Osaki OS4000 User manual

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OS4000Maintenance Service Manual
MODEL OS4000
Voltagespecification 110-120V
ByCustomerServiceDepartment
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TableofContents
ISpecifications .3
II. ..Appearance ofthechair .4
III . Nameandfunctions ofcomponents (remotecontroller) ...5
IV ..Malfunctioncatalog 6~8
VTroubleshootingflowchart ..9~13
VI Maintenance ofthebackrest 14~19
VII ..Maintenance oftheseatpart .20~25
VIII .Maintenance ofthefootrest ..26~29
Model OS4000
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I. Specifications
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II.Appearance ofthechair
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III.Nameand functionsofcomponents(remotecontroller)
Maincontrolbuttons
Auto-programbuttons
Angleadjustmentbutton
Lengthautoadjustment
buttonsforlegrest
Manualback
massage programs
The adjustment button
forback body
Remotecontroller
LCD
Sensorreceiver
Back speed/Air
intensity
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IV. Malfunctioncatalog
CommonTroubles andMaintenance Methods arelistedas following:
Serial
NO. Phenomenon Description Maintenance Methods Referto
01 No Function
WhenStarting.
The LCD isn tilluminating:
①Fuse(s)burnout (the one
IsinthePowerSourceBoxand
the otherone on the mainPCB).
②Powersupplycircuit poorly
connected.
③EMCBoardfails.
④mainPCBfails.
①ReplaceFuse(s).
②Replacethe powersupply
cord.
③ReplaceEMCBoard.
④ReplacemainPCB.
①Page 25/20
②(Ellipsis)
③&④
Page 23-24/18
02 No function
whenstarting.
The LCD isilluminating
①The Up orDownStroke
Photo-electricityfails.
MainPCBfails.
②Kneading ison without
pressing anykeywhen
starting and no response
bypressing otherkeys.
①Replacethe Up orDown
StrokePhoto-electricity.
②Replacethe mainPCB.
③WidthInspection Boardof
PCBfails, replaceit.
①Page 19/8
②Page
23-24/18
③Page 18/7.1
03 No Width
switchover.
①The terminalsofWidth
Inspection on mainPCB
and wiresarepoorly
connected.
②The terminalsofWidth
Inspection on massage
mechanical and wiresare
poorlyconnected.
③WidthInspection fails.
④MainPCBfails.
①&②Plug the terminal
securelyorreplacethe wires.
③ReplaceWidthInspection.
④Replacethe mainPCB.
①&②&③
Page 18/7.1
④Page
23-24/18
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04 No Rolling.
①TerminalorWirePoorly
Contacts.
②Down-strokePhoto-
ElectricitySubassemblyFails.
③Up-strokePhoto-electricity
SubassemblyFails.
④Rolling MotorFails.
⑤MainPCBFails.
①Plug the terminalsecurely
orreplacethe wires.
②ReplaceDown-Stroke
Subassembly.
③ReplaceUp-StrokeSub-
assembly.
④ReplaceRolling Motor.
⑤ReplacemainPCB.
①Page
23-24/18
②&③
Page 19/8
④Page 17/6.2
⑤Page
23-24/18
05
No kneading.
①The terminalson mainPCB
and wiresarepoorly
connected.
②Kneading motorfails.
③MainPCBfails.
①Plug the terminalsecurely
orreplacethe wires.
②Replacethe kneading
motor.
③ReplacemainPCB.
①&③
Page 23-24/18
②Page
16-17/6.1
06 No tapping.
①The terminalson main
PCBand wiresarepoorly
connected.
②Tapping motorfails.
③MainPCBfails.
①Plug the terminalsecurely.
②Replacethe tapping motor.
③ReplacemainPCB.
①&③
Page 23-24/18
②Page 18/6.3
07
No response
whenpressing
the keyson the
remote
controller.
①The terminalsand wiresare
poorlyconnected.
②The PCBinthe remote
controllerfails.
①Plug the terminalsecurely
orreplacethe wires.
②Replacethe remote
controller.
①Page 20/11
②Page 20/10
08
Back rest cannot
be reclined or
raised
①The terminalsof reclining
actuatorand wiresarepoorly
connected.
②The reclining actuatorfails.
③MainPCBfails.
①Plug the terminalsecurely.
②Replacereclining actuator.
③ReplacemainPCB.
