Octane Fitness Q45 Service Manual
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Octane Fitness Q45 Service Manual

Octane Fitness Q45 Service Manual

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Summary of Contents for Octane Fitness Q45

  • Page 1 Q45/Q45e/Q45ce...

  • Page 3: Table Of Contents

    Belt Tensioner Replacement ...................... 3.7 Brake Assembly/Pulley Replacement ..................3.8 Servomotor Replacement ......................3.9 Brake Cable Adjustment ......................3.10 Upper and Lower Wiring Harnesses Replacement..............3.11 Pivot Shaft Replacement ......................3.12 Speed Sensor Replacement ....................3.13 Heart Rate Sensor Cable Replacement .................. 3.14 Heart Rate Contact Handgrip Replacement ................3.15 Console Replacement ......................3.16 Console Overlay Replacement ....................3.17 Console Software Micro-Controller Replacement ..............3.18 Controller Board Replacement ....................3.19 Limit Switch Assembly Replacement ..................3.20 SECTION IV: Supporting Documentation Q45/Q45e/Q45ce/Q45ce Assembly Instructions Q45/Q45e/Q45ce/Q45ce Operations Manual Q45/Q45e/Q45ce Service Manual 04.06v2...
  • Page 5 otes...
  • Page 6 Figure 1.1 Right Clevis Notice step orientation to outside of machine Figure 1.3 Figure 1.2...

  • Page 7: Section I: General Service Tips

    SECTION I: General Service Tips 1.1 Part Locations Figure 1.1 highlights the locations of the main components of the Q45/Q45e/Q45ce linkage system. Figure 1.1 represents units with Serial Numbers ranging from ________________ to ________________; Figure 1.2 illustrates the modified location of the controller board in units having Serial Numbers _______________ and higher. “Right” and “Left” assemblies and motors are indicated by “R” and “L”, respectively, either etched into the metal or on a decal.The right and left pedal arms are differentiated by the stepped out clevis; the step should be oriented to the outside of the unit, as shown in Figure 1.3. The following key components are not shown in the picture:  Moving handlebars  Speed sensors (2), mounted onto frame  Two-piece wire harness, coming down from the console *WARNING: LINKAGES PRESENT NUMEROUS PINCH POINTS.
  • Page 8 Figure 1.4 Q45 1.2...

  • Page 9: Diagnostic Mode Settings And Error Codes

    1.2 Diagnostic Mode Settings and Error Codes The Q45/Q45e/Q45ce elliptical machine offers a diagnostics mode to test the console and brake functions. To enter the diagnostics mode, hold down the Time +/- and Level +/- keys simultaneously for three (3) seconds. The tests and results are displayed in the console windows (as shown in Figure 1.4, upper and lower keypads), as indicated in the chart below. The first three tests (D1 through D3) run automatically. You must use the +/- keys to navigate through the remaining diagnostic tests options, pressing Enter to select the test you want to perform. The following diagnostics are available on the Q45/Q45e/Q45ce: Description Matrix Window 1 Window 2 Window 3 Window 4 Check memory Brake motor test...
  • Page 10 Error Codes The Octane Q45/Q45e/Q45ce elliptical machine displays four errors indicating faulty components: Display Definition Err1 Servomotor (brake motor) issues Err2 Left stride motor issues Err3 Right stride motor issues Err4 RPM of #1 route Err5 RPM of #2 route Err6 Low limit switch issue, left stride motor Err7 High limit switch issue, left stride motor Err8 Low limit switch issue, right stride motor Err9 High limit switch issue, right stride motor Err10 EEPROM Err11 Communication issues Please contact Octane Fitness Customer Service for guidance in diagnosing and resolving these error codes.

