Octane Fitness Q45, Service Manual

Page 1: ...Q45 Q45e Q45ce ...

Page 2: ......

Page 3: ...t Replacement 3 5 Retaining Bracket Replacement 3 6 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 Cons...

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Page 5: ...Notes ...

Page 6: ...Figure 1 1 Figure 1 3 Right Clevis Notice step orientation to outside of machine Figure 1 2 ...

Page 7: ...strates 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...

Page 8: ...Q45 1 2 Figure 1 4 ...

Page 9: ...Ds in all windows when you have verified all LEDs press any key to move to the next test All LEDs light up All LEDs light up All LEDs light up All LEDs light up All LEDs light up Software version Version Version Version Version Total distance of machine TD Distance value Total time of machine usage TT Usage hours Total motor on time MOT Motor on hours When you first enter the diagnostic mode three...

Page 10: ...de 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 Resolution may require replacement of parts Octane strongly suggests that you keep an inventory of key parts on hand so that you and your customer wil...

Page 11: ...IGHT W MOTOR 2 10B826KX Q45 BELT TENSION ASS Y W BEARING 2 10B826KG Q45 BRAKE ASS Y 1 10B826K9 Q45 BRAKE CABLE 2 10B826K8 Q45 CONTROLLER BOARD 3 10B826K3 Q45 DC SERVO MOTOR 2 257226LB Q45 DRIVE BELT 2 29WH2 Q45 SHAFT RETAINER 4 10B8291H Q45 ROLLER WHEELS 8 10B8291V Q45 E HARDWARE PACK 3 SHROUD BACK NO DECALS Q45 2 Q45 SHROUD LEFT WITH CHROME PIECE 2 Q45 SHROUD RIGHT WITH CHROME PIECE 2 TOP SHROUD ...

Page 12: ...Figure 2 2 Figure 2 3 Figure 2 1 Q45 2 1 ...

Page 13: ...ctrical connections within unit Unplug the machine then remove the four 4 screws securing the console to the console upright tube Unplug and re plug the cable into the console to ensure it is a good connection Figure 2 2 Check and secure the upper wire harness connections at the base of the upright post Figure 2 3 Check and secure the lower wire harness connections at the controller board and the ...

Page 14: ...Figure 2 5 Q45 2 2 Figure 2 6 ...

Page 15: ... 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 brake The brake adjuster must be located at the top of its slot when the machine is set to level 1 Use a flash...

Page 16: ...Figure 2 7 Q45 2 2 Figure 2 8 Nylock nut Clevis bushing Figure 2 9 ...

Page 17: ...ure 2 7 shows the locations of the pivot bolts Pedal arm top of adjustable link assembly is assembled improperly the two actuator bushings and nylock nuts may be improperly seated into the pedal arm clevis Loosen the two nylock nuts on the pedal arm at the top of the adjustable link assembly Figure 2 8 Re tighten the pedal arm bolt Make sure it is properly seated and snug but not overly tight Clev...

Page 18: ...Q45 2 2 Figure 2 11 Figure 2 12 Figure 2 10 ...

Page 19: ...ive belt tension is too high With your fingers twist the drive belt between the belt tensioner and the drive pulley it should twist approximately 90º To loosen the belt locate the double nut setup on the adjuster rod Figure 2 11 Loosen the first one back off the other one full turn then re tighten the first Recheck the drive belt tension as above making sure that slippage does not occur between th...

Page 20: ...Q45 2 2 Figure 2 13 Figure 2 14 Figure 2 16 Figure 2 15 ...

Page 21: ... Faulty wiring cable assembly Use the Level keys to increase and decrease the resistance If the servomotor does not respond and Err1 is not displayed on the console indicating a servomotor issue replace the cable assembly according to the directions in Section III Plug the servomotor speed sensor and power jack cable into the new wiring harness and verify that all functions are working Faulty serv...

Page 22: ...Q45 2 2 Figure 2 20 Figure 2 19 Figure 2 17 Figure 2 18 ...

Page 23: ...n Figure 2 19 Power on the machine then push the Level button to move the resistance through levels 1 to 20 and then push the 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 20 If it is not contact Octane Fitness Customer Service for further assistance in making...

Page 24: ...Figure 2 22 Q45 2 3 Figure 2 21 Speed Speed Sensors Sensors ...

