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Octane Fitness Q35 Service Manual

Summary of Q35

  • Page 1

    Q35.

  • Page 2: Q35

    Octane fitness confidential 1-800-68-634 q35 service manual table of contents section i: general service tips 1.1 accessingtheinsideofthemachine...........................................................................................................................3 1.2 partlocations.................

  • Page 3: Section I:

    3 1-800-68-634 octane fitness confidential section i: general service tips 1.1 accessing the inside of the machine toremovetheaccesspanelandtopcover: 1. Removethetwo(2)phillipsscrewssecuringtheaccesspaneltothemachineandgentlypullthepanelaway (figure1.1). 2. Removetherubbermastbootfromaroundthemast(f...

  • Page 4: Numerous Pinch Points.

    4 octane fitness confidential 1-800-68-634 forsomeserviceactivities,youmayneedtoremoveleftand/orrightshrouds.Youmustfirstremovetheaccesspanel, asoutlinedonthepreviouspage,butyoucanremoveasideshroudwithoutremovingthetopcover. Figure1.4highlightsthelocationsoftheshroudscrews. Toremoveasideshroud: 1. R...

  • Page 5: 1.2  Part Locations

    5 1-800-68-634 octane fitness confidential 1.2 part locations figure1.5highlightsthelocationsofthemaincomponentsoftheq35linkagesystem. Thefollowingkeycomponentsarenotshowninthepicture: moving handlebars speed sensor,mountedontoframe cable assembly,comingdownfromtheconsole belt tensioner assembly,loc...

  • Page 6

    6 octane fitness confidential 1-800-68-634 1.3 diagnostic mode settings and error codes theq35ellipticalmachineoffersadiagnosticsmodetotesttheconsoleandbrakefunctions.Toenterthe diagnosticsmode,holddowntheprogram+/-andlevel+/-keyssimultaneouslyforthree(3)seconds.Severaltests andresultsaredisplayedin...

  • Page 7: Window 1

    7 1-800-68-634 octane fitness confidential window 1 matrix window 2 window 3 window 4 figure1.6.

  • Page 8

    8 octane fitness confidential 1-800-68-634 errorcodes theoctaneq35ellipticalmachinedisplaysthreeerrorsindicatingfaultycomponents: display definition err1 servomotor(brakemotor)goingwrongdirection err2 servomotor(brakemotor)notmoving err3 servomotor(brakemotor)timeout resolutionoftheseerrorsmayrequir...

  • Page 9

    9 1-800-68-634 octane fitness confidential 1.4 q35 suggested dealer stock list octanefitnesssuggeststhatdealersandservicetechniciansmaintainaminimalinventoryofcommonlyneeded partsandsuppliessothatcustomerserviceissuesmaybepromptlyandaccuratelyaddressed.Thefollowingtable identifiespartsandrecommended...

  • Page 10: Section Ii:

    10 octane fitness confidential 1-800-68-634 section ii: troubleshooting tips 2.1 power/electrical issues issue possiblecause whattodo nopowertotheconsole. Looseorimproperplug-inat wallorunit. Checkthatthepowersupplyisproperlyand securelypluggedintoaworkingacpower outlet(wallplug-in). If there is sti...

  • Page 11: Screws  To

    11 1-800-68-634 octane fitness confidential screws to remove figure2.2 figure2.3 figure2.1 connection from top of frame connector for software updates keypad overlay connection figure2.4.

  • Page 12: 2.2  Resistance Issues

    1 octane fitness confidential 1-800-68-634 2.2 resistance issues youmayneedtoremoveoneormoreshroudsinordertodiagnoseresistanceissues.Section1.1providesdirections forremovingtheshrouds. Issue possible cause what to do resistanceistoohigh(rollers aredifficulttomoveonlowest resistancesetting). Consoles...

  • Page 13

    13 1-800-68-634 octane fitness confidential figure2.6 cable installed correctly; brake adjuster at level 1 lock nut adjuster barrel brass nipple axle bolt arrow shows direction of pulley rotation from level 1 to level 20. Pulley shown at level 1. Correct cable installation; cable wraps around the si...

  • Page 14

    14 octane fitness confidential 1-800-68-634 issue possible cause what to do resistanceistoohigh(rollers aredifficulttomoveonlowest resistancesetting). Drivebelttensionistoohigh. twist the drive belt with your fingers; it shouldtwistapproximately90º. Locatethedoublenutontheadjusterrod (figure2.7).Lo...

  • Page 15

    15 1-800-68-634 octane fitness confidential belt tensioner (behind plate) adjuster rod double nut belt screws figure2.7 figure2.8 1/8” approx. Magnet speed sensor figure2.9.

  • Page 16

    16 octane fitness confidential 1-800-68-634 issue possible cause what to do noresistancechange. Consoleisnotproperly connected. Unplugthemachine,thenremovethefour(4) screws securing the console to the console mast(figure2.10). Unplugandre-plugthecableintotheconsole, listening for the click to ensure...