  • Page 11: Suggested Dealer Stock List

    110428CU ELASTIC STRAP FOR CHEST MONITOR 10B727R2 HR SENSOR CABLE ONLY 1005-SPS4501-01 Q45 POWER TRANSFORMER 10B827KH Q45 ACTUATOR NUT LEFT 10B827HB Q45 ACTUATOR NUT RIGHT 10B826KW Q45 ADJ LINK ASS’Y LEFT W/MOTOR 10B826KV Q45 ADJ LINK ASS’Y RIGHT W/MOTOR 10B826KX Q45 BELT TENSION ASS’Y W/BEARING 10B826KG Q45 BRAKE ASS’Y 10B826K9 Q45 BRAKE CABLE 10B826K8...
  • Page 12 Figure 2.2 Figure 2.1 Figure 2.3 Q45 2.1...

  • Page 13: Section Ii: Troubleshooting Tips

    Check and secure the lower wire harness connections at the controller board and the servomotor (Figure 2.4).  Plug in the machine to verify power to the console. 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. Units with controller mounted above flywheel Units with controller mounted near the floor. Figure 2.4 Q45 2.1...
  • Page 14 Figure 2.5 Figure 2.6 Q45 2.2...

  • Page 15: Resistance Issues

    (shown in Figure 2.6).  Use a screwdriver to gently push the brake adjuster up to ensure that it is properly positioned at the top of its slot.  If the brake is not fully disengaged or the cable has too much slack when the cable is properly installed and the brake adjuster is in its proper position for level 1, you may need to re-install or adjust the cable. Refer to Section III for instructions. Q45 2.2...
  • Page 16 Figure 2.7 Nylock Clevis bushing Figure 2.9 Figure 2.8 Q45 2.2...
  • Page 17 the clevis bushing (Figures 2.8 and 2.9.  Remove the nylock nut.  Use while lithium grease to lubricate the actuator nut posts where the clevis bushing slides.  Move the clevis bushing to ensure that it slides freely.  Replace and tighten the nylock nut. Q45 2.2...
  • Page 18 Figure 2.10 Figure 2.12 Figure 2.11 Q45 2.2...
  • Page 19 Belt tracking is off center.  The drive belt should ride in the center, not shifted to the right or left (Figure 2.12). If it is off center, you may feel some added resistance and will hear a rubbing or swishing noise.  Inspect the belt tensioner (Figure 2.11). If it is bent, causing the belt to be off center, replace it following the directions in Section III. Q45 2.2...
  • Page 20 Figure 2.13 Figure 2.14 Figure 2.16 Figure 2.15 Q45 2.2...
  • Page 21 Level - button to move the resistance back down through all levels. Verify that the pulley is in the proper position at level 1, with the notch on the pulley oriented to “10 o’clock”. (Figure 2.16). If it is not, contact Octane Fitness Customer Service for further assistance in making the proper adjustment.  If this resolves the issue, complete the installation of the new servomotor according to the directions in Section III. Q45 2.2...
  • Page 22 Figure 2.18 Figure 2.17 Figure 2.20 Figure 2.19 Q45 2.2...
  • Page 23 Plug in the unit and check. If this resolves the issue, complete the installation of the new console according to the directions in Section III. Brake is stuck and the  Adjust the brake cable according to the directions servomotor is unable to move in Section III.  Using a screwdriver, slide the brake adjuster up toward the center of the brake to ensure it is not stuck in the slot.  If the brake remains stuck, replace the brake assembly according to the directions in Section III. Q45 2.2...
  • Page 24 Speed Speed Sensors Sensors Figure 2.21 Figure 2.22 Q45 2.3...