Page 25: ... 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 missing contact Octane Fitness Customer Service for assistance Faulty console speed sensors or upper wire harness If the speed sensors and magnet are properly installed positioned and aligned you will need t...

Page 26: ...Q45 2 3 Figure 2 27 Figure 2 25 Figure 2 23 Figure 2 24 ...

Page 27: ... reverse their positions plugging the black plug into the white socket and the white plug into the black socket Figure 2 25 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 a...

Page 28: ...Figure 2 28 Figure 2 27 Figure 2 29 ...

Page 29: ...ition on the frame Note If Err11 is displayed or if all the LEDs are lit the new chip is seated in its socket upside down and you will need to remove it and reinsert it in the socket correctly If the stride motor left or right causing the error moves up one turn upon reset instead of returning down to the default position the controller board must be replaced following the directions in Section II...

Page 30: ...Figure 2 30 Figure 2 32 Figure 2 31 ...

Page 31: ...0 If it is connected disconnect it and plug in a new limit switch and test If the error is resolved complete the installation of the new limit switch according to the directions in Section III Err11 is displayed on the console indicating a communications issue Faulty wiring harness Unplug the machine Unplug and re plug all connections to the controller board and servomotor Figure 2 31 older units ...

Page 32: ... WARNING LINKAGES PRESENT NUMEROUS PINCH POINTS USE CAUTION TO AVOID INJURY Q45 2 4 Nylock nut Clevis bushing Figure 2 33 Figure 2 34 Figure 2 35 ...

Page 33: ...ed to replace the pedal arm or rails according to the directions in Section III Machine produces squeaking noise from within shrouds when in use Actuator nut is too big or broken Remove the nylock nut and inspect the actuator nut Figures 2 33 and 2 34 if it is broken replace it according to the directions in Section III Use while lithium grease to lubricate the actuator nut posts where the clevis ...

Page 34: ...eck and tighten the four socket head screws 17mm attaching the stability links to the frame Figure 2 36 Try the machine at slow and fast pace forward and backward to see if the noise is still present If the noise is still present check the 2 pivot links and the adjustable link assembly for looseness and side to side motion A slight side to side motion is normal at the rocker arm and 2 pivot link c...

Page 35: ...of motion This will help you determine if there is anything hitting and or clunking such as the wire harness rubbing against another part Check to make sure all pivot joints on both sides of the machine are tight Figure 2 36 Check and tighten the four socket head screws attaching the stability links to the frame and the four bolts attaching the crank shaft plate to the large drive pulley Figure 2 ...

Page 36: ...gure 2 38 Figure 2 39 Actuator shaft retaining bracket Motor spindle orient as shown Remove screws to free motor and actuator shaft retaining bracket Actuator motor Actuator shaft Thrust bearing assembly Actuator nut not shown Figure 2 40 ...

Page 37: ...or nut posts where the clevis bushing slides Move the clevis bushing to ensure that it slides freely Replace and tighten the nylock nut Actuator shaft threads are not properly lubricated Apply white lithium grease to the threaded actuator shaft Figure 2 39 including the top middle and just below the retaining bracket Broken actuator shaft retaining bracket Inspect the black retaining bracket to se...

Page 38: ...Q45 2 5 Figure 2 41 ...

Page 39: ...elevisions personal stereos cordless or wireless telephones stop watches wireless computers Internet PDAs or other exercise machines may interfere with the heart rate transmission Turn off other devices to isolate and eliminate the interference Erratic or illogical heart rate reading from the handgrips too high or too low Q45ce only Faulty handgrips The digital contact heart rate sensors on the st...

Page 40: ...Q45 2 5 Figure 2 42 ...

Page 41: ... 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: ...Q45 3 1 Figure 3 1 ...

Page 43: ... 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 6 Install the washer and button head cap screw and tighten with the 6mm hex key 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 ...

Page 44: ...Q45 3 1 Notes ...

Page 45: ...actuator nylock nuts that hold the pedal arm in place remove the two bushings and push the pedal arm down the rails so it is out of the way Figure 3 2 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 tighte...

Page 46: ...Q45 3 2 Notes ...