①&②Page
22/15
②Page 23-24
/18
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09
Foot rest cannot
be raised or
lowered.
①The terminalsoffootrest
actuatorand wiresare
poorlyconnected.
②The footrest actuatorfails.
③MainPCBfails.
①Plug the terminalsecurely.
②Replacefootrest actuator.
③ReplacemainPCB.
①&②Page
22-23/16
②Page 23-24
/18
10 No gascharging
intheseat-pad.
①The terminalof the snuffle
valvesand wiresarepoorly
connected.
②The snufflevalvesfail.
③The inflatorpumpfails.
④MainPCBfails.
①Plug the terminalsecurely.
②Replacethe snufflevalves.
③Replacethe inflatorpump.
④ReplacemainPCB.
①&②&③
Page24/19
④Page
23-24/18
11 No gascharging
inthefootrest.
①The terminalofthe snuffle
valvesand wiresarepoorly
connected.
②The snufflevalvesfail.
③The inflatorpumpfails.
④MainPCBfails.
①Plug the terminalsecurely.
②Replacethe snufflevalves.
③Replacethe inflatorpump.
④ReplacemainPCB.
①&②&③
Page24/19
④Page
23-24/18
12
No gascharging
intheveil
forbackrest
①The terminalof the snuffle
valvesand wiresarepoorly
connected
②The snufflevalvesfail
③The inflatorpumpfails
④MainPCBfails
①Plug the terminalwell
②Replacethe snufflevalves
③Replacethe inflatorpump
④ReplacemainPCB
①&②&③
Page24/19
④Page
23-24/18
13
No extending
Orshrinking
of the calves-rest
①The terminalsand wiresare
poorlyconnected
②The output voltage isnot
24VAC
③The limit sensorfail
④Motorfails
①Plug the terminalwell
②Replacethe mainPCB
③Replacethe limitsensor
④Replacethe motor
①Page 25/22
②Page
23-24/18
③Page 27/24
④Page 26~27
/23
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V.Troubleshootingflowchart
Notesforrepairingchairorreplacingparts:
①Makesurethe powerisOFF beforetearingdownthe wires,movingterminalsorreplacingparts.
②Semiconductors(suchasICandothers)areveryeasytobedamaged bystatic,sowhen youtouch
the PCB,pleasemakesureyourbodyisgrounding(bywearingagirdingstaticring),oryourhandsare
touchingwithearthinggrip(householdelectricalappliancesputtingtoearth,suchasfridges,washers
and soon)toreleaseall staticofthe body.
1. Nofunctionwhenstarting.
NY
YN
Y
否
是N
N
Y
YY
N
N
N
Y
否
N
IstheLCD
illuminating? Isthefusemelted?
Replacefuse.
(Page 25/20)
AretheterminalsofUp
and DownStroke
Subassemblyconnected
securely?
Isthepowercord
open-circuit?
TheswitchesofUpandDown
StrokeSubassemblyfail ornot?
TheEMCBoard
failsornot?
Replace thepower
supplycord.
Replace it. (Page
23-24/18)
Connect
securely.
Replace them.
(Page 19/8)
Iskneadingonwithoutpressingany
keywhenstarting?
WidthInspection
Boardfailsornot?
Replace mainPCB.
(Page 23-24/18)
Replace Width
InspectionBoard.
(Page 18/7.1)
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2. Nowidthswitchover.
N
Y
Y
N
3. Nofunction fixed-spotorpartial）
N
Y
4. Norolling
N
YY
NY
NY
N
AretheterminalsofWidthInspectionBoardandmain
PCB connectedsecurely? Connectsecurely.
WidthInspectionBoardfailsornot? Replace it.
(Page 18/7.1)
Replace mainPCB.
(Page 23-24/18)
AretheterminalsofmainPCB connected
securely?
Connectsecurely.
Replace MainPCB.
(Page 23-24/18)
Aretheterminalsofrollingmotorwireand
mainPCB connectedsecurely? Connectsecurely
Rollingmotorfailsornot
Replace themotor
(Page17/6.2)
UpstrokePhoto-electricitysubassemblyfailsornot Replace it
(Page
19
/
8
)
DownstrokePhoto-electricitysubassemblyfailsornot
Replace it
(Page19/8)
Replace mainPCB
(Page 23-24/18)
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5. Nokneading
N
Y
Y
N
Y
N
6. Notapping.
N
Y
Y
N
7. Remotecontrollerdoesn twork.
N
YY
N
Aretheterminalsofkneadingmotorwireandmain
PCB connectedsecurely? Connectsecurely.