  • Page 25: Console Issues

    2.3 Console Issues The General Service Information Manual provides directions for removing shrouds to access the inside of the unit. Issue Possible Cause What to Do Machine enters “pause” mode Speed sensors are  The Q45/Q45e/Q45ce has two speed while in use. improperly connected or sensors to detect forward and reverse aligned. motion. The speed sensors must be properly aligned with the magnet (Figure 2.21).  Disconnect and reconnect each speed sensor at the cable harness to ensure a good connection.
  • Page 26 Figure 2.23 Figure 2.24 Figure 2.25 Q45 2.3 Figure 2.27...
  • Page 27 Plug in the unit. After the motors stop moving (8 to 15 seconds), unplug the unit again.  Ground yourself before touching the circuit board. Unplug the stride motor plugs from the controller board and plug each one back into its default socket: Left (black) plug into the black socket and Right (white) plug into the white socket (Figure 2.26).  If the stride motor (left or right) causing the error is unresponsive, it should be replaced following the directions in Section III. Figure 2.26 Q45 2.3...
  • Page 28 Figure 2.28 Figure 2.27 Figure 2.29...
  • Page 29 Issue Possible Cause What to Do “Err2” (left) or “Err3” (right) Faulty communications  Unplug the unit. Remove the Q45/Q45e/Q45ce controller is displayed on the console. chip on controller board. board from the frame. The controller board is located directly under the main drive pulley (Figure 2.278) or on the right shroud mounting tube attached to the main upright tube (Figure 2.28).  Ground yourself before touching the circuit board. Use a chip puller to gently remove the old IC chip (PD-21- SD45-XX), shown in Figure 2.29.
  • Page 30 Figure 2.30 Figure 2.32 Figure 2.31...
  • Page 31 (Figure 2.31, older units, or Figure 2.32, newer units.).  If the issue is not resolved, you will need to replace the wiring harness according to the directions in Section III. Console buttons are not Faulty console key.  Replace the keypad overlay according to the responding or are sticking. directions in Section III. Q45 2.3...
  • Page 32 Nylock Clevis bushing Figure 2.34 Figure 2.33 Figure 2.35 *WARNING: LINKAGES PRESENT NUMEROUS PINCH POINTS. USE CAUTION TO AVOID INJURY. Q45 2.4...

  • Page 33: Noise Issues

    Replace and tighten the nylock nut. Machine produces “scraping” Hanging wires on links.  Identify and secure any dangling or sound when in use. rubbing wires. Use zip-ties to gently tie 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. 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 2.35. If it is bent, causing the belt to be off center, replace it following the directions in Section III. Q45 2.4...
  • Page 34 2-pivot link connection. No side-to-side motion should be seen in the adjustable link assembly. Section III provides directions for replacing links if necessary. Broken bearing or magnetic/  Inspect the brake pulley. If it is broken, flywheel assembly. replace the brake assembly following the directions in Section III. Figure 2.37 Figure 2.36 Q45 2.4...
  • Page 35 Section III provides directions for replacing links if necessary.  If the noise persists, detach the crank arm from the middle adjustable link bolt on both right and left sides. Move the drive pulley; if the noise persists you may need to replace the pivot shaft and/or crank shaft assembly. Refer to Section III for directions. Q45 2.4...
  • Page 36 Nylock Clevis bushing Figure 2.38 Figure 2.39 Thrust bearing Actuator assembly shaft Actuator nut (not Actuator shown) shaft retaining bracket Motor spindle (orient as shown) Remove screws to free motor and actuator shaft retaining bracket Actuator motor Figure 2.40 Q45 2.4...
  • Page 37  Replace and tighten the nylock nut. Actuator shaft threads are  Apply white lithium grease to the threaded not properly lubricated. actuator shaft (Figure 2.39), including the top, middle, and just below the retaining bracket. Broken actuator shaft  Inspect the black retaining bracket to see if it is retaining bracket. cracked or broken (Figure 2.40). If it is, replace it according to the directions in Section III. Faulty stride motor.  If a motor is unresponsive or continues to labor, you will need to replace the adjustable link assembly according to the directions in Section III. Q45 2.4...
  • Page 38 Figure 2.41 Q45 2.5...

  • Page 39: Heart Rate Monitoring Issues

     The heart rate sensor cable is a single wire which runs from the right side of the console to the center (Figure 2.41). Remove it from the glue holding it to the console, unplug it from the console, and replace it with a new one according to the directions in Section III.  Check the console ground connection by loosening and re-tightening it. You may need to scrape off a bit of paint to ensure good ground connection.  If the issue is still present, replace the handgrips according to the directions in Section III. Q45 2.5...
  • Page 40 Figure 2.42 Q45 2.5...
  • Page 41 Issue Possible Cause What to Do Erratic or illogical heart rate Faulty heart rate sensor  Remove the four (4) screws securing the reading , or “NO HR” message cable in the console, or faulty console to the console upright tube. from both the chest strap and console. the handgrips(Q45ce only) .  The heart rate sensor cable is a single wire which runs from the right side of the console to the center (Figure 2.42). Remove it from the glue holding it to the console, unplug it from the console, and replace it with a new one according to the directions in Section III.  If heart rate issues still exist, unplug the cable and plug it into a new console, listening for the click to ensure a good connection. Plug in the unit and check.
  • Page 42 Figure 3.1 Q45 3.1...