  • Page 17: Screws  To

    17 1-800-68-634 octane fitness confidential screws to remove figure2.10 figure2.11 figure2.12 connection from top of frame connector for software updates keypad overlay connection.

  • Page 18: 2.3 Console Issues

    18 octane fitness confidential 1-800-68-634 2.3 console issues youmayneedtoremoveoneormoreshroudsinordertodiagnoseandresolveconsoleissues.Section1.1provides directionsforremovingtheshrouds. Issue possible cause what to do machineenters“pause” modewhileinuse. Speedsensorisimproperly connectedoraligne...

  • Page 19

    19 1-800-68-634 octane fitness confidential 1/8” approx. Magnet speed sensor figure2.13.

  • Page 20

    0 octane fitness confidential 1-800-68-634 issue possible cause what to do “err1”,“err2”,or“err3”is displayedontheconsole, indicatingbrake/servomotor issues. Looseconnectionsor damaged/faultycable assemblies. Unplug the machine, then remove the four (4) screwssecuringtheconsoletotheconsolemast (figu...

  • Page 21

    1 1-800-68-634 octane fitness confidential figure2.17 figure2.14 figure2.15 connection from top of frame connector for software updates keypad overlay connection screws to remove speed sensor power servomotor figure2.16.

  • Page 22

    Octane fitness confidential 1-800-68-634 issue possible cause what to do “err1”,“err2”,or“err3”is displayedontheconsole, indicatingbrake/servomotor issues. Brakecableisincorrectly positioned,tootight,orstuck. Verifythatthebrakecableisinstalledcorrectly, asshowninfigure2.18. Unplugtheunitatthebase.Lo...

  • Page 23

    3 1-800-68-634 octane fitness confidential arrow shows direction of pulley rotation from level 1 to level 20. Pulley shown at level 1. Correct cable installation; cable wraps around the side of the pulley closest to the base of the servomotor that is attached to the frame. Cable installed correctly;...

  • Page 24: 2.4 Noise Issues

    4 octane fitness confidential 1-800-68-634 2.4 noise issues youmayneedtoremoveoneormoreshroudsinordertodiagnoseandresolvenoiseissues.Section1.1provides directionsforremovingtheshrouds. Issue possible cause what to do machineproduces“squeaking” noisewheninuse. Rubbingrollerwheels. Clean and lubricate...

  • Page 25: Bolts to Check,

    5 1-800-68-634 octane fitness confidential bolts to check, both right and left sides figure2.21.

  • Page 26: Bolts to Check,

    6 octane fitness confidential 1-800-68-634 issue possible cause what to do machineproduces “scraping”soundwhen inuse. Pedalarmrubbingagainst rockerarm. If the scraping noise is metallic, inspect the space betweenthepedalarmandtherockerarmoneachside of the machine while moving the pedals. This can be...

  • Page 27

    7 1-800-68-634 octane fitness confidential issue possible cause what to do machineproduces“clunking” noisewheninuse. Looselinks,pivots,or rockerarms. Checktherails,wheels,andwheelcoverstoensure that they are not rubbing against each other or againstthebackshroud. Openthetopcoverandusingthemovinghand...

  • Page 28: Section Iii:

    8 octane fitness confidential 1-800-68-634 section iii: part replacement & adjustment procedures 3.1 roller wheel replacement 1. Verifythatyouhavethecorrectwheelsavailable.Thewheelsfortheq35area“shallowcut”style(figure3.1). Contactoctanefitnesscustomerserviceifyouneedassistanceidentifyingheproperwhe...

  • Page 29: 3.2

    9 1-800-68-634 octane fitness confidential 3.2 pedal arm replacement 1. Unplugthemachine.Removetheaccesspanelandtopshroudsothatyoucanseewherethepedalarmisattached tothetopofthe3-pivotlink.Followthedirectionsbelowforbothpedalarms(leftandright). 2 usetwo17mmwrenchestoloosenthenutandremovethebolt,assho...

  • Page 30: 3.3

    30 octane fitness confidential 1-800-68-634 3.3 moving handlebar replacement 1. Unplug the unit. Handlebars are labeled “l” (left) and “r” (right); be sure to select the correct handlebar for replacement. 2 removethehandlebarcoverfromthehandlebarpivotpointbypullingitgentlyawayfromthemachine. 3. Usea...

  • Page 31: 3.4

    31 1-800-68-634 octane fitness confidential 3.4 rails replacement 1. Unplugtheunitandremovethesideshrouds,followingthedirectionsinsectioni. 2 removebothleftandrightpedalarms.Usetwo17mmwrenchestoloosenthenutandremovethebolt;referback tofigure3.2.Supportthepedalarmsoitdoesnotdropwhentheboltisremoved.R...