Kneadingmotorfailsornot?
WidthInspectionBoardfailsornot?
Replace mainPCB.
(Page 23-24/18)
Replace themotor.
(Page 16/6.1)
Replace it.
(Page 18/7.1)
Aretheterminalsoftappingmotorwireandmain
PCB connectedsecurely? Connectsecurely.
Tappingmotorfailsornot? Replace themotor.
(Page 18/6.3)
Replace mainPCB.
(Page 23-24/18)
Aretheterminalsofremotecontrollerwireand
mainPCB connectedsecurely? Connectsecurely.
Theconductiverubberfailsornot? Replace it.
(Page 20/11)
Replace theremotecontroller.
(Page 20/10)
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8.Actuatordoesn twork.
NN
YY
YY
NN
9. Nogas charging.
NN
YY
YY
NN
NN
YY
YY
NN
Aretheterminalsof
reclining actuatorand main
PCB connectedsecurely?
Connect
securely.
Aretheterminalsoffootrest
actuatorandmainPCB
connectedsecurely?
Connect
securely.
Therecliningactuator
failsornot? Replace it.
(Page 22/15)
Thefootrestactuator
failsornot?
Replace it.
(Page 22-23/16)
Replace mainPCB.
(Page 23-24/18)
Aretheterminalsofsnuffle
valveforbagsintheseat
padandmainPCB
connectedsecurely?
Snufflevalvefails
ornot?
Aretheterminalsofsnuffle
valveforbagsintheFoot
RestandmainPCB
connectedsecurely?
Snufflevalvefailsornot?
Connect
securely. Connect
securely.
Aretheterminalsof
inflatorpumpandmain
PCB connectedsecurely?
Replaceit.
(Page24/19) Replace it.
(Page24/19)
Replace it.
(Page26/19) Replace it. (Page24/19)
Aretheterminalsofinflator
pumpandmainPCB connected
securely?
Connect
securely.
Connect
securely.
Inflatorpump failsornot?
Inflatorpump failsornot?
Replace mainPCB.
(Page 23-24/18)
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10. Nogas chargingintheoutercoatingofbackrest
N
Y
Y
N
N
Y
Y
N
12. Noextendingorshrinkingofthecalves-rest
N
Y
N
Y
Y
N
N
Y
N
Commontroubleaboutelectriccontroland processingmethodsofOS4000
arementionedabove.Itis
forindicationonly.
Theterminalofsnufflevalvesconnected
well ornot?
Thesnufflevalves fail ornot?
Plugterminalswell
Theterminaloftheinflatorpump
connectedwellornot?
Replace thesnufflevalves
(Page24/19)
Plugterminalswell
Replace mainPCB
(Page 23-24/18)
Replace theinflatorpump
(Page24/19)
Theinflatorpumpfailsornot?
Theterminalofthecalves-rest
connected well or not?
Thewirewithterminalconnected
well ornot?
Plugterminalswell
Thelimitsensorfail ornot?
Plugthewirewithterminalswell
Replace mainPCB
(Page 23-24/18)
Replace thelimit sensor
(Page 27/24)
Theterminalofthemotorconnected
well ornot? Plugterminalswell
Motorofthecalves-restfails Replace themotor
(Page 26-27/23)
Y
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VI. Maintenance ofthebackrest
1. Disassemblyand replacementofbackpad
①Find the zipperon the topofthe back rest. Unzipit, then the back pad can beremoved.
②Therearetwoairhosesat thebottomofthe back pad, pull out the connectorsifareplacement needed.
③Thereisazipperatthe bottomofthe back pad.Unzipitand lift the sponge,then youcan seetheair
bagsthere.
④Pull out theconnectorsofthe hoses,thenyou canreplacethe airbag(s)ifneeded.
2. Disassemblyand replacementofthebackrest
Ifthe completebackrest isbroken and needtobereplaced, pleaseconsult thestepsasbelow.
①Find the “stopper”underthe backrest andpress it , thenyoucan foldbackrest on seat part
②Find the wireplugsand pull out them.
⑤Disconnect the airhoseofthe backrest.
