Cozzia 16028 Manual

16028 Maintenance Service Manual
MODEL: 16028
By Customer Service Department

CATALOG
1: Precautions for inspection and repair
2: Massage chair auto-check list
3: Common Troubles and Maintenance Methods list.
4: Tools List
5-1:Guidance of disassemble the backrest pad assy
5-2: Guidance of disassemble the backrest
5-3: Guidance of detach front cover & rear cover of backrest.
5-4: Guidance of detach up & down limit sensor
5-5: Guidance of detach the kneading motor.
5-6: Guidance of change the counting sensor of rolling motor
5-7: Guidance of disassemble the massage mechanism
5-8: Guidance of change rolling motor unit.
5-9:Guidance of service the seat pad assy
5-10:Guidance of disassemble the side board.
5-11: Guidance of disassemble main PCB
5-12: Guidance of disassemble the Transformer
5-13: Guidance of disassemble the Air valve.
5-14: Guidance of disassemble Inflator Pump
5-15: Guidance of disassemble the remote control
5-16: Guidance of disassemble footrest actuator and backrest actuator
5-17: Guidance of change the lower side board
5-18: Guidance of service the footrest.
6: Main PCB connecter diagram.

1. Precautions for inspection and repair
Inspection
Verify that the power cord is tightly connected on the machine.
Be careful to avoid electric shock.
Repair
Power off the supply before repair work begins.
Keep things tidy and in order during repair work.
When changing more than one part, identify the parts that are damaged and reuse the
serviceable parts.
During the dismantling or assembling process, do not damage other parts and PCB.
Be on the alert for loose or disconnected connectors during repair.
Do not leave any screws or other foreign objects in the unit after it is assembled.
Carry out test operation of the machine after the repair work is done.
It is preferable to perform the repair work on a carpet to prevent scratching or dirtying the
unit.
Clean the workplace after repair work is completed.

2:massage chair auto-check list
ON/OFF: KNEAD + TAP + POWER(buttons on the controler), press and hold the three buttons in two
senconds to turn on the automatic analysis system model.
After activating the "auto-checking model", the display screen of the controller keeps flashing; if
there is something wrong with the chair, the time area will show you the exact code of the
malfunction, meanwhile the buffer will make noise.
Code
Phenomenon
Malfunction description
Solutions
Remarks
01
remote control
tested any key
pressed more
than 25 seconds
1.one of the KEY has been
blocked.
1.check the key of the
remote control
turn on the
chair
02
remote control did
not connected
1.the remote control wire
is broken or the remote
control wire is
disconnected
1.reconnecte the
remote control wire or
change the remote
control wire.
turn on the
chair
03
backrest signal is
abnormity
1.backrest wire(black) is
not well connected.
2.up & down limit sensor
is broken
1.check whether the
backrest wire(black) is
well connected
2.change the up &
down limit sensor
turn on the
chair
04
backrest signal is
abnormity
1.backrest wire(black) is
not well connected.
2.the counting sensor of
the rolling motor is broken
1.check whether the
backrest wire(black) is
well connected
2.change the counting
sensor of the rolling
motor
activate the
Rolling
function
07
tested more than 2
wideth inspection
signal
1.wideth inspection board
is broken
2.wideth inspection wire is
not well connected
1.change wideth
inspection board
2.change backrest
wires.(black)
activate the
Rolling
function
08
more than 5
seconds did not
tested the wide
signal
1.wideth inspection board
is broken
2.the wire connect to the
wideth inspection board is
disconnected
3.kneading motor is
1.change wideth
inspection board
2.change backrest
wires.(black and gray)
3.change kneading
motor
activate
auto-check
model

broken or kneading belt is
lost
09
more than 5
seconds did not
tested the middle
signal
1.wideth inspection board
is broken
2.the wire connect to the
wideth inspection board is
disconnected
3.kneading motor is
broken or kneading belt is
lost
1.change wideth
inspection board
2.change backrest
wires.(black and gray)
3.change kneading
motor
activate
auto-check
model
10
more than 5
seconds did not
tested the narrow
signal
1.wideth inspection board
is broken
2.the wire connect to the
wideth inspection board is
disconnected
3.kneading motor is
broken or kneading belt is
lost
1.change wideth
inspection board
2.change backrest
wires.(black and gray)
3.change kneading
motor
activate
auto-check
model
12
when not
kneading but the
wideth inspection
signal still can be
tested
1.Main PCB is broken
1.Change PCB
activate
auto-check
model
13
tested signals
from up & down
limit sensor at the
same time.
1.up & down limit sensor
are broken
2.backrest wire(black) is
disconnected.
1.Change up & down
limit sensor
2.check whether the
backrest wire(black)is
well connected
activate
auto-check
model
14
more than 40s
didn't tested the
signal from the up
limit sensor
1.upper limit sensor is
broken.
2.backrest wires( black
and gray) are
disconnected
3.rolling motor is broken
or rolling motor wire
disconnected
1.change upper limit
sensor
2.check whether the
backrest wire(black) is
well connected.
3.change rolling motor
or rolling motor wire.
activate
auto-check
model

