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Panasonic EP3203-U1 Service Manual

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ORDER NO.HPD0401U11C1
E11
MASSAGE LOUNGER
EP3203-U1
SPECIFICATIONS
SPECIFICATIONS
1

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Summary of Contents for Panasonic EP3203-U1

  • Page 1 ORDER NO.HPD0401U11C1 MASSAGE LOUNGER EP3203-U1 SPECIFICATIONS SPECIFICATIONS...

  • Page 2: Components Identification

    1. COMPONENTS IDENTIFICATION 1.1. Massage lounger...
  • Page 3 1.2. Controller...
  • Page 4 2. MASSAGE RANGE (MOVEMENT RANGE OF MASSAGE WHEELS) SHIATSU MASSAGE, SWEDISH MASSAGE, KNEADING, VIBRATING, TAPPING A, TAPPING B, TAPPING C, WHOLE BACK ROLLING, REGIONAL ROLLING...
  • Page 5 Width adjustment Approx.50 to 210 mm (2.4in. to 8.3in.) Intensity adjustment Shiatsu, Swedish, Knead, vibration, Tap A, Tap B, Tap C, whole back roll, and Regional roll (from gentle to strong) :50mm(2.4in.)-wide adjustability where massage heads push out toward body as intensity increases.

  • Page 6: Turning On The Power

    3. TURNING ON THE POWER...
  • Page 7 1. Plug the power plug into the power socket. 2. Turn the lock switch to the open position. 3. Turn on the power switch on the back of the unit. - When the operating lock switch is pointing toward 'lock', the power switch cannot be moved to the 'on' position.

  • Page 8: Required Tools

    4. REQUIRED TOOLS...

  • Page 9: Actual Wiring Diagram

    5. ACTUAL WIRING DIAGRAM 5.1. Connecting cord for power source to Sub PCB...

  • Page 10: Display Method Of Massage Block Total Use Time And Operation Time

    6. DISPLAY METHOD OF MASSAGE BLOCK TOTAL USE TIME AND OPERATION TIME...
  • Page 11 Adjustment of pressure sensor First, keep the Massage mechanism block unloaded with pressure and move it upward halfway. If the Massage mechanism block is at the highest or lowest position, you cannot arrange the pressure sensor correctly because the fabric becomes tense with pressure.

  • Page 12: Motion Of The Clutch And Belt Based On Various Massager Operations

    It is possible to indicate up to 5,995 hours. If the use time is less than 5 hours, 5 hour unit does not light up. If it is less than 10 hours, one 5 hour unit lights up. Chart for reading each function use time 7.

  • Page 13: Control Of The Air-Massage Operation

    Massager operation and clutch motion 8. CONTROL OF THE AIR-MASSAGE OPERATION...
  • Page 14 Air massage functions with the operations of the pump unit x 1pc, 3-way electromagnetic valve x 1pc, and 2-way electromagnetic valve x 2pcs. 1. Air massage is operated by the pump and electromagnetic valves. 2. When not in operation, all the pump and the electromagnetic valves are in Off position.

  • Page 15: Massager Up/Down Sensor Gear Adjustment Method

    9. MASSAGER UP/DOWN SENSOR GEAR ADJUSTMENT METHOD When the massager is removed from the chair, the position of the up/down sensor gear changes, resulting in a change of the up/down stop position. When installing the massager on the back frame, be sure to adjust the position with the up/down detection gear.
  • Page 16 Up/down sensor gear position adjustment procedure 1. Before mounting, the massager on the back frame must be moved down to the lowest position by setting the controller manual operation MASSAGE HEAD ADJUSTMENT button to DOWN. 2. Install Rail pieces (left/right) and screw them with each three screws. 3.

