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Nustep TRS 4000, Service Manual

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Nustep TRS 4000 Service Manual Download Page 6

TRS 4000

[email protected] - (800) 322-4434 - (734) 769-3939 x 5

[email protected] - (800) 322-4434

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

Cover

Cover 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

Summary of Contents for TRS 4000

Page 1: ...NuStep TRS 4000 Recumbent Cross Trainer Service Manual Complete...

Page 2: ......

Page 3: ...etter 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...

Page 4: ...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 d...

Page 5: ...ding 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 y...

Page 6: ...on 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...

Page 7: ...otpedal 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...

Page 8: ......

Page 9: ...pace 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 combinati...

Page 10: ...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 T...

Page 11: ...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...

Page 12: ...ease 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...

Page 13: ...uction 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 w...

Page 14: ...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...

Page 15: ...astic 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 Fo...

Page 16: ...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 GO...

Page 17: ...om 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 u...

Page 18: ...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 otherw...

Page 19: ...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 resistanc...

Page 20: ...wl 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 scr...

Page 21: ...4 5 Remove top cover 6 Remove 2 screws Cover Removal Installation 7 Remove screw from front Slide boot up out of way 8 Remove screw from rear 9 Remove left side cover 10 Remove right side cover Pull r...

Page 22: ...r Removal 5 1 05 11 To install cover do previous steps in reverse order Note the following Install nose of side covers first then push rear of covers over wheels Hang side covers on bracket directly b...

Page 23: ...er of non textured area on left side of cover 3 Remove remainder of adhesive backing while holding front edge of label down No photo 4 Carefully align label along bottom edge of non textured area NOTE...

Page 24: ...anging 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...

Page 25: ...t fall 2 On back of display push 2 locking tabs outward on each side of connector to unlock cable connector 3 Hold onto cable connector and pull outward from display connector 4 To install align key...

Page 26: ...cessory 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 k...

Page 27: ...dea to change batteries during this instruction also Tools Required Phillips screwdriver 1 Remove battery access panel 2 Remove Polar receiver from jack 3 Install new Polar receiver into jack 4 Make s...

Page 28: ...ts To avoid injury wear safety glasses CAUTION 1 Remove covers See Cover Removal instructions 2 For S N 428173 unhook timing belt springs See Timing Belt Springs instructions For S N 428174 unhook bel...

Page 29: ...7 Pry bearing off 8 Replace bearing NOTE If replacing right side bearings most shafts have a groove that the set screws must engage in No photo 9 Tighten nuts to 200 inch lbs 10 Install components and...

Page 30: ...Remove poly v belt and sheave See Poly V Belt Sheave instructions 3 Remove self locking ring from right side of idler arm shaft 4 Remove belt idler arm from seat rail assembly Ring will be destroyed...

Page 31: ...install sheave and belt Belt Idler Arm 10 Check belt alignment per Poly V Belt instructions No photo 11 Install covers No photo 42011 Belt Idler Arm 5 1 05 23 7 Reference photo Close up showing right...

Page 32: ...lt idler NOTE The idler pulley used for units with serial numbers 424793 428326 does not have flanges and is installed without washers 3 Remove and replace idler Install washer s on the side they were...

Page 33: ...Springs instructions For S N 428174 unhook belt idler spring See Flat Belt Belt Idler Spring instructions 3 Remove and replace idler Belt Idlers Poly V Right Left Timing Belt Idlers 42013 Belt Idlers...

Page 34: ...6 Pry front rod end off shoulder bolt with large screwdriver 42015 Connecting Link 5 1 05 26 4 Slide boot up remove front nut 2 Remove step through support To avoid injury or damage to the product use...

Page 35: ...rod end and nut 11 Slide boots down test operation and install covers No photo 27 8 Place a few drops of Loctite 242 on front shoulder bolt and threads To avoid injury and prevent adverse health effe...

Page 36: ...2 Remove step through support assembly See Step Through Support instruction To avoid injury wear safety glasses CAUTION 4 Remove idler spring from flat belt clamp and right timing belt clamp 3 Pull fl...

