seat Release Lever 5-1-05...
  • Page 116 Material safety against the data sheets are available via the bracket. internet at www.loctite.com or by calling Henkel Corporation at (800) 562- 8483. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42093 Seat Release Lever 5-1-05...

  • Page 117: Seat Wheel (157)

    NOTE: For units with S/N < 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42095 Seat Wheel 5-1-05...

  • Page 118: Swivel Release Lever (143)

    3. Swivel seat channel assembly 45° ° ° ° ° to access four bolts that attach seat channel to seat. 4. Remove four bolts and washers. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42099 Swivel Release Lever 5-1-05...
  • Page 119 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 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42099 Swivel Release Lever 5-1-05...
  • Page 120 200 inch-lbs 12. Install seat release bracket. See Seat Release Bracket Installation instruc- tions. 13. Check seat locking operation. Install seat assembly onto NuStep. See Seat Assembly Removal instructions. support@nustep.com - (800) 322-4434 support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 121: Troubleshooting Guide

    Ribbon cable connector not Remove display to Refer to Display does not operate. plugged in correctly. investigate. Installation instruction. 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...
  • Page 122 Bearings instruction. consistent with speed. SEAT ASSEMBLY The seat “jumps” to The seat lock wasn’t fully Make sure the seat is the next position. engaged. fully locked in place. support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5...

  • Page 123: Parts List 1.4

    EC DISK ASSY S/N >= 411115 41246 PHPS Typ F #10-24x3/8 Black (not shown) 4041 EC DISK ASSY S/N 411001-411114 41100 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...
  • Page 124 30153 3/8-16x1-3/4 HHCS G5 Zinc 41154 THPS #10-24x3/4" Black 40366 Flat Belt Clamp-L 41252 THPS #6-32x1/4 40363 Timing Belt Clamp-Top L 4070 TIMING BELT SPROCKET ASSY support@nustep.com - (800) 322-4434 - (734) 769-3939 x 5 42117 Parts List 1.4 4-1-05...
  • Page 125 42119 Figures 4-1-05...
  • Page 126 42119 Figures 4-1-05...
  • Page 127 42119 Figures 4-1-05...
  • Page 130 (800) 322-2209 Made in USA www.nustep.com 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 improvement, specifications and descriptions are subject to change without notice.

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