③UnattachtheconnectingrodandtheUstayforkof the recliningactuatorwithaflatheadrivet, andpull
out thesplit pin.
④Lift the backrest at 90 degrees, then takeitawayfromthe chair.
The hosesof the backpad
Pulloutthe hoses
The zipperon the top ofthe backrest
The zipperatthe bottomof the backrest
Note:Insertthewireplugsback
blacktoblackand graytogray,
otherwisedamagetothechair
mayresult
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3. Replacementofclothofthefrontcover
①Unfasten the zipperofthe back pad, and laythe back pad on theseat pad.
②Youcan find thezipperofthe clothat theleft side. Unzipit and replacethe clothifneeded.
Laythe backpad on the seat part
Unfasten the zipperzip
A.
Connectingrod(onthebackrest)
B. Ustayforkofrecliningactuator(ontheseat)
C. Flatheadrivet
D. Split pin
Liftthebackrest
at90 degrees.
Disconnecttheairhoseofthebackrest
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4. Disassemblyand replacementoftherearcover
Ifyou find anycracks on therearcover, you canproceed asfollow:
①Unfasten the zippersofthe outerclothoftherearcover.
②Find 4piecesofscrewsfixingthe rearcover.
③Removethe screwswithaplusscrewdriver.
④Then the rearcovercan beremoved.
⑤Ifitsdamaged, anewone shouldbereplaced.
Attention: Takecarenot todamagethe rearcoverto
avoidbad externalappearance. Proceed inthe reverse
orderofdisassemblywhen assemblingthe rearcover.
Tool: aplusscrewdriver
5. Disassemblyand replacementofthefrontcoverofthebackrest
Ifyou find anycracks on thefront coveroranyripsinthe insidecloth,you canproceed asfollow:
①Afterdisassemblethe rearcover,youcanfind 6piecesofscrewsfasteningthe frontcovertoback frame.
②Removethe screwswithaplusscrewdriver, then the front covercan beremoved.
③Proceed inthe reverseorderofaboveoperation ifreplacement needed.
Attention: Thereareblocks between the front coverand back frame.
Tool: aplusscrewdriver
6. Replacementofthekneading,tappingandrollingmotors
Attention: The voltageofthismassagechairishigh and the motorsarerotatinginhighspeed,somake
surethe powerisOFF beforedisassembly. Forsafety,youshouldremoveplugfromoutlet.
6.1Kneadingmotor DC -24V）
①Disassemblethe rearcoverofthe back rest,
and find thebelt at topofthe massagemechanism,
then loosen the belt.
②Find the wireofkneadingmotor, and cut
the cabletiestighteningthewirewithwirecutters.
③Removethe close-end wireconnectorscoveringthe wireswithKneading motor
Screwssecuring the rearcover
Screwsfastening the front
covertothe back frame(6
PCS)
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nipperpliers, then disconnect the wires.
④Find 4piecesofscrewsfixingthe kneadingmotortothe sheet-metal,
removethe screwswithaplusscrewdriver.
⑤Replaceanewone ifit doeswork.
⑥Proceed inthereverseorderofdisassemblywhen replacinganewone.
Note You shouldadjusttheposition ofthesmall beltwheel,sothe small and bigbeltwheelsareinthe
sameplane toprolongthe life-span ofthe belt.
6.2Rollingmotor DC -24V）
①Disassemblethe rearcoverofthe back rest, find the massagemechanism.
②Find the rail on the topofbackrest and removethe screwstodisassembleit.
③Disassemblethe massagemechanismfromthe chair.（referto7.2）
④Removerollingcartakefromrack rail, thereare2waystochoose, but “a”is
moreconvenient than “b”.
a)Makethe rollingmotorpoweron, thenrevolveit until the rollingcartakefrombackrest.
b)Usetoolsturnaround axletree torevolveuntil the rollingcartakefrombackrest.
⑤Find 5piecesofscrewsfixingthe Rollingmotortothe sheet-metal,removethe screwswithaplus
screwdriver.
⑥Replaceanewone ifit doeswork.
Cut the cabletiesand remove
close-end wireconnector Tools
Removethe screws
(2pcs)
Turnaroundaxletreeto
revolveuntil the rolling
cartakefrombackrest.
Rolling motor
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6.3Tappingmotor DC -24V）：
①Disassemblethe rearcover, then find the tapping motor.