Page 37: ...inches 7 Attach flat belt to right timing belt using the belt timing clamp 8 Hook belt idler spring to left timing belt clamp and to flat belt clamp 9 Install flat belt on front pulley 10 Adjust posit...

Page 38: ...Loctite down into set screw holes Tighten all 4 set screws back down 5 Realign EC Magnet and disk before installing covers See EC Magnet Gap Alignment instructions NOTE Due to Loctite strength it is o...

Page 39: ...onto the side with the red or black dot 5 Press red dot side of magnet into indent The sensors will not work if red dot is out 6 Check gap Gap should be 1 8 3 16 from magnet to sensor Test display to...

Page 40: ...owever 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 on both sides Lowe...

Page 41: ...ght collar shown Note Right side shown 4 With set screws removed from both sides pour a few drops of 290 Loctite down into set screw holes Tighten set screws back down and replace caps 42063 Pivot Sha...

Page 42: ...er pulley must be replaced as well the new idler pulley does not have flanges Tools Required 5 32 hex key 2 Remove belt idler spring NOTE If you are just replacing the spring do it now and replace cov...

Page 43: ...on shaft and loosen 2 set screws to remove poly v sheave 9 Tighten 2 set screws of poly v sheave securely Install covers See photo above for Step 5 Poly V Belt Sheave Belt Idler Spring 42067 Poly V Be...

Page 44: ...ly v sheave 42068 Poly V J6 Flex Belt Sheave Without Grooves 5 1 05 3 Note If you are just replacing the belt GO TO Step 6 No photo 4 Note location of poly v sheave on shaft and loosen 2 set screws to...

Page 45: ...not move poly v sheave in or out on shaft until belt tracks true No photo 8 Cut the zip ties off the sheave 42068 Poly V J6 Flex Belt Sheave Without Grooves 5 1 05 6 To install new belt secure belt t...

Page 46: ...osen 4 nuts of bearings Remove right bearing only 42069 Rear Shaft Sprockets 5 1 05 38 1 Remove covers See Cover Removal instruction 2 Remove poly v belt and sheave For S N 428325 see Poly V Belt Shea...

Page 47: ...photo 39 6 Slide rear shaft toward poly v side and remove plastic spacers and sprockets and shaft 7 To install slide new shaft from poly v side Install parts in order 3 spacers sprocket 2 spacers spro...

Page 48: ...s Right belt under high right idler and over load lever tube Timing sprocket Pivot disk Rear view belts wrapped around timing sprockets Bottom view belts clamps hooked to springs and frame The NuStep...

Page 49: ...ew holes Tighten all 4 set screws back down 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...

Page 50: ...or S N 428173 unhook timing belt springs See Timing Belt Springs instructions For S N 428174 unhook belt idler spring See Flat Belt Belt Idler Spring in structions 4 Remove right nut and bolt using wr...

Page 51: ...verse order See reference photos on last page of these instructions L side pivot disk should be rotated rearward to allow clamp to come off 42101 Timing Belt 5 1 05 43 6 With both hands slide clamp an...

Page 52: ...and transfer to new belts For S N 428174 remove clamps that attach to flat belt and belt idler spring and transfer to new belts 13 Route belts correctly attach timing belt springs for S N 428173 or f...

Page 53: ...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 and under load lever t...

Page 54: ...fully move arms to decrease tension on spring you are replacing Move right arm rearward shown to reduce tension on right spring then replace right spring Move left arm rearward to reduce tension on le...

Page 55: ...eats into each hole on plate 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 plu...

Page 56: ...head screwdriver 9 16 deep socket Arbor press Loctite 680 for cylindrical parts Safety glasses 1 Remove covers See Cover Removal instructions 2 Remove poly v belt or poly v J6 flex belt For S N 42832...

Page 57: ...on the bearing races can work shown 49 6 Remove flywheel side bearing Bearings will be destroyed during removal DO NOT REUSE 7 Remove belt side bearing s NOTE Early models have 1 bearing here while l...

Page 58: ...nstalling the nut instead of the snap ring nut should only bottom out against shaft shoulder Do not tighten nut so that it preloads the bearings Spin the disk and if disk slows rapidly when tightening...