Page 47: ...een the rails and rear support 8 Insert and tighten the rear bolts using the 5mm hex wrench 9 Insert and tighten the screws at the front of the rail assembly using the 8mm hex wrench 10 Wipe down the chrome rails with a dry rag You may apply a thin coat of white lithium grease to all four rails Do not use WD 40 or a silicone spray With a clean rag or paper towel work the grease down the rails cove...

Page 48: ...Figure 3 7 Q45 3 4 Figure 3 6 Stability Link 18mm Bolt ...

Page 49: ...er bolt and lay the stride motor down on the ground 6 Using an 18mm wrench loosen the bolt connecting the stability link to the stride motor assembly and remove the stride motor from the stability link 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 ...

Page 50: ...orient as shown Remove screws to free motor and actuator shaft retaining bracket Actuator motor Actuator shaft Thrust bearing assembly Actuator nut not shown Figure 3 8 Caution thrust bearing and washer may separate during removal Actuator shaft Figure 3 9 ...

Page 51: ...he 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 ...

Page 52: ...ndle orient as shown Remove screws to free motor and actuator shaft retaining bracket Actuator motor Actuator shaft Thrust bearing assembly Actuator nut not shown Figure 3 11 Caution thrust bearing and washer may separate during removal Actuator shaft Figure 3 12 ...

Page 53: ... 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...

Page 54: ...Q45 3 6 Notes ...

Page 55: ... 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 ...

Page 56: ...Q45 3 8 Figure 3 14 Figure 3 15 ...

Page 57: ...foot pedals and remove it from the unit 6 Slide the new brake into its slot and push it toward the front of the machine 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 Adjus...

Page 58: ...Figure 3 16 Figure 3 17 Figure 3 18 Q45 3 9 ...

Page 59: ...the unit 6 Press the Level button to move the resistance through 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 to 10 o clock Figure 3 17 If it is not contact Octane Fitness Customer service for further assistance in making t...

Page 60: ...Q45 3 9 Notes ...

Page 61: ...l 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 pla...

Page 62: ...Q45 3 11 Figure 3 21 Figure 3 20 Figure 3 22 Older units Newer units ...

Page 63: ... the cable assembly and thread the harness up through the mast Figure 3 21 9 Plug the new upper wire harness into the console listening for the click to ensure a good connection 10 Secure the console to the upright mast with the four Phillips screws 11 If required plug a new lower wire harness at the top of the frame where it connects with the upper harness allowing the old lower wire harness to d...

Page 64: ...Q45 3 12 Figure 3 24 Figure 3 23 ...

Page 65: ...g an old style non threaded non hex collar shaft do not install the second washer 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 res...

Page 66: ...Figure 3 26 Figure 3 25 Speed Sensors Q45 3 13 ...

Page 67: ...w 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 tes...

Page 68: ...Notes Q45 3 13 ...

Page 69: ...ng 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 ...

Page 70: ...Q45 3 15 Figure 3 29 Figure 3 28 ...

Page 71: ...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 handg...

Page 72: ...Q45 3 15 Notes ...

Page 73: ...pright 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 ...

Page 74: ...Q45 3 17 Figure 3 31 Figure 3 32 Figure 3 33 ...

Page 75: ... 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 ...

Page 76: ...Q45 3 18 Figure 3 34 Figure 3 35 Figure 3 36 ...

Page 77: ...ts slot on the console board Figure 3 35 9 Align the semi circle mark on the new software micro controller Figure 3 36 with the semi circle mark by the circuit board slot and gently press the micro controller prongs into the slot holes Use caution as the micro controller fits snugly and the prongs bend easily 10 Flip the console board back over making sure that the LEDs are aligned properly in the...

Page 78: ...Q45 3 19 Figure 3 37 Figure 3 38 ...

Page 79: ... remove the tape markings 6 Test for proper functioning 7 Replace the left shroud and reposition the top shroud secure with shroud screws 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 fr...

Page 80: ...Q45 3 20 Figure 3 39 Figure 3 41 Figure 3 40 ...

Page 81: ...sembly from the motor Figure 3 39 4 Using a Phillips screwdriver remove the four 4 screws securing the limit switch unit to the motor assembly 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 Re...

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Page 83: ...SECTION IV Supporting Documentation Q45 Q45e Q45ce Assembly Instructions Q45 Q45e Q45ce Operations Manual ...