  • Page 43: Section Iii: Part Replacement & Adjustment Procedures

    SECTION III: Part Replacement/Adjustment Procedures 3.1 Roller Wheel Replacement 1. Verify that you have the correct wheels available. The wheels for the Q45/Q45e/Q45ce are grey (Figure 3.1). Follow these instructions for both the left and right wheels. 2. Remove two (2) Phillips screws and remove the plastic wheel cover. 3. Use a 6mm hex key to remove the button-head cap screw and the washer that holds the wheel on the axle. This screw may be very tight; use a pipe or a long breaker bar and a hex driver socket if you need additional leverage. 4. Remove the wheel assembly. If the wheel is stuck, you may need to pry it off using a large-blade flat screwdriver or a small 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. Be careful not to damage the bearings.
  • Page 44 Q45 3.1...

  • Page 45: Pedal Arms Replacement

    4. Remove the old pedal arm and slide the new one into position. 5. Pedal arms are side-specific. Make sure that the stepped portion of the clevis (Figure 3.3) is oriented toward the outside of the unit. 6. Install nylock nuts and Phillips screws and tighten. 7. Move the pedal arms forward and backward a few times; they should feel tight with no side-to-side motion. Right Clevis Notice step orientation to outside of machine Figure 3.3 Figure 3.2 Q45 3.2...
  • Page 46 Q45 3.2...

  • Page 47: Rails Replacement

    WD-40® or a silicone spray. With a clean rag or paper towel, work the grease down the rails, covering the rails with a small amount of lubricant. Remove excess grease with a dry rag; only a very thin film should remain. 11. Replace the pedal arms. 12. Pedal the unit for several minutes to test, then once again wipe the rails with a clean dry rag to remove excess grease. 13. Reposition the back shroud; check to make sure the inlet plug did not unplug from the cable assembly or get pinched. Secure the back shroud with its four screws. Replace the right, left, and top shrouds and secure. Figure 3.5 Figure 3.4 Q45 3.3...
  • Page 48 Figure 3.6 18mm Bolt Stability Link Figure 3.7 Q45 3.4...

  • Page 49: Adjustable Link Assembly Replacement

    7. Cut the zip ties and remove the old stride motor. 8. Position the new stride motor and secure with zip ties. 9. Reattach the stride motor to the stability link using an 18mm wrench. 10. Lift the stride motor on the stability link up into position, reinsert the center bolt into the 2-pivot link and crank arm, and use a 19mm wrench to secure it with the nylock nut. 11. Push the pedal arm up the rails into position, replace the two bushings, and use a 13mm wrench to retighten the two (2) actuator nylock nuts. 12 Replace and tighten the two (2) Phillips screws that secure the actuator nut bushings on each side of the pedal arm. 13. Plug the stride motor into its proper plug on the controller board (Left is black, Right is white), turn on the unit, and test for proper functioning. 14. Zip-tie the wires down so that they don’t get tangled. Q45 3.4...
  • Page 50 Actuator nut (not Actuator shown) shaft retaining bracket Motor spindle (orient as shown) Remove screws to free motor and actuator shaft retaining bracket Actuator motor Figure 3.8 Actuator shaft Caution: thrust bearing and washer may separate during removal Figure 3.9 Q45 3.4...