  • Page 32: 3.5

    3 octane fitness confidential 1-800-68-634 3.5 3-pivot link replacement 1. Unplugtheunitandremovetheshroudstoaccesstheinside.Followthedirectionsbelowforeachsideofthe machine(leftandright3-pivotlinks).Figure3.6identifiesthelinksandbolts. 2. Usetwo17mmwrenchestoremovetheboltandnutthatattachthepedalarm...

  • Page 33: 3.6

    33 1-800-68-634 octane fitness confidential 3.6 console replacement 1.Removethefour(4)screwssecuringtheconsoletothemastplate(figure3.8);removetheconsolefromthemast anddetachtheconnection. 2.Attachtheplugfromtheconsolemasttubetotheconnectiononthebackofthenewconsole— listen for the click to make sure ...

  • Page 34: 3.7

    34 octane fitness confidential 1-800-68-634 3.7 keypad overlay replacement 1. Unplugtheunit. 2 removethefour(4)phillipsscrewssecuringtheconsoletothemast(figure3.10) 3. Unplugthekeypadcablefromthekeypadcircuitboard(figure3.11). 4. Carefullypeeltheoldoverlayfromthekeypadontheconsoleandpullthecableouto...

  • Page 35: 3.8

    35 1-800-68-634 octane fitness confidential 3.8 software update softwareupdatesforyouroctanefitnessellipticalcrosstrainerareinstalledusingasmallhandhelddevicecalleda pocketprogrammer(figure3.12).Toobtainapocketprogrammer,contactoctanefitnesscustomerservice. 1. Removethefour(4)screwssecuringtheconsol...

  • Page 36: 3.9

    36 octane fitness confidential 1-800-68-634 3.9 belt tensioner replacement and adjustment 1. Unplugtheunitandremovetheleftshroud.Figure3.14showsthebelttensionerassembly.Figure3.15showsthe belttensionerfromthetopofthemachine. 2. Locatethetwo(2)hexheadscrewsthatholdthebelttensionerassemblytotheframe.N...

  • Page 37

    37 1-800-68-634 octane fitness confidential figure3.14 belt tensioner (behind plate) adjuster rod double nut belt screws figure3.15 belt tensioner top of adjuster rod belt brake assembly.

  • Page 38: Cable Installed

    38 octane fitness confidential 1-800-68-634 3.10 brake assembly/pulley replacement 1. Usethelevel-keytomakesuretheresistanceofthemachineissettolevel1(thelowestlevel). 2. Unplugtheunitandremovetheaccesspanelandsideshrouds. 3. Loosenthebelttensionerboltenoughtoallowyoutoremovethebelt. 4. Loosentheaxle...

  • Page 39

    39 1-800-68-634 octane fitness confidential 3.11 servomotor replacement 1. Unplugtheunitandremovetheshroudstoaccesstheinside.Unplugtheservomotorfromthecableassembly. 2. Unscrewtheservomotorfromtheunitbaseusingaphillipsscrewdriver. 3. Noticethewaythatthebrakecablewrapsaroundthemotortensioningpulley,s...

  • Page 40: Cable Installed

    40 octane fitness confidential 1-800-68-634 3.12 brake cable adjustment 1. Usingthelevel-button,makesuretheresistanceissettolevel1(thelowestlevel). 2. Unplugtheunitandremovetheshroudstoaccesstheinside. 3. Checkthatthebrassnippleattheendofthebrakecablerestsintheslotofthetensionslidehousing. 4. Thebra...

  • Page 41: Hex Head Bolts

    41 1-800-68-634 octane fitness confidential 3.13 pivot shaft replacement 1. Unplugtheunitandremovetheshroudstoaccesstheinside.Followthedirectionsbelowforeachsideofthe machine (left and right pivot shafts). Figure 3.20 illustrates the pivot shaft assembly on the right side of the machine. 2. Removeth...

  • Page 42

    4 octane fitness confidential 1-800-68-634 3.14 cable assembly replacement theq35usestwocableassemblies.Theuppercableassemblyrunsfromtheconnectionatthetopoftheframetothe console.Thelowercableassemblyrunsfromthetopoftheframetojustbelowtherightcrankarm. To replace the upper (console-to-frame) cable: 1...

  • Page 43

    43 1-800-68-634 octane fitness confidential figure3.22 screws to remove figure3.21 figure3.23 speed sensor power servomotor figure3.24 connection from top of frame connector for software updates keypad overlay connection.

  • Page 44

    44 octane fitness confidential 1-800-68-634 3.15 speed sensor replacement 1. Unplugtheunitandremovetheaccesspanelandrightsideshroud. 2. Unplugtheoriginalsensorfromthemainwireharness. 3. Unscrewtheoriginalsensorfromtheframe. 4. Attachthenewsensortotheframewiththescrew;levelandalignthesensorwiththepul...

  • Page 45: Section Iv:

    45 1-800-68-634 octane fitness confidential section iv: supporting documentation q35 assembly instructions q35 operations manual.