Octane Fitness Q35, Service Manual

Page 1: ...Q35 ...

Page 2: ...ustment 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 Adju...

Page 3: ...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 u...

Page 4: ...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 ...

Page 5: ...y 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 ...

Page 6: ...ION 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 ...

Page 7: ... 1 800 628 2634 Octane Fitness Confidential Window 1 Matrix Window 2 Window 3 Window 4 Figure 1 6 ...

Page 8: ...rong 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 ...

Page 9: ... 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 STABI...

Page 10: ...ail 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 powe...

Page 11: ...11 1 800 628 2634 Octane Fitness Confidential Screws to Remove Figure 2 2 Figure 2 3 Figure 2 1 Connection From Top of Frame Connector for Software Updates Keypad Overlay Connection Figure 2 4 ...

Page 12: ...The cable must be installed correctly positioned to wrap around the top of the servomotor pulley as it rotates counterclockwise to increase resistance On level one the cable and pulley should be positioned as shown in Figure 2 5 with the notch on the pulley oriented to 10 o clock Note the arrow in Figure 2 5 is for illustration only no arrow is imprinted on the pulley itself Inspect the cable and ...

Page 13: ...r 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 side of the pulley closest to the base of the servomotor that is attached to the frame Figure 2 5 ...

Page 14: ...n changing direction while pedaling Belt tracking is off center The drive belt should ride in the center not shifted to the right or left Figure 2 8 If it is off center you may feel some added resistance and will hear a rubbing or swishing noise Inspect the belt tensioner Figure 2 8 If it is bent causing the belt to be off center replaceitfollowingthedirectionsinSection III Speed sensor magnet are...

Page 15: ...15 1 800 628 2634 Octane Fitness Confidential Belt Tensioner behind plate Adjuster Rod Double Nut Belt Screws Figure 2 7 Figure 2 8 1 8 Approx Magnet Speed Sensor Figure 2 9 ...

Page 16: ...ot the other you may have a faulty key on the console Refer to Section 1 3 Diagnostics Mode to further isolate the problem You may need to replace the keypad overlay according to the directions in Section III Faulty console If the resistance still does not change when you change levels on the console unplug the cable and plug it into a new console If this resolves the issue replace the old console...

Page 17: ...17 1 800 628 2634 Octane Fitness Confidential Screws to Remove Figure 2 10 Figure 2 11 Figure 2 12 Connection From Top of Frame Connector for Software Updates Keypad Overlay Connection ...

Page 18: ...installed or aligned Verify that the magnet is magnetic by touching it with a steel screwdriver If it is not contact Octane Fitness Customer Service for assistance Verify that the magnet is installed in the drive pulley If it is not contact Octane Fitness Customer Service for assistance Faulty console speed sensor or cable assembly If the speed sensor and magnet are properly installed positioned a...

Page 19: ...19 1 800 628 2634 Octane Fitness Confidential 1 8 Approx Magnet Speed Sensor Figure 2 13 ...

Page 20: ... Figure 2 17 Listen for the clicks to ensure good connections Inspect the lower cable assembly It may be zip tied too tightly to the frame damaging the wire and interrupting power to the servomotor If it appears that the cable assembly has been damaged by the zip tie replace it according to the directions in Section III Plug in the unit and check that the error message is no longer displayed Posit...

Page 21: ... 2634 Octane Fitness Confidential Figure 2 17 Figure 2 14 Figure 2 15 Connection From Top of Frame Connector for Software Updates Keypad Overlay Connection Screws to Remove Speed Sensor Power Servomotor Figure 2 16 ...

Page 22: ...Level keys to change the resistance level of the machine You should be able to hear and see the servomotor moving If it is not moving and you have verified that the lower cable assembly is working it is likely that the servomotor is faulty Place a new servomotor next to the old one and plug it in to the lower cable assembly Power on the machine then push the Level button to move the resistance thr...