  • Page 51: Actuator Nut Replacement

    4. Remove the two (2) hex-head screws holding the motor to the pivot link. 5. Pull the actuator motor away from the actuator shaft. 6. Slide the shaft down and away from the 3-pivot link, and remove the actuator shaft bracket. Use caution as the thrust bearing and washer may separate as you pull the shaft out of the upper bushing (Figure 3.9). 7. Thread the old actuator nut off the bottom the threaded actuator shaft. 8. Thread the new actuator nut onto the shaft. 9. Slide the shaft up and into the 3-pivot link and push the actuator shaft toward the actuator motor. 10. Replace and tighten the 2 (2) hex-head screws holding the motor to the pivot link. 11. Replace and tighten the two (2) hex-head screws holding the retainer bracket to the pivot link. 12. Inspect the crank arm alignment to verify that it is flush with the crank shaft. 13. Replace and tighten the two (2) nylock nuts and two (2) Phillips screws that attach the pedal arm to the adjustable link assembly. 14. Plug in the unit and test. Q45 3.5...
  • Page 52 Actuator assembly shaft Caution: thrust bearing and washer Actuator may separate during nut (not removal Actuator shown) shaft retaining bracket Motor spindle (orient as shown) Figure 3.12 Remove screws to free motor and actuator shaft retaining bracket Actuator motor Figure 3.11 Q45 3.6...

  • Page 53: Retaining Bracket Replacement

    3.6 Actuator Shaft Retaining Bracket Replacement 1. Use the console keypad to extend the stride length to 23, the top of the actuator shaft. 2. Unplug the unit and remove the shrouds to access the inside. 3. Remove the two (2) hex-head screws holding the retainer bracket to the pivot link (Figure 3.11). 4. Remove the two (2) hex-head screws holding the motor to the pivot link. 5. Pull the actuator motor away from the actuator shaft. 6. Slide the shaft down and away from the 3-pivot link, and remove the actuator shaft retaining bracket. Use caution as the thrust bearing and washer may separate as you pull the shaft out of the upper bushing (Figure 3.12). 7. Install the new bracket onto the shaft. 8. Slide the shaft up and into the 3-pivot link and push the actuator shaft toward the actuator motor. 9. Replace and tighten the two (2) hex-head screws holding the motor to the pivot link. 10. Replace and tighten the two (2) hex-head screws holding the retainer bracket to the pivot link. 10. Plug in the unit and test. Q45 3.6...
  • Page 54 Q45 3.6...

  • Page 55: Belt Tensioner Replacement

    3.7 Belt Tensioner Replacement 1. Unplug the unit and remove the shrouds to access the inside. Figure 3.13 shows the belt tensioner assembly. 2. Use a 13mm wrench to remove the double nut and the adjuster rod. 3. Remove the nylock nut that holds the belt tensioner to the frame. 4. Remove the belt tensioner and replace it with a new one. 5. Tighten the nylock nut that holds the belt tensioner to the frame. 6. Tighten the double nut on the adjuster rod. 7. Twist the drive belt with your fingers. It should move approximately 90º. Adjust as necessary so that slippage does not occur between the belt and the pulley while pedaling the unit and when changing direction while pedaling. Figure 3.13 Q45 3.7...
  • Page 56 Figure 3.14 Figure 3.15 Q45 3.8...

  • Page 57: Brake Assembly/Pulley Replacement

    7. Tighten the axle bolts to hold the brake flywheel in place. 8. Replace the brake cable into the sliding piece on the brake. 9. Put the belt drive on the new brake and re-tighten the belt tensioner bolt. 10. Twist the drive belt with your fingers. It should move approximately 90º. Adjust as necessary so that slippage does not occur between the belt and the pulley while pedaling the unit and when changing direction while pedaling. 11. Plug in the unit and test. Q45 3.8...
  • Page 58 Figure 3.16 Figure 3.17 Figure 3.18 Q45 3.9...

  • Page 59: Servomotor Replacement

    7. Verify that the brake cable slider is positioned at the top of its slot (toward the center of the flywheel) when the unit is at resistance level 1 (Figure 3.18. See Brake Cable Adjustment in this section for more information. 8. Re-attach the servomotor and bracket to the unit base using a Phillips screwdriver, and zip-tie the cable to the frame. Q45 3.9...
  • Page 60 Q45 3.9...