Page 59: ...ction 2 Remove 2 or 3 screws holding magnet assembly 3 On older models remove screws holding this separate bracket to EC Magnet bracket shown On newer models there is no separate bracket Insert screwd...

Page 60: ...cover See Cover Removal instruction 2 Slightly loosen 3 screws holding magnet assembly 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 r...

Page 61: ...mmer SIlicone grease white or clear Safety glasses 2 x4 wood 1 Remove covers See Cover Removal instructions 2 Remove poly v belt or poly v J6 flex belt For S N 428325 remove poly v belt See Poly V Bel...

Page 62: ...d lube and tighten shoulder bolts Bracket should slide easily back and forth If it doesn t slightly bend shoulder bolts to make bracket slide easily on Nyliners 9 Install plunger plate through Nyliner...

Page 63: ...t until it just contacts Nyliner Make sure plunger stud does not come out of shoulder washer see Step 9 11 Install load lever and set ball plunger See Load Lever instructions See Ball Plunger Adjustme...

Page 64: ...olding nut on 3 Tap gently on nut to disengage 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...

Page 65: ...hoto 6 Carefully install new PCB and insulator board between wiper and frame using pop rivets see reference photo below before proceeding 8 Test all electronics before installing covers 7 Reconnect wi...

Page 66: ...er not shown Push jack through the hole in the frame on the inside of the cover as shown 3 Remove wiring from clips there may be more clips than shown 4 Unplug power cable from board Unsnap connector...

Page 67: ...lace 6 Prepare power cable 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 lockwashe...

Page 68: ...makes it easier to access wire The red black white wire on right 4 Unscrew sensor bracket from inside of frame 5 Remove sensor wiring from cable clips along frame NOTE Bottom view shown The photo abo...

Page 69: ...t To Set Gap Alignment 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 install...

Page 70: ...able is fastened securely to board connector in step 3 above 3 Before installing covers it s a good idea to test the display to make sure everything is working correctly 42073 Ribbon Cable 5 01 05 62...

Page 71: ...sor wire 4 Unscrew sensor bracket from frame 5 Remove sensor wiring from cable clips along frame Note Bottom view shown 42107A VR Sensor 5 01 05 The black white wire on left The photo above shows the...

Page 72: ...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 c...

Page 73: ...e 1 on bottom Snap tabs of connector outward 3 Pull out cable from connector 4 Slide both rubber boots up and off electronic tube No photo 5 Remove 4 bolts that attach electronic tube and remove tube...

Page 74: ...nd tighten bolts to 160 in lbs 8 Make sure ribbon cable is secured in clips and does not hit boot on the footpedal tube during operation Electronic tube and footpedal bumper removed from picture for c...

Page 75: ...hooking timing belt springs to remove tension on the drivetrain Tools Required socket and ratchet 1 Remove covers See Cover Removal instruction 2 Remove step through support 3 To install do above ste...

Page 76: ...d 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...

Page 77: ...clamp maybe Safety glasses 1 Turn NuStep gently onto the side that you want to remove the footpedal from left side is shown 2 Remove lower retaining ring from footpedal support tube inside frame This...

Page 78: ...at top and bottom If 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 retainin...

Page 79: ...16 hex key Loctite 242 wrench Large flat head screwdriver Snap ring pliers 90 tip Safety glasses 1 Remove upper nut from stabilizer Prevent shoulder bolt from turning 2 Pry rod end off shoulder bolt...

Page 80: ...shaft and install into footpedal 7 Tighten nut securely Prevent shoulder bolt from turning 8 On both rod ends wipe grease on both sides of rod end into spaces between rod end and washer and rod end a...

Page 81: ...elow Tools Required Large flat head screwdriver Hammer Blocks of wood Safety glasses 1 Remove footpedal See Footpedal 1999 or Footpedal 2000 instructions 2 Insert screwdriver against end of bearing wa...

Page 82: ...nd or magnetic preferred 1 Remove 2 screws and current bumper and discard 2 Align new bracket over existing holes and install 2 new flat head fasteners and tighten Push right footpedal forward to remo...