②Cut the cabletiessecuringthe wireon the sheet-metalofEMC.
③Removethe close-end wireconnectorsofthetappingmotor
wires, then disconnect them.
④Loosen the belt oftappingmotor, then removethe screws
securingthe tappingmotor.
⑤Then the tappingmotorcan beremoved and replaced.
⑥Proceed inthereverseorderofdisassemblywhen assembly.
7.Maintenance ofthemassagemechanism
7.1ReplacementoftheWidthInspectionBoard
Note：①Ifthe massagemechanismisjustkneadingbutno tappingorrolling,oritdoesn tworkwhen power
ison, andthemainPCBisok, inthiswecan thinkofthat the WidthInspection Boardfails.
②Itsnotnecessarytodisassemblethe massagemechanismwhen replacingthe WidthInspection Board,
just disassemblethe front and rearcoverofthe backrest.
①Disassemblethe front and rearcoverofthe back rest asit ismentioned above.
②Pull out theterminalon the boardand cut thecabletiesfixingthe wires.
③Removethe screwssecuringthe board, thenanewone can bereplaced.
④Proceed inthereverseorderofdisassemblywhen assembly.
Tools: aplusscrewdriver,wirecutters
Tappingmotor
Close-end wireconnectorof tapping motor
1terminalson the board Screws(2pcs)securing the board
Screwssecuring the rolling motor(3pcs)
Screws(5pcs)securing the Rolling motor
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7.2Disassemblyand replacementofthemassagemechanism
Note: Ifthe swinging armsarebroken oritistoo noisy,you cantrytodosomethingtothe massage
mechanism.You shoulddisassemblethe rearcoverand the clothofthe back rest.
①Disassemblethe rearcoverofback rest, removetheback pad,and disassemblethe clothoftheback
rest, cut all thecabletiestighteningthe wires.
②Removethe close-end wireconnectorsoftappingmotorwires, then disconnectthe wires.
③Pull out theterminalsofthe WidthInspection Board, 3PCS.
④Takedownthebeltoftappingmotor, thendisassemblethe tappingmotor. Removethescrewssecuring
the massagemechanismon the runningframeand the screwssecuringnylon clampwhichfixeswires.
⑤Adjustthepositionofthemassagemechanismandthewidthoftheswingingarms,until themassage
mechanismistaken off.
8. Replacementofup ordownstrokephoto-electricityassembly
①Disassemblethe rearcoverofthe back rest.
②Pull out theterminalofthe wire.
③Removethe screwstighteningthe PCBofupordownstrokephoto-electricityassembly
tothesheet-metalwithaplusscrewdriverand nipperpliers.
④Proceed inthereverseorderofdisassemblywhen replacement needed.
Tools: aplusscrewdriverand nipperpliers
Screwssecuring the mechanism
Massage mechanismtaken down
Removethe screws
(3pcs)
The terminalof
the wire
Adjustthe position ofthe massage
mechanismand the widthofthe
swingingarms
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VII. Maintenanceoftheseatpart
9. Replacementoftheremotecontrollerholder
①Pull out theremotecontrollerfromthe holder.
②Removethe screwbolt tighteningthe holder.
③Takeawaythe holderfromthe support.
④Install anewholderon thesupport.
⑤Tighten the holderwiththe screwbolt.
10. Replacementoftheremotecontroller
①Removethe screws(9pcs)on the back coverofthe controller
②Disconnect the wireterminalofcontrollerPCB;Then removethe screws(2pcs)on the PCB
.
③Then you canreplaceanypartsofthe controllerincludingPCB, Front coverand Back cover.
11. Replacementoftheremotecontrollerwire
④Alongthe controllerwireand removethe screws(6pcs)fixingthe “R”nip
and disconnect wireterminalofcontroller.
⑤Replacethe newwireand fixit on theboard, thenconnect
the terminalofcontroller.
.
12. Replacementofthefrontpanelofseatpart
①Turnonthepowerand raisethe foot resttothe highest position.
②Operatethe Zero-G 2function toraisetheseat-rest,
③Removethe screws(12pcs)securingthe front panel.
④Then the front panelcan beremoved, replaceitwithanewone, and tightenit withscrews.
Raisethe foot resttothe
highest position
Screwbolt
“R”nip
Screwbolt
Screws(12pcs)securing the front panel
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