  • Page 61: Brake Cable Adjustment

    2. Unplug the unit and remove the shrouds to access the inside. 3. Check that the brass nipple at the end of the brake cable rests in the slot of the tension slide housing. 4. The brake adjuster must be at the top of its slot (toward the center of the flywheel) at resistance level 1, as shown in Figure 3.19. If it is not at the top 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. Retighten the lock nut to hold the adjuster barrel in place. 8. Plug in the unit and use the Level +/- buttons to test resistance changes, making sure the brake adjuster returns to the top of the slot when the machine is at level 1. Figure 3.19 Q45 3.10...
  • Page 62 Figure 3.20 Figure 3.21 Older units Newer units Figure 3.22 Q45 3.11...

  • Page 63: Upper And Lower Wiring Harnesses Replacement

    12. Follow the old lower wire harness down the frame (Figure 3.22), unplugging the old wire harness and plugging in the new one at three connection points: controller board, servomotor, and speed sensor (not shown). 13. Once the new wire harness is connected, cut the zip ties and remove the old wire harness. 14. Plug in the unit and test. 15. Use zip ties to secure the wiring new harness to the frame. 16. Replace all shrouds and secure with shroud screws. Q45 3.11...
  • Page 64 Figure 3.23 Figure 3.24 Q45 3.12...

  • Page 65: Pivot Shaft Replacement

    6. Install the hex collar by hand as shown in Figure 3.24 with the set screws closer to the holes in the shaft. (The white dot in Figure 3.24 is for illustration only and does not appear on the actual hex collar.) 7. Position the hex collar up against the bronze bushing. Make sure you can spin the shaft by hand. (A little resistance is fine.) 8. Re-install the moving handlebars and move them side to side to determine the appropriate tightness for the pivot shaft. The handlebars should move freely but without lateral movement or wobble. 9. Apply Blue Loctite© and tighten the two (2) set screws in hex collar to lock it into place. 10. Use the two (2) bolts and washers to attach the rocker arm to the pivot shaft. 11. Replace the shrouds and shroud screws. Q45 3.12...
  • Page 66 Speed Sensors Figure 3.25 Figure 3.26 Q45 3.13...

  • Page 67: Speed Sensor Replacement

    3.14 Speed Sensor Replacement 1. Unplug the unit and remove the shrouds to access the inside. 2. Unplug the original sensor from the main wire harness. 3. Unscrew the 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 (Figures 3.25 and 3.26). Tighten screw to secure position. 5. Ensure that cables are not dangling loose into the linkage system. 6. Plug the new sensor into the wiring harness and power on the unit to test. Q45 3.13...
  • Page 68 Q45 3.13...

  • Page 69: Heart Rate Sensor Cable Replacement

    6. Plug a new heart rate sensor/cable into the console circuit board. 7. Place the two pieces of the console casing together, holding the circuit board in place. Plug the console cable into the console, listening for the click to ensure a good connection. 8. Carefully flip over the console casing and power on the machine. Put on a heart rate strap and verify that a heart rate reading is displayed on the console. 9. Separate the console pieces again and glue the new heart rate sensor cable to the console, making sure the wires are properly positioned so they won’t be pinched when the console pieces are pressed back together. 10. Place the console pieces together once more, making sure that the LEDs are aligned properly in the console windows, and secure the console casing with the six (6) Phillips screws, 11. Re-attach the console to the upright tube with the four (4) Phillips screws. Figure 3.27 Q45 3.14...
  • Page 70 Figure 3.28 Figure 3.29 Q45 3.15...

  • Page 71: Heart Rate Contact Handgrip Replacement

    3.15 Heart Rate Contact Handgrip Replacement (Q45ce) 1. Use a screwdriver to remove the end caps from the top of the stationary handgrips on each side of the machine (Figure 3.28). Repeat the following steps for both the left and right handgrips. Beginning at the top, carefully separate the two sides of the handgrip. You may need to use a flat screwdriver to lever the pieces apart. 3. Use tape to label the two heart rate connectors so that you know which one connects to each side of the handgrip (Figure 3.29). 4. Disconnect the two heart rate connectors and remove the old handgrips. 5. Position the new handgrip pieces and connect the two heart rate connectors to the appropriate connectors in the new handgrip. 6. Carefully snap the two sides of the handgrip together, avoiding pinching the wires 7. Replace the end cap. Q45 3.15...
  • Page 72 Q45 3.15...