Page 83: ...iers Loctite 242 Large flat head screwdriver Hammer Grease silicone white or clear preferred Torque wrench Safety glasses 1 Remove upper nut from stabilizer Prevent shoulder bolt from turning 2 Remove...

Page 84: ...pedal 76 3 Pry upper rod end off 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...

Page 85: ...com 800 322 4434 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 Foot...

Page 86: ...iers Quick clamp maybe Safety glasses 1 Turn NuStep gently onto the side that you want to remove the tube from left side is shown 2 Remove lower retaining ring from footpedal support tube inside frame...

Page 87: ...sh with equal pressure at top and bottom 6 Install upper ring to secure tube to footpedal Lock ring in place If hard to insert use quick clamp shown at top and bottom Do not install lower retaining ri...

Page 88: ...spective 2 Remove lower retaining ring from left footpedal support tube inside frame Do not remove upper ring near footpedal Note After removing the ring the shaft may snap into the frame and there ma...

Page 89: ...het 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 428341 see Seat Release Bracket instructions...

Page 90: ...mounting bracket see old seat Transfer armrests to new seat 8 Position springs with larger diameter coil against seat Install mounting bracket over both springs Springs go through holes in bracket Lu...

Page 91: ...channel see old channel 13 To install seat channel place Loctite on swivel bolts 80 inch lbs Torque Setting To avoid injury and prevent adverse health effects use Loctite in accordance with the manuf...

Page 92: ...gh cutouts 15 Swivel assembly 90 to install next two bolts through cutouts 16 Tighten all four bolts to 200 in lbs 84 17 Check swivel and release lever operation 18 Install seat release bracket For S...

Page 93: ...ce armrest or armrest bracket at this time No photo 4 To install spacers go on each side of bracket inside armrest Slide bolt through from outside in 5 Tighten nut until armrest moves smoothly but not...

Page 94: ...f seat rail Keep upward pressure on front of seat to prevent scratching end of seat rail 5 To install do steps in reverse order No photo 42081 Seat Assembly Removal 5 01 05 86 4 If you are going to wo...

Page 95: ...mbly See Seat Assembly Removal instruction 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 drillin...

Page 96: ...00 322 4434 Seat Locking Upgrade 42058 Seat Locking Upgrade Instruction 5 01 05 6 Install new seat stop pin weldment using new screws 7 Install covers and seat assembly See Cover Removal instruction N...

Page 97: ...assembly See Seat Assembly Removal instructions 2 Remove seat release bracket For S N 428341 see Seat Release Bracket instructions For S N 428342 see Seat Release Bracket With Stud instructions 3 Swiv...

Page 98: ...mbly 6 Remove the two remaining bolts that attach seat mounting bracket to seat and remove seat mounting bracket 7 Align holes of new seat mounting bracket assembly with seat weldnuts and rear seat le...

Page 99: ...12 Swivel assembly 45 to install two bolts through cutouts 42263 Seat Mounting Bracket Assembly 5 01 05 91 80 inch lbs Torque Setting To avoid injury and prevent adverse health effects use Loctite in...

Page 100: ...racket With Stud instructions 92 13 Swivel assembly 90 to install next two bolts through cutouts 15 Check swivel lever operation Swivel seat left and right and check that swivel locks in place 14 Tigh...

Page 101: ...y Needle nosed pliers socket and ratchet Long socket extension 7 16 socket and ratchet Torque wrench 242 Loctite Safety glasses 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove s...

Page 102: ...r Nyliners GOTO Step 12 Insert Nyliners with large flange out 94 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 4...

Page 103: ...afety 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 80 inch lbs Torque Setting S...

Page 104: ...ten all shoulder bolts to 80 in lbs swivel bracket shown Don t get Loctite on Nyliners Seat Mounting Bracket Seat Release Lever Bracket Swivel Release Lever Bracket Springs Nyliners 42083 Seat Mountin...

Page 105: ...Release Lever Bracket Swivel Release Lever Bracket Springs Nyliners 97 18 Check swivel and release lever operation Swivel seat left and right and check that swivel locks in place 19 Install seat rele...