15
height counting
signal error
1.the counting sensor of
the rolling motor is broken
2.backrest wire(black) is
disconnected
1.change the counting
sensor of the rolling
motor.
2.check whether the
backrest wire(black) is
well connected.
activate
auto-check
model
16
can't test signal
from foot rest
recline actuator
1.down limit sensor is
broken
1.change down limit
sensor
2.check whether the
backrest wire(black) is
well connected.
3.change rolling motor
activate
auto-check
model
17
more than 40s
didn't tested the
signal from the up
limit sensor
1.down limit sensor is
broken
2.the backrest wire(black)
is disconnected.
3.rolling motor is broken
or disconnected
1.change down limit
sensor
2.check whether the
backrest wire(black) is
well connected.
3.change rolling motor
activate
auto-check
model
18
after tested signal
from down limit
sensor then
tested signal from
up limit sensor in
2 seconds.
1.upper limit sensor is
broken.
1.change upper limit
sensor
activate
auto-check
model
25
when start the
backrest recline
actuator, there is
no counting signal
for more than 2.5
seconds
1.backrest recline actuator
is broken
2.backrest recline actuator
wire is disconnected
3.the signal wire of the
backrest recline wire is
disconnected
1.change backrest
recline actuator
2.check whether the
backrest recline
actuator motor wire is
well connected.
3.check whether the
signal wire of the
backrest recline
actuator is well
connected
activate
auto-check
model

3: Common Troubles and Maintenance Methods are listed as following:
Serial
NO.
Phenomenon
Description
Maintenance Methods
01
No Function
When Starting.
The LCD isn’t illuminating:
①Fuse melts (in the Power Source Box or on
the transformer wire).
②Power supply circuit poorly connected.
③main PCB fails.
①Replace Fuse.
②Replace Power Box.
③Replace main PCB.
02
No function
when starting.
The LCD is illuminating：
①Mechanical switch fails or it’s wire is
opened.
②Up or Down Stroke Photo-electricity fails.
③Main PCB fails.
④Kneading is on without pressing any key
when starting and no response by pressing
other keys.
①Replace mechanical switch or it's
wire.
②Replace Stroke Photo-
electricity.
③Replace the main PCB.
④Width Inspection Board of PCB
fails, replace it.
03
No Width
switchover.
①The terminals of Width Inspection on main
PCB and wires are poorly connected.
②The terminals of Width Inspection on
massage mechanical and wires are poorly
connected.
③Width Inspection fails.
④Main PCB fails.
①&②Plug the terminal securely or
replace the wires.
③Replace Width Inspection.
④Replace the main PCB.

04
No Partial
Function.
①Height Inspection Terminal or wire poorly
contacts.
②Height Counting Subassembly fails.
①Plug the terminal securely or
replace the wires.
②Replace Height Counting Sub
-assembly.
05
No Rolling.
①Terminal or Wire Poorly Contacts.
②Down-stroke Photo-electricity
Subassembly Fails.
③Up-stroke Photo-electricity
Subassembly Fails.
④Rolling Motor Fails.
⑤Main PCB Fails.
①Plug the terminal securely or
replace the wires.
②Replace Down-Stroke Sub-
assembly.
③Replace Up-Stroke Sub-
assembly.
④Replace Rolling Motor.
⑤Replace main PCB.
06
No kneading.
①The terminals on main PCB and wires are
poorly connected.
②Kneading motor fails.
③Main PCB fails.
①Plug the terminal securely or
replace the wires.
②Replace the kneading motor.
③Replace main PCB.
07
No tapping.
①The terminals on main PCB and wires are
poorly connected.
②Tapping motor fails.
③Main PCB fails.
①Plug the terminal securely.
②Replace the tapping motor.
③Replace main PCB.

08
No response
when pressing
the keys on the
remote
controller.
①The terminals and wires are poorly
connected.
②The PCB in the remote controller fails.
①Plug the terminal securely or
replace the wires.
②Replace the remote controller.
09
Back rest
cannot be
reclined or
raised
①The terminals of reclining actuator and
wires are poorly connected.
②The reclining actuator fails.
③Main PCB fails.
①Plug the terminal securely.
②Replace reclining actuator.
③Replace main PCB.
10
Foot rest
cannot be
raised or
lowered.
①The terminals of foot rest actuator and
wires are poorly connected.
②The foot rest actuator fails.
③Main PCB fails.
①Plug the terminal securely.
②Replace foot rest actuator.
③Replace main PCB.
11
No vibration by
the motors in
the seat-pad.
①Print motors fail.
②The terminals and wires are poorly
connected or the wires fail.
③Main PCB fails.
①Replace the print motor.
②Plug the terminal securely or
replace the wires.
③Replace main PCB.
12
No gas charging
in the seat-pad.
①The terminal of the snuffle valves and
wires are poorly connected.
②The snuffle valves fail.
③The inflator pump fails.
④Main PCB fails.
①Plug the terminal securely.
②Replace the snuffle valves.
③Replace the inflator pump.
④Replace main PCB.