  • Page 17: Disassembly And Assembly Instruction

    *When adjusting the up/down position, hold the 'Gear' and adjust it. ( Do not touch the detector board.) 6. While adjusting the distance between the square hole and Guide roller assy. to 10mm, check by using the up/down adjustment button found on the manual operation panel of the controller.
  • Page 18 2. Pull the Arm rest backward(1) and pull it up(2) and take it away.
  • Page 19 3. You can remove both Arm rests. Tips of installing Insert the Arm rest to the Arm rest holder so that both triangle marks meet each others, and pull the Arm rest forward to lock.
  • Page 20 10.1.2. Removing the Controller stand 1. Take off the Controller, and unscrew three Hex screws(4mm) of the Controller stand.
  • Page 21 10.2. Removing the Outside covers 10.2.1. Removing the Rear cover 1. Unscrew two screws at the top of the Rear cover top and two Push return rivets, and pull it off.
  • Page 23 2. Take off the hook with nippers, which fixes the Rear cover bottom and the Rear cover fixing plate.
  • Page 24 3. Take off two Brush clips on the Rear cover bottom and pull it off. 10.2.2. Removing the Under cover 1. Take off 8 push-return-rivets fixing Under cover left/right and one brush clips (for Under cover right.)
  • Page 27 2. Take off the Under covers right/left. *When you take off the Under cover right, first take off the parts around the Power source box.
  • Page 28 Caution when installing When installing the Under covers, be sure to confirm that the Under covers do not pull or crush the Air hoses, and move the Ottoman to confirm that the Ottoman does not pull anything. 10.2.3. Removing the Side cover 1.
  • Page 30 3. Unhook two hooks on the top of the Side cover and take off the Side cover. Caution When installing the Side cover, first hook two hooks and then screw screw-rivets. 10.3. Removing the Massage mechanism block...
  • Page 31 Move the Massage mechanism block to the lowest position by the Upward button. Be sure to lean the Massage chair on chairs or desk so that the work will be easy. 1. Unscrew four screws on the Rear cover fixing plate. 2.
  • Page 32 3. Unscrew a screw fixing the ground wire and disconnect two connectors.
  • Page 33 4. Pinch the hook of the Insulated tie and remove it.
  • Page 34 5. Remove the Connecting cord for power source from the Cover clip.
  • Page 35 6. Remove Rail piece set at both sides.
  • Page 36 10.4. Removing the Under box and the Under box cover 1. Follow the procedure 10.2.1 Removing the Under cover. 2. Lift the Ottoman and put it on some desk and unscrew three screws on the Under box top/left and float the Under box top/left.
  • Page 37 3. Disconnect five Ottoman hoses going through the hole on the Under box top/left and take off the Under cover box top/left.
  • Page 38 4. Unscrew a screw on the Under box top/right and slide the Under box top/right to the left and unhook four hooks.
  • Page 39 5. Remove the Sub PCB.
  • Page 40 6. Unscrew three screws on the Under box and pull out the Under box. Be careful how Ottoman hoses are going out. Be sure that all hooks are hooked.
  • Page 42 10.5. Removing the Lift units 10.5.1. Removing the Ottoman lift unit 1. Follow the procedure 10.3 Removing the Massage mechanism block. *It is safer to unload the Massage mechanism block. 2. Follow the procedure 10.3 Removing the Under cover. 3. Follow the procedure 10.4 Removing the Under box and the Under box cover 1 to 4, and disconnect the connectors red(CN103- CN110) connecting to the Sub PCB.
  • Page 43 unit. *It would be easy to remove the Ottoman lift unit if you unload the Massage mechanism block.
  • Page 44 10.5.2. Removing the Reclining lift unit 1. Follow the procedure 10.3 Removing the Massage mechanism block. *It is safer to unload the Massage mechanism block. 2. Follow the procedure 10.3 Removing the Under cover. 3. Follow the procedure 10.4 Removing the Under box and the Under box cover 1 to 4, and disconnect the connectors blue(CN102- CN111) connecting to the Sub PCB.
  • Page 45 4. Remove the Ottoman lift pin long and the Snap pin, and remove the Reclining lift unit. *It would be easy to remove the Reclining lift unit if you unload the Massage mechanism block.
  • Page 47 10.6. Removing the Seat 1. Follow the procedure 10.2.1 Removing the Rear cover, 10.1.1 Removing the Arm rest, and 10.2 Removing the Outside covers. 2. Unhook the hooks at both sides of the Seat. 3. Cut off the Insulated tie and unzip the zippers of the Seat and the Ottoman and unscrew one each Push return rivets on both sides, and take off the Seat.