  • Page 73: Console Replacement

    3.16 Console Replacement 1. Unplug the unit. 2 Remove the four (4) Phillips screws securing the console to the upright tube. 3. Unplug the connector from the back of the console and plug it into the new console, listening for the click to ensure a good connection (Figure 3.30). 4. Power on the unit to verify the new console is working properly. 5. Re-attach the new console to the upright tube with the four (4) Phillips screws. Figure 3.30 Q45 3.16...
  • Page 74 Figure 3.31 Figure 3.32 Figure 3.33 Q45 3.17...

  • Page 75: Console Overlay Replacement

    4. Remove the six (6) Phillips screws holding the two pieces of the console casing together and separate the console casing. 5. Unplug the main overlay ribbon cable from the console circuit board (Figure 3.31). 6. Carefully peel the old overlay from the console keypad and pull the cable out of its slot in the console (Figures 3.32 and 3.33). 7. Make sure the area is free of dirt or dust, then feed the new overlay cable through its slot, but do not attach it to the console circuit board. 8. Carefully align the overlay on the keyboard so that you can feel the buttons beneath it and press it into place. 9. Attach the overlay cable to the console circuit board. 10. Place the two pieces of the console casing together, holding the circuit board in place and making sure that the LEDs are aligned properly in the console windows. 11. Plug the console cable into the console, listening for the click to ensure a good connection. 12. Power on the unit and test to ensure proper functioning. 13. Secure the console casing with the six (6) Phillips screws, 14. Re-attach the console to the upright tube with the four (4) Phillips screws. Q45 3.17...
  • Page 76 Figure 3.34 Figure 3.35 Figure 3.36 Q45 3.18...

  • Page 77: Console Software Micro-Controller Replacement

    10. Flip the console board back over, making sure that the LEDs are aligned properly in the console windows, and re-attach it to the console casing with the three (3) screws. 11. Re-connect the console board to the console overlay. 12. Fit the two console casings together and secure them with the six (6) screws. 13. Plug the console cable into the console, listening for the click to ensure a good connection. 14. Power on the unit to verify that console is working properly. If you need further assistance, contact Octane Fitness Customer Service. 15. Re-attach the console to the upright tube with the four (4) Phillips screws. Q45 3.18...
  • Page 78 Figure 3.37 Figure 3.38 Q45 3.19...

  • Page 79: Controller Board Replacement

    Follow these instructions for units with the controller board mounted on top of the right shroud mounting tube. 1. Unplug the unit, loosen and rotate the top shroud. 2 Use masking tape to mark each wire so you will remember where it goes, then unplug all the wires from the controller board. 3. Using needle nose pliers, squeeze the four (4) plastic mounts and pop the board off of the frame (Figure 3.38). 4. Install the new board on the plastic mount. Listen for the “snap” to verify that it is properly seated. 5. Plug all the wires into the correct spots on the new board and remove the tape markings. 6. Test for proper functioning. 7. Reposition the top shroud; secure with shroud screws. Q45 3.19...
  • Page 80 Figure 3.39 Figure 3.41 Figure 3.40 Q45 3.20...

  • Page 81: Limit Switch Assembly Replacement

    (Figure 3.40), cut the small zip-tie, and remove the limit switch unit. 5. Position the new limit switch unit (Figure 3.41), attach it to the motor assembly with the Phillips screws, and secure the cable with a zip-tie.. 6. Reconnect the limit switches to the motor 7. Reconnect the motor to the controller board. 8. Replace the right shroud (if it was removed), then the left shroud, and reposition the top shroud; secure with shroud screws. Q45 3.20...
  • Page 83 SECTION IV: Supporting Documentation Q45/Q45e/Q45ce Assembly Instructions Q45/Q45e/Q45ce Operations Manual...

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