13
No gas charging
in the foot rest.
①The terminal of the snuffle valves and
wires are poorly connected.
②The snuffle valves fail.
③The inflator pump fails.
④Main PCB fails.
①Plug the terminal securely.
②Replace the snuffle valves.
③Replace the inflator pump.
④Replace main PCB.

4: Tools List Tools required
Screwdriver
size 1,2,3
Diagonal cutter and
long nose pliers
Soldering Kit
Spanner tools Kit
Test pen
Allen Key set
Ratchet Tools Set
Blower
Electric Driver
electrical
adhesive tape
Cable Ties
WIRE
CONECTORS

5-1:Guidance of disassemble the backrest pad assy.
A：Unzip the zipper fixing big pillow and the backrest pad
B：Then discontent the hose for small pillow，remove big pillow and small pillow.
(As the picture below)
Locate the zipper
Unzip the zipper
Locate the hose
Remove the pillow
Remove the pillow

C:Take down the cover for small pillow
D：Unzip the zipper of small pillow and take down the leather
E: Push the paper up，unfasten the belt，discontent the hose，then we can change the air bag.
Take down the cover
Unzip the zipper
The leather has been taken
down
Push the paper up
Unfasten the belt

F: Unzip the zipper between backrest pad and backrest. (As the pictures below show.)
G: Find the other zipper between backrest pad and seat pad. Then unzip it. (As the pictures
below show.)
H：Put the pad on the seat，then discontent the hose and the terminal of the heater
Discontent the hose
Unzip the zipper
Locate the zipper
Locate the zipper
Unzip the zipper
Put the pad on the seat
Locate the 3 hose of backrest pad

I: Take off the backrest pad.
J:At the middle of the rear of the backrest pad, we can find a sponge assy inside. (As the
pictures below show)
Backrest pad has been taken off.
Attention the colour
Discontent the terminal of the heater
Locate the sponge
Pull the sponge assy out.
The sponge assy has been taken out

K:Unzip the zipper，discontent the hose，then change the air bag . And discontent the terminal
of the heater，then change the heater
5-2: Guidance of disassemble the backrest.
A: Unzip the zipper between backrest and backrest pad. Then detach the Backrest pad Assy
from the backrest Assy and rest it on the Seat cushion Assy . ( As picture below show.)
Locate the zipper
discontent the terminal of the
heater，then change the heater
Pull out the air bag
Discontent the hose then change air bag
Unzip the zipper
Put the pad on the seat

B: There is a hook at the bottom of the backrest. Pull the hook up then push the backrest
forward. And then lay the backrest above the seat pad assy. ( As pictures below show.)
D: Disconnect backrest wire connecters. ( One is gray, one is black)
Pull the hook as the yellow
arrow show!
Locate the hook
Pull the hook up then push the
backrest forward.
The backrest has been lay
above the seat pad assy.
Locate backrest wire connecters.
Backrest wire has been taken down

E: At the front of the backrest actuator there is a bolt. The bolt fixed by a bin. Use pliers take
off the bin first, Then remove the bolt. ( As pictures below show.)
E: Hold the backrest vertically and pull it up, then we can take off the backrest. ( As pictures
below show.)
5-3: Guidance of detach front cover & rear cover of backrest.
A: Take down the backrest.（refer to 5-2: Guidance of disassemble the backrest）
B: Unzip the 2 zipper，then we can see the screws fixing the rear cover of backrest
Locate the pin
The pin has been taken out
Hold the backrest vertically and pull
it up
The backrest has been taken down
Hold the backrest vertically and pull
it up
The zipper has been unzipped

C: Slacken and remove the screws which fixing the rear cover of backrest. Then take off the
rear cover.
D: Slacken and remove the four screws which fixing front cover to the backrest frame. Then we
can take off the front cover of backrest. ( As pictures below show.)
E: There are two zippers attach the fabric the front cover of backrest. Unzip these two zippers
then we can detach the fabric.
Front cover of backrest
has been detached.
Locate screws.
The rear cover has been taken off
4 screws fixing front cover
Slack and remove the 4
screws fixing front cover
Unzip the zippers attach
the fabric
The zippers attach the
fabric

5-4: Guidance of detach up & down limit sensor.
A: Detach the rear cover of backrest. Then we can find up & down limit sensor. ( Refer to
Guidance of detach rear cover of backrest.)
B: Cut cable ties which fixing the limit sensor wire to the frame.
Locate up limit sensor.
Locate down limit sensor.
Locate cable tie.
Use diagonal cutter get
ride of the cable tie.
The fabric has been detached.