Page 106: ...etic if possible 1 Roll seat back to position 15 2 Remove 2 screws holding seat position indicator 3 To install place indicator in position and tighten screws just to hold indicator in position 4 Make...

Page 107: ...325 see Poly V Belt instructions For S N 428326 see Poly V J6 Flex Belt instructions 3 Remove 4 bolts washers and nuts that attach seat rail to frame 4 Lift seat rail off of frame 5 To replace seat st...

Page 108: ...port nustep com 800 322 4434 7 Replace applicable parts and transfer old parts to new 8 Install seat rail onto frame Tighten nuts securely Install cov ers Idler arm Bracket 2 Seat Rail Seat Rail Seat...

Page 109: ...y removing front and rear shoulder bolts rear shown 3 Remove seat release spring 4 Replace seat release bracket or spring or Nyliners now not shown Before installing lubricate bracket along slots and...

Page 110: ...shoulder bolt may extend out from end of Nyliner 8 Install spring 9 Test seat locking operation Install seat assembly onto NuStep See Seat Assembly Removal instruc tions 102 5 Install seat release bra...

Page 111: ...embly Removal instructions 2 Remove seat release bracket by removing front locknut front flange bearing and rear shoulder bolt keep rear washer and bolt 42091A Seat Release Bracket Instruction 5 1 05...

Page 112: ...e Bracket Instruction 5 1 05 6 Place thrust washer on bracket stud 5 Lubricate new seat release bracket along slots on bottom and on tab on top where the lever pin contacts the bracket see old bracket...

Page 113: ...lder bolt through rear seat channel hole and washer thread bolt into bracket and tighten to 80 in lbs Seat Release Bracket With Stud Seat Release Spring 42091A Seat Release Bracket Instruction 5 1 05...

Page 114: ...ight and then back off until the bracket rotates freely from the pull of the spring 13 Test seat relese bracket opera tion by depressing the seat release lever 14 Install seat assembly on NuStep See S...

Page 115: ...ase Lever 42093 Seat Release Lever 5 1 05 NOTE Follow Steps 1 2 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 se...

Page 116: ...against the bracket REFERENCE PHOTO 80 inch lbs Torque Setting To avoid injury and to ensure safe operation of this product fasteners must be tightened to the proper torque CAUTION To avoid injury and...

Page 117: ...embly See Seat Assembly Removal instructions 2 Remove wheel s 3 Install new wheel s and tighten bolts to 80 in lbs No photo To avoid injury and to ensure safe operation of this product fasteners must...

Page 118: ...tchet 3 8 wrench Torque wrench 242 Loctite 1 Remove seat assembly See Seat Assembly Removal instructions 2 Remove seat release bracket For S N 428341 see Seat Release Bracket instructions For S N 4283...

Page 119: ...en to 80 in lbs 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 To avoid injury and prevent adverse health effec...

Page 120: ...ck swivel and release lever operation Swivel seat left and right and check that swivel locks in place 10 Tighten all four bolts to 200 in lbs 12 Install seat release bracket See Seat Release Bracket I...

Page 121: ...ot installed correctly or cut Verify cable is installed correctly and does not have any cuts Refer to Ribbon Cable instruction VR Sensor METS WATTS CALORIES TIME and or Hall Effect Sensor TOTAL STEPS...

Page 122: ...be Refer to Timing Belt Spring Replacement instruction Metal to metal squeaking noise linked to each step taken Set screw loose on the pivot shaft Inspect pivot shaft to verify the shaft is not rotati...

Page 123: ...1 41012 Belt Timing Right 65 6 41234 HHCS G5 5 16 18x1 2 Black 15 1 40322 Belt Clamp Left 66 4 41218 HHCS G5 5 16 18x1 3 4 16 1 40320 Belt Clamp Right 67 8 41062 HHCS G5 5 16 18x3 4 19 2 41016 Belt Id...

Page 124: ...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...

Page 125: ...42119 Figures 4 1 05 E...

Page 126: ...42119 Figures 4 1 05 F...

Page 127: ...42119 Figures 4 1 05 G...

Page 128: ......

Page 129: ......

Page 130: ...ation 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 thi...

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