Page 23: ...evel 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 brake adjuster at level 1 Cable installed correctly brake adjuster at level 1 Lock Nut Adjuster Barrel Brass Nipple Axle Bolt Figure 2 20 Figure 2 18 Figure 2 19 ...

Page 24: ...fy and secure any dangling or rubbing wires Gently tie off the cables to the frame Be careful not to tie the wires too tightly as ties that are too tight can damage the wires and interrupt the cable signals Loose bolts on 3 pivot links On each side of the machine check and tighten the bolt attaching the 3 pivot link and 2 pivot link to the crank arm and the bolt attaching the pedal arm to the 3 pi...

Page 25: ... 25 1 800 628 2634 Octane Fitness Confidential Bolts to check both right and left sides Figure 2 21 ...

Page 26: ... making this inspection call Octane Fitness Custom Service for further direction Belt tracking is off center The drive belt should ride in the center not shifted to the right or left If it is off center you may feel some added resistance and will hear a rubbing or swishing noise Inspect the belt tensioner shown in Figure 2 22 If it is bent causingthebelttobeoffcenter replaceitfollowing the directi...

Page 27: ... and tighten the four bolts attaching the crank shaft plate to the large drive pulley Figure 2 24 Check and tighten the clamp bolt securing the crank arm Figure 2 24 Try the machine at slow and fast pace forward and backward to see if the noise is still present Check the 2 pivot links and the 3 pivot links for looseness and side to side motion A slight side to side motion is normal at the rocker a...

Page 28: ...mall pry bar 5 Install the new wheel on the axle If necessary tap the wheel lightly with a rubber or hard plastic mallet to ensure that it is seated properly 6 Install the washer and bolt and tighten with the 17mm wrench 7 Replace the plastic wheel cover and secure it with the two Phillips screws 8 Wipe down the chrome rails with a dry rag You may apply a thin coat of white lithium grease to all f...

Page 29: ... washer and the 3 pivot link on the inside of the pedal arm connection If the wave washer has worn away you will need to replace it before attaching the new pedal arm Remove the retaining ring and the flat washer on the outside of the connection Remove the axle pulling it toward the inside of the machine Place a new wave washer over the end of the axle then re insert the axle through the 3 pivot l...

Page 30: ...ng it gently away from the machine 3 Use a hex wrench to remove the four 4 6mm hex key bolts Figure 3 3 4 Remove the handlebar and slide the new one into position 5 Insert and tighten the four 4 6mm hex key bolts Make sure these bolts are very tight 6 Move the handlebars forward and backward a few times they should feel tight with no side to side motion 7 Position the handlebar cover over the hand...

Page 31: ...top of the rails using the 10mm hex wrench 8 Insert and tighten the lower rail bolts using the 6mm hex wrench 9 Reposition the rear rail cover and secure with five 5 Phillips screws 10 Slide one pedal arm into position and insert the bolt secure the bolt with the nut tighten Repeat for the second pedal arm Move the pedal arms forward and backward a few times they should feel tight with no side to ...

Page 32: ... 3 pivot link Make sure that the end of the 3 pivot link that is rounded is attached to the pedal arm and that the stud at the bottom of the 3 pivot link points toward the inside of the machine Figure 3 7 6 Re install the retaining ring that attaches the stability link to the 3 pivot link stud 7 Position the crank arm to the center pivot of the 3 pivot link and re insert the center bolt making sur...

Page 33: ...ion on the back of the new console listen for the click to make sure you have a positive connection Figure 3 9 3 Make sure excess cable is pushed into upright tube 4 Position the new console on the plate at the top of the mast and insert four 4 Phillips screws through the mast plate into the console back Tighten screws to secure Figure 3 8 Figure 3 8 Screws to Remove Connection From Top of Frame C...

