Octane Fitness Q35 User manual

Q35

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Octane Fitness Confidential 1-800-628-2634
Q35
Service Manual
Table of Contents
SECTION I: General Service Tips
1.1 Accessing the Inside of the Machine...........................................................................................................................3
1.2 Part Locations...............................................................................................................................................................5
1.3 Diagnostic Mode Settings and Error Codes.................................................................................................................6
1.4 Suggested Dealer Stock List........................................................................................................................................9
SECTION II: Troubleshooting Tips
2.1 Power/Electrical Issues .............................................................................................................................................10
2.2 Resistance Issues ......................................................................................................................................................12
2.3 Console Issues............................................................................................................................................................18
2.4 Noise Issues ...............................................................................................................................................................24
SECTION III: Part Replacement & Adjustment Procedures
3.1 Roller Wheel Replacement ........................................................................................................................................28
3.2 Pedal Arm Replacement.............................................................................................................................................29
3.3 Moving Handlebar Replacement ...............................................................................................................................30
3.4 Rails Replacement......................................................................................................................................................31
3.5 3-Pivot Link Replacement...........................................................................................................................................32
3.6 Console Replacement.................................................................................................................................................33
3.7 Keypad Overlay Replacement ....................................................................................................................................34
3.8 Software Update........................................................................................................................................................35
3.9 Belt Tensioner Replacement and Adjustment............................................................................................................36
3.10 Brake Assembly/Pulley Replacement ........................................................................................................................38
3.11 Servomotor Replacement...........................................................................................................................................39
3.12 Brake Cable Adjustment.............................................................................................................................................40
3.13 Pivot Shaft Replacement............................................................................................................................................41
3.14 Cable Assembly Replacement....................................................................................................................................42
3.15 Speed Sensor Replacement.......................................................................................................................................44
SECTION IV: Supporting Documentation
Q35 Assembly Instructions
Q35 Operations Manual
Q35 Service Manual 09.07v2

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SECTION I:General Service Tips
1.1 Accessing the Inside of the Machine
To remove the access panel and top cover:
1. Remove the two (2) Phillips screws securing the access panel to the machine and gently pull the panel away
(Figure 1.1).
2. Remove the rubber mast boot from around the mast (Figure 1.2).
3. Remove the two (2) Phillips screws securing the top cover to the frame, and remove the top cover (Figure
1.3).
Figure 1.3
Figure 1.1 Figure 1.2
To replace the access panel and top cover:
1. Place the top cover on top of the main housing. Make sure the steel bracket on the front of the top
cover clips on to the front of the main frame. Replace the 2 Phillips screws securing the top cover to the
frame.
2. Place the rubber mast boot around the mast. Starting at the front of the machine, tuck the edges of the boot
under the lip of the top cover.
3. Position the access panel and slide the front edge into the recess of the mast boot. Press the access panel
firmly into place and secure it to the frame on the left and right sides using the two (2) Phillips screws.

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For some service activities, you may need to remove left and/or right shrouds. You must first remove the access panel,
as outlined on the previous page, but you can remove a side shroud without removing the top cover.
Figure 1.4 highlights the locations of the shroud screws.
To remove a side shroud:
1. Remove the three (3) screws at the front of the shroud; these are holding the two shrouds together.
2. Remove the one (1) screw from the side of the left shroud, below the handlebar pivot cover.
3. Remove the one (1) screw from the side of the shroud, near the rails.
4. Pull the bottom of the shroud from the rail, and remove the shroud from the machine.
To replace a side shroud:
1. Place the shroud into position; the bottom of the shroud will snap onto the rail.
2. Replace the screw at the base of the shroud, near the rails, and tighten.
3. Replace the screw under the handlebar pivot cover and tighten.
4. Replace the three (3) screws at the front of the shroud, securing the two side shrouds together.
Figure 1.4
*WARNING: LINKAGES PRESENT
NUMEROUS PINCH POINTS.
USE CAUTION TO AVOID INJURY.
Screws to
be removed

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1.2 Part Locations
Figure 1.5 highlights the locations of the main components of the Q35 linkage system.
The following key components are not shown in the picture:
Moving handlebars
Speed sensor, mounted onto frame
Cable assembly, coming down from the console
Belt tensioner assembly, located on the left side of the machine, next to the magnetic brake assembly.
Figure 1.5
Magnetic
Brake/
Flywheel
Crank
Arm
3-Pivot
Link
Stability Link
Rocker Arm
2-Pivot
Link
Pedal
Arm
Servomotor
Drive Pulley