  • Page 49 10.7. Removing the Air Ottoman 10.7.1. Removing the Air Ottoman 1. Follow the procedure 10.4 Removing the Under Cover. 2. Follow the procedure 10.6 Removing the Seat 3 and unzip the zippers and the Push return rivet of the Seat and the Ottoman. 3.
  • Page 50 4. Unscrew two screws and take off the Leg slide lever from the Under pipe.
  • Page 51 5. Unscrew a screw and take off the Wire fixing plate. 6. Unhook the hook of the wire from the Leg slide lever and pull off the wire.
  • Page 52 7. Move the Hose clamps and pull off the Hoses and take off the two Rod holders.
  • Page 54 Caution when installing Be sure not to make the hook side of the Rod holder face the Seat, which might cause the tear.
  • Page 56 8. Remove four Lift bushings and four Snap pins, and take off the Parallel link. 9. Take off the left/right Hinge pin Bs, Washers, and U nuts, and you can take off the Ottoman.
  • Page 57 10. Pull out the Snap pin from the Ottoman and remove the Parallel link. Caution when installing Be careful of the directions when installing the Parallel link.
  • Page 60 11. Unscrew three screws each at both sides of the Slide guide.
  • Page 61 12. Unscrew two screws and remove the Spring. 10.7.2. Removing the Air Ottoman fabric 1. Follow the procedure 10.7.1 Removing the Ottoman. 2. Unzip the Zippers(two) of the bottom of the Air Ottoman.
  • Page 62 3. Cut off the Insulated tie on the Hose for sole, and pull off the Hose from the fabric.
  • Page 63 4. Remove the Fabric.
  • Page 64 Caution when installing *Be careful of the hole of the Fabric in which the Hose goes in when installing the Fabric.
  • Page 66 10.7.3. Removing the Air Ottoman inside (Air bags, Hoses) 1. Follow the procedure 10.7.1 Removing the Air Ottoman and the procedure 10.7.2 Removing the Air Ottoman fabric. 2. Cut off all the Insulated ties binding Hoses. When installing the Insulated ties, refer to the 10.7.4 Air Ottoman hoses.
  • Page 67 10.7.4. Air Ottoman hoses...
  • Page 68 10.8. Removing the Head rest, Back cushion, and Massage wheel cover...
  • Page 69 10.8.1. Removing the Head rest 1. Remove the Head rest. 10.8.2. Removing the Back cushion 1. Unzip the Zippers and remove the Back cushion.
  • Page 70 10.8.3. Removing the Massage wheel cover *You can work without unloading the Massage mechanism block. 1. Follow the procedure 10.2.1 Removing the Back cover. 2. Cut off the three Insulated ties on the Seat panel.
  • Page 71 3. Unscrew eight screws on the Massage wheel cover and remove the Massage wheel cover. *Move the Massage mechanism block up and down and unscrew screws.
  • Page 72 10.9. Removing the Power source box 1. Unscrew a screw and remove the Bushing cover. Pull out the Controller cord and disconnect the Connector and you can remove the Controller block. *Use a screwdriver so as not to break the screw head.
  • Page 73 2. Unscrew two screws and remove the Power source box.
  • Page 74 3. Micro switch, Fuses, Power cord, and switch can be removed. *Be careful not to break the screw heads.
  • Page 75 Caution when installing Controller cord and Power cord Refer to the figure when installing cords.
  • Page 76 Caution when removing and installing the Power cord Cut the Insulated time at two parts as the figure and use the new Insulated tie and fix the Power cord.
  • Page 77 10.10. Adjustment of the Up/down sensor gear When the Massage mechanism block is removed from the chair, the position of the Up/down sensor gear changes resulting in a change of the up/down stop position. When installing the Massage mechanism block on the back frame, be sure to adjust the position with the Up/down sensor gear.
  • Page 78 1. Before mounting, the Massage mechanism block on the back frame must be moved down to the lowest position by setting the controller manual operation massage head adjustment button to Down. 2. Make sure that the Massage mechanism block has been mounted horizontally by moving the Massage mechanism block to the position shown in the figure.
  • Page 79 3 pcs. each). 6. Using the manual operation of the controller, conduct the rolling operation. Set the massage heads adjustment switch to level 1, and check the up/down stroke. 10.11. Installing the Connecting cord for power source Move the Massage mechanism block to the highest position. *After installing each Connecting cords, be sure to confirm that each Connecting cords do not touch belts or Rear cover fixing plate or being stuck in the gear by operating the Up/down button in the controller manual mode.