Page 34: ...ure the area is free of dirt or dust then feed the new overlay cable through its slot but do not attach it to the keypad circuit board 6 Carefully align the overlay on the keypad so that you can feel the buttons beneath it and press it into place 7 Attach the overlay cable to the keypad circuit board 8 Plug in and power on the unit and test to ensure proper functioning 9 Re attach the console to t...

Page 35: ... is on the right Figure 3 12 3 Insert the 6 pin black connector of the pocket programmer firmly into the 6 pin black slot on the back of the console Figure 3 11 4 The light on the pocket programmer will be yellow indicating a proper connection Figure 3 13 Press the button on the front of the pocket programmer to begin the software update When the software update is complete the light on the pocket...

Page 36: ...en the screw head and the frame 5 Remove the belt tensioner and replace it with a new one threading the belt around the bottom the roller of the belt tensioner 6 Replace and partially tighten the two 2 hex head screws that hold the belt tensioner to the frame 7 Replace the adjuster rod and replace and tighten the double nut Rotate the belt tensioner so that the screw in the slot is aligned with it...

Page 37: ...37 1 800 628 2634 Octane Fitness Confidential Figure 3 14 Belt Tensioner behind plate Adjuster Rod Double Nut Belt Screws Figure 3 15 Belt Tensioner Top of Adjuster Rod Belt Brake Assembly ...

Page 38: ...belt drive on the new brake and re tighten the belt tensioner bolt 9 Replace the brake cable into the sliding piece on the brake The sliding piece should be at the bottom of its slot and the brake cable should be coming out of the slot at the 5 o clock position Figure 3 17 10 Tighten the axle bolt to hold the brake flywheel in place 11 Twist the drive belt with your fingers It should move approxim...

Page 39: ...gh levels 1 to 20 and then push Level to move the resistance back down through all levels Verify that the pulley moves through the levels and that it is in the proper position at level 1 with the notch on the pulley oriented as shown in Figure 3 18 If it is not contact Octane Fitness Customer service for further assistance in making the proper adjustment 7 Verify that the brake cable slider is pos...

Page 40: ...t the bottom of the slot free up the cable adjusting sleeve by backing off loosening the lock nut 5 Rotate the adjuster barrel to make sure the brass nipple and the brake adjuster are touching 6 Turn the adjuster barrel so that the brake adjuster is all the way at the top of the tension slide housing 7 Re tighten the lock nut to hold the adjuster barrel in place 8 Plug in the unit and use the Leve...

Page 41: ...ng and the washer from the end of the pivot shaft slide the shaft out The shaft fits snugly you may need to tap it gently to remove it 6 Insert a new pivot shaft replace the washer and the spring washer on the outside surface and re secure it with a retaining ring 7 Position the rocker arm and re insert the two hex head screws that attach it to the pivot shaft Use an 8mm hex wrench to tighten the ...

Page 42: ... out through the side hole Replace the rubber gasket in the hole and connect the cable to the connection at the top of the frame 5 Position the console on the console mast and secure with four 4 Phillips screws Replace and secure the top cover and access panel To replace the lower cable assembly 1 Unplug the unit Remove the access panel and right shroud according to the directions in Section 1 1 2...

Page 43: ... 2634 Octane Fitness Confidential Figure 3 22 Screws to Remove Figure 3 21 Figure 3 23 Speed Sensor Power Servomotor Figure 3 24 Connection From Top of Frame Connector for Software Updates Keypad Overlay Connection ...

Page 44: ...e original sensor from the frame 4 Attach the new sensor to the frame with the screw level and align the sensor with the pulley magnet Leave a gap of approximately 1 8 inch between the sensor and the magnet taking care that no physical contact occurs Figure 3 27 Tighten screw to secure position 5 Plug the new sensor into the cable assembly and power on the unit to test Figure 3 27 1 8 Approx Magne...

Page 45: ...45 1 800 628 2634 Octane Fitness Confidential SECTION IV Supporting Documentation Q35 Assembly Instructions Q35 Operations Manual ...