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1.3 Diagnostic Mode Settings and Error Codes
The Q35 elliptical machine offers a diagnostics mode to test the console and brake functions. To enter the
diagnostics mode, hold down the Program +/- and Level +/- keys simultaneously for three (3) seconds. Several tests
and results are displayed in the console windows (as shown in Figure 1.6), as indicated in the chart below. You must
use the +/- keys to navigate through the diagnostic tests options. When  is displayed in Window 1, you must
press Enter for the test to begin. To exit a test, press Pause/Clear twice, then use the +/- keys to move to the next
test. The following diagnostics are available on the Q35:
Description Matrix Window 1 Window 2 Window 3 Window 4
Software version SOFTWARE
VERSION
Version # Version # d1
Check all LEDs. The machine
cycles through all LEDs in all win-
dows; or, press any key to halt to
automatic cycle and step through
the test manually. When you have
verified all LEDs, press Pause/
Clear twice to exit this test, then
press +/- to move to another test.
DISPLAY

d2
Check all keys
You must press each key and
listen for the beep to verify that
it works properly before you can
move on to the next test. Press
Pause/Clear twice to exit this
test, then press +/- to move to
another test.
KEYPAD

TEST
PASS
(Count
of keys
pressed)
d3
Brake motor test. Press Pause/
Clear to exit this test.
BRAKE

TEST
Actual
reading
d4 Target
Speed sensor check; pedal the
machine to display RPM
RPM RPM value d5
Total time of machine usage MACHINE
HOURS
Usage
hours
d6
Total distance of machine usage MACHINE
MILES
Distance
value
d7
Brake motor usage time BRAKE
MINUTES
# of
Minutes
d8
To exit the diagnostics mode at any time, press the Pause/Clear button twice within 2 seconds.

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Window 1
Matrix
Window 2 Window 3
Window 4
Figure 1.6

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Error Codes
The Octane Q35 elliptical machine displays three errors indicating faulty components:
Display Definition
Err1 Servomotor (brake motor) going wrong direction
Err2 Servomotor (brake motor) not moving
Err3 Servomotor (brake motor) time out
Resolution of these errors may require replacement of parts. Octane strongly suggests that you keep an inventory of
key parts on hand so that you and your customer will not experience delays in resolving issues due to parts ordering
and shipment. Refer to the Suggested Dealer Stock List for more information.

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1.4 Q35 Suggested Dealer Stock List
Octane Fitness suggests that dealers and service technicians maintain a minimal inventory of commonly needed
parts and supplies so that customer service issues may be promptly and accurately addressed. The following table
identifies parts and recommended stock quantities for your inventory.
Part Number Description Qty.
100964-001 POWER TRANSFORMER Q35 2
100744-001 Q35 2P LINK ASSEMBLY 3
100741-001 Q35 3-PIVOT LINK ASSEMBLY 3
900018-001 Q35 BRAKE 2
100761-001 Q35 BRAKE CABLE 2
100405-001 Q35 DRIVE BELT 2
900015-001 LEVELER, 50 MM OIA Q35 5
959938-009 Q35 LEVELER NUT 10
100747-001 Q35 TENSIONER ASSEMBLY 1
100836-001 Q35 POWER INPUT PLUG (NEW) 2
100449-001 Q35 SERVOMOTOR 2
300533-001 Q35 ROLLER WHEEL 8
101052-001 Q35 ROCKER ARMS OFFSET 2
100400-001 SHROUD, UPPER REAR -- NO DECALS Q35 2
100398-001 SHROUD, LEFT -- NO DECALS Q35 2
100397-001 SHROUD, RIGHT -- NO DECALS Q35 2
100915-001 TOP SHROUD 2
100880-001 CONSOLE, STANDARD WITH EVERYTHING 2
100754-001 SHROUD SCREWS 12
100739-001 STABILITY LINK Q35 2
MAIN WIRE HARNESS/CABLE ASSEMBLY 1
100718-001 SPEED SENSOR -Q35 2
101409-001 ASSEMBLY MANUAL Q35 2
101410-001 OPERATIONS MANUAL Q35 V1.4 6
100738-001 FLYWHEEL MAGNET 2
100882-001 DECAL, SIDE SHROUD 4
101040-001 DECAL, 65 DIA BUG 4
101041-001 DECAL, MEDIUM OCTANE 4
100367-001 COVER, REAR RAIL 2
101053-001 PIVOT SHAFT
101307-001 SHROUD ACCESS PANEL 2
101273-001 COVER, HANDLEBAR Q35 4
101293-001 ASS’Y RIGHT ARM Q35 2
101294-001 ASS’Y LEFT ARM Q35 2

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SECTION II: Troubleshooting Tips
2.1 Power/Electrical Issues
Issue Possible Cause What to Do
No power to the console. Loose or improper plug-in at
wall or unit.
Check that the power supply is properly and
securely plugged in to a working AC power
outlet (wall plug-in).
If there is still no power to the console,
check that the power supply cord is properly
and securely inserted into the power input
jack located below the right rail (Figure
2.1).
Loose or improper electrical
connections within unit.
Unplug the machine, then remove the four
(4) screws securing the console to the
console mast (Figure 2.2).
Unplug and re-plug the cable into the
console board, listening for the click to
ensure a good connection (Figure 2.3).
Check and secure the cable assembly
connection on the top of the frame (Figure
2.4).
Plug in the machine to verify power to the
console.
Position and secure the console on the
console mast with the four (4) screws.
If power is not restored to the console after all the connections have been checked and secured, you may need to
replace the console itself. Refer to Section III for more information.