  • Page 80 10.12. Lead wires of Massage mechanism block Refer to the following figure for the fixing of the Main PCB, motors, sensors, parts, and Insulated ties.
  • Page 81 10.13. Assembly and disassembly of Massage mechanism block 10.13.1. Removing the Up/down sensor...
  • Page 82 1. Disconnect the Connector (CN206)(1) on the Main PCB. 2. Cut off the Insulated tie medium (2) of the lead wires. 3. Unscrew two installation screws (3) of the Up/down gear box B and the Up/down sensor plate and remove the Up/down sensor. Caution when installing When installing the Up/down sensor, be sure to insert the Sensor plate to the groove of the Up/down gear box B.
  • Page 83 10.13.3. Removing the Intensity sensor 1. Disconnect the Connector (CN205) (9) on the Main PCB. 2. Cut off the Insulated tie medium (10) of the lead wires. 3. Unscrew a screw (11) of the Massage mechanism block and the Intensity sensor plate.
  • Page 84 10.13.5. Removing the Tapping sensor *Follow the procedure 10.13.4 Removing the Width sensor 1-3. 1. Unscrew a screw of the Tapping sensor. Caution when installing - When fixing Lead wires with insulated ties, make sure that the Lead wires are not pulled moving the Massage mechanism block for the Intensity directions.
  • Page 85 10.13.6. Removing the Air unit 1. Disconnect Connectors (CN201, CN208) of the Main PCB. 2. Unscrew five screws of the Main PCB installation plate and four screws of the Air unit. 3. Cut off the Insulated tie medium of the Air hoses. Caution when installing - You can remove the Air unit with the five screws loose of the Main PCB installation plate.
  • Page 86 - It would be easy to remove the Air unit if you set the Massage balls at widest and strongest. 10.13.9. Removing the Shoulder holding Air bags 1. Remove the Massage mechanism block from the Rear frame. 2. Unscrew two Hex screws of the Air bags. 3.
  • Page 87 10.13.10. Removing the Up/down gear block *You should disassemble the Up/down gear block before replacing the Up/down shaft and the Up/down motor. *Follow the procedure 10.13.4 Removing the Width sensor 1-3. 1. Remove the Massage mechanism block from the Rear frame. 2.
  • Page 88 10.13.11. Removing the Intensity gear block *Follow the procedure 10.13.4 Removing the Width sensor 1-3. *Follow the procedure 10.13.10 Removing the Up/down gear block 1-3. 1. Unscrew five screws of the Intensity gear box and the Intensity driving installation plate. 2.
  • Page 89 10.13.12. Removing the Width driving block *Follow the procedure 10.13.4 Removing the Width sensor 1-3. *Follow the procedure 10.13.10 Removing the Up/down gear box 1-3. 1. Take off the clamps of the Shoulder air bag hose 1.2 and remove the Width driving block.
  • Page 90 - When installing the Width driving block, install the Intensity driving shaft pinion and the Intensity gear with each gears bitten correctly. You do not need to adjust the position with the Intensity sensor. *If you operate the Massage chair with the gears bitten incorrectly, it may cause the crack of the gears.
  • Page 91 11. ACTUAL WIRING DIAGRAM 11.1. Air Ottoman...
  • Page 93 12. CHECKING...
  • Page 94 12.1. Controller, Massage mechanism block...
  • Page 98 12.2. Air bags...
  • Page 100 12.3. Checking the pressure of the Air bags 1. Follow the procedure 10.4 Removing the Under cover. 2. Connect the Air pressure gauge and the Special hose to the Hose 2-row leg A. 3. Turn on the On/off switch of the Controller and push the Squeeze button.
  • Page 101 4. Check the three pressures of the Intensity legs button on the Controller. If the pressure rates are within certain ranges, the Air bag and the Pump unit are OK. If the rates are low, check the pressure of the Pump unit. If the Pump unit is OK, there are something wrong with the Air bag or the Electromagnetic valves.
  • Page 102 12.4. Checking Electromagnetic valves Follow the procedure 10.4 Removing the Under cover and 10.4 Removing the Under box, Under box cover.
  • Page 103 1. Turn on the On/off switch of the Controller and push the Squeeze button. 2. Disconnect the Hoses with the air flow and the operating voltages of the Electromagnetic valves. There should be about DC90V between the Connectors(CN106) of the Sub OCB.
  • Page 106 3. There should be the following resistance between the terminals of each Electromagnetic valves: - 3-way electromagnetic valves: about 1.8- 2.1k - 2-way electromagnetic valves: about 1.3-1.5k 13. GREASE...

  • Page 108: Exploded View

    14. EXPLODED VIEW...

  • Page 109: Replacement Parts List

    15. REPLACEMENT PARTS LIST NOTES:...
  • Page 110 Ref.No. Part No. Part Name & Description Remarks Per Unit WEP3200L0087 BACK FRAME WEP3200L0887 RESIN BUSHING WEP3203L0048 REAR COVER FIXING PLATE WEP2000L9567 SCREW(CUP.K4-10) WEP2005L0687 CORD WIRE WEP3200L0767 RAIL PIECE RIGHT EP3200L0777 RAIL PIECE LEFT WEP573L6627 SCREW(CUP.S.K4-6) WEP3200L3027 PROTECTION COVER RIGHT WEP3200L3037 PROTECTION COVER LEFT WEP2110L0907...
  • Page 111 Ref.No. Part No. Part Name & Description Remarks Per Unit WEP3200L0177 SPRING WEP3200L4487 LEG SLIDE LEVER WIRE WEP3200L1387 SLIDER PLATE WEP3200L9607 SCREW(CUP.S.K4-18) WEP3200L1407 LINEAR SLIDE WEP3200L1437 SLIDE STOPPER WEP3200L1467 SLIDE GUIDE WEP3200L1497 SLIDE HOLDER WEP3200L1487 POSITION PLATE WEP2000L9567 SCREW(CUP.S.K4-10) WEP2800L0477 HOSE CLAMP WEP3200L0897 BUTTOCKS AIR BAG...
  • Page 112 Ref.No. Part No. Part Name & Description Remarks Per Unit WEP3200L0657 HOSE 2-WAY WEP3200L0647 HOSE 3-WAY WEP2800L0477 HOSE CLAMP WEP3200L0287 SURGE TANK WEP3200L2277 HEAT RESISTANCE SHEET 1 WEP3200L2287 HEAT RESISTANCE SHEET 3 WEP005W8537 INSULATED TIE MEDIUM T30R/SF WEP005W8517 INSULATED TIE T30R WEP3203K4458 CONTROLLER BLOCK WEP3203K0018...
  • Page 113 Ref.No. Part No. Part Name & Description Remarks Per Unit WEP545H1937 GUIDE ROLLER B WEP2200L1907 PINION C SPRING WEP578AL0317 RUBBER RING WEP3200L1447 PINION C WEP3200L1477 GUIDE ROLLER B BLOCK WEP3200L0427 PINION B WEP3200L1417 UP/DOWN WORM WHEEL WEP2200L0337 UP/DOWN SHAFT HOLDER B WEP3203L4378 UP/DOWN MOTOR BLOCK WEP3200L0187...
  • Page 114 Ref.No. Part No. Part Name & Description Remarks Per Unit WEP2200L3417 UP/DOWN BELT WEP3203L4638 WIDTH SHAFT BLOCK WEP3203L4028 TAPPING BLOCK WEP3200L0207 ECCENTRIC LING PLATE RIGHT WEP3200L0217 ECCENTRIC LING PLATE LEFT WEP3200L0157 ARM PULLING SPRING WEP3203L1788 BACK VIBRATOR(RIGHT) WEP3203L1798 BACK VIBRATOR(LEFT) WEP2110L0367 SNAP PIN SSP-5 WEP3203L3858...

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