SERVICE MANUAL Massage chair
Contents
1. Trouble described left is displayed 3 seconds after the power is turned ON The upward motion is effected immediately only after the power is turned ON 3 seconds later 3 Check the Printed board relay CN201 connector for come off 4 Check the Printed board relay CN203 connector for come off 5 Check the Printed board main CN13 connector for come off 6 Check the Printed board relay CN201 connector and Printed board main CN13 connector for come off of each lead wire pin thereof both No 1 black and No 6 red or No 5 blue 7 Check the main harness CN201 to CN13 for disconnection or shorting No 1 black No 6 red and No 5 blue Insert the connector Insert the connector Insert the connector Insert each lead wire pin Replace the main harness The power lamp the center of the speed lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting 12 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Trouble described left is displayed 3 seconds after the power is turned ON or after starting elevation Start elevation 3 seconds later or 30 seconds after elevation 8 Check the upper and lower limit switches for trouble micro switch and harness lt Under norma2. 1 FILE No SERVICE MANUAL Massage chair HEC 902 GENERAL HEC 904 GENERAL REFERENCE NO SM6510035 00 MODEL Power consumption Rated time Timer Dimension Weight Exterior cloth Number of massagings Number of tappings Tapping width Vertical movement speed Backborn stretching width Massaging ball up down range Height adjustment of massaging ball Leg vibration Reclining angIe Reclining method Accessory HEC 902 HEC 904 90 W 130 W 30 min manual about 15 minutes automatic neck shoulder about 11 minutes upper half of the body about 13 minutes waist about 13 minutes 660 mm width X 1 000 mm depth X 1 030 mm height When not reclined with foot rest retracted 660 mm width X 1 650 mm depth X 570 mm height When reclined with foot rest set horizontally Approx 50 kg Approx 52 kg Polyester chloride 100 3 stages 20 times min 25 times min 30 times min 3 stages 360 times min 480 times min 600 times min 3 stages Approx 70 mm 100 mm 130 mm One reciprocating motion in approx 27 sec 3 stages Approx 70 mm 100 mm 130 mm Approx 600 mm 3 stages Vibration type Approx 120 170 Manual method Motor driven type Head cover 2 Wiring Diagram HEC 902 GENERAL Motor Massage Motor Elevation Motor Leg vibrator Limit switch Limit switch Printed board Relay Printed board Remote control Printed board
3. Main Transfomer Transfomer Switch Fuse 250V 3 15A Condenser 10 F 250V Reactor Reactor Printed board Massage pulse CN201 CN203 CN202 CN301 CN7 CN14 CN13 CN8 CN6 CN9 CN1 CN11 CN101 CN2 CN3 CN4 CN10 3 Circuit Diagram HEC 902 GENERAL Printed board Main Printed board Remote control Transfomer Printed board Relay Printed board Pulse Reactor Reactor Motor Tapping Motor Massaging Condenser 10 F 250 V Reclining motor Motor Leg vibrator Fuse 250 V 3 15 A Switch Limit switch Tapping pulse IC 301 IC 202 Massaging pulse 4 Circuit Diagram HEC 902 GENERAL Printed board Main Printed board Remote control RESET SI 5V SO GND SCLK 5 Wiring Diagram HEC 904 GENERAL Motor Massage Motor Elevation Reclining motor Motor Leg vibrator Limit switch Limit switch Switch Switch Motor Printed board Relay Printed board Remote control Printed board Main Transfomer Transfomer Switch Fuse 250V 3 15A Condenser 10 F 250V Reactor Reactor Printed board Massage pulse CN201 CN203 CN202 CN301 CN7 CN14 CN13 CN8 CN6 CN9 CN1 CN11 CN101 CN2 CN3 CN4 CN5 CN12 CN10 6 Circuit Diagram HEC 904 GENERAL Printed board Main Printed board Remote control Transfomer Printed board Relay Printed boar
4. 11 Be careful not to allow adhesion of grease to the belt drive unit etc Adhesion of grease thereto would result in malfunction due to slip 9 Replacement of gear box 1 Take off the belt MOMI Photo 12 2 Unscrew two stay HARNESS fixing screws to remove the stay HARNESS Photo 12 3 Unscrew one holder MAGNET WIDTH fixing screw to remove the holder MAGNET WIDTH from the shaft Photo 12 4 Take off C ring from the shaft Photo 12 5 Loosen a little four right side shaft M fixing screws Photo 10 6 Unscrew four gear box fixing screws to separate the gear box from the shaft Photo 13 7 Remove the pulley M from the gear box Photo 13 8 Unscrew two stay fixing screws at each side of the gear box to remove the stays left and right Photo 13 20 Replacement procedure HEC 902 GENERAL HEC 904 GENERAL Photo 16 Back rest Screws Power switch Photo 15 Limit switch Switch holder Connectors Connectors Photo 17 Arm lock nuts Arm right Arm left Screws Helical spring Photo 14 Printed board Relay Printed board Pulse Screws Screws 10 Replacement of Printed boards Relay or pulse 1 Disconnect three connectors connected to the Printed board Relay Photo 14 2 Unscrew one screw fixing the Printed board Relay to remove the Printed board Relay Photo 14 3 Disconnect one connector connected to the Printed board pulse Photo 14 4 Unscrew one screw
5. S from the screw rod Photo 18 3 Unscrew two screw rod holder screws from the backside Photo 18 15 Replacement of leg vibrator 1 Disconnect the lead wires of the leg vibrator motor 2 Remove the seat cover from underside with the foot rest lifted 3 Open the fastener and take out the leg vibrator Fig 16 16 Replacement of transfomer 1 Unscrew three fixing screws to remove the transformer cover Photo 20 2 Unscrew fixing screws to remove the folder and pull out a connector 3 Unscrew fixing screws to remove the transformer Photo 21 22 SANYO Electric Co Ltd Osaka Japan Replacement procedure Nov 99 500 Printed in Japan HEC 902 GENERAL HEC 904 GENERAL Photo 22 Photo 21 Cylinder Disconnect the reclining wire Reclining wire Lock C ring and pin Lock C ring and pin Reclining motor 17 Replacement of reclining unit HEC 902 1 Disconnect the reclining wire 2 The cylinder is fixed at its both end sides Take off the lock C ring at the both sides and pull out the pin Photo 21 HEC 904 1 Disconnect the lead wires from the reclining motor 2 The reclining motor is fixed at the both end sides Take off the lock C rings from the both ends and pull out the pin Photo 22
6. be changed over to approximately 20 25 and 30 cycles minute When patting and stretching the backbone line the massage ball position ball moving range can be changed over in three steps after starting the patting motor 3 Elevation motor This motor rotates to transmit its rotating torque to the threaded rod via the driving belt whereby the massage unit is moved upward and downward This motor rotates clockwise and counterclockwise to thereby move the massage unit upward and downward Tapping massaging You can enjoy the good comfort that you can not do by hand tapping massage by starting both the tapping motor and the massage motor simultaneously I shaped tapping Z shaped massaging Massaging same portion can be prevented by moving minutely the massage balls upward and downward by starting the elevation motor while running the tapping motor for tapping operation or the massage motor for massaging operation Screw bar 3 Elevation motor 1 Tapping motor 1 3 2 2 2 Massage motor 17 Replacement procedure HEC 902 GENERAL HEC 904 GENERAL Screws Rear cover Remote control Fig 1 Screws Cover Printed board main Reactor Screw Transfomer Printed board main Photo 2 Photo 3 Photo 5 Photo 4 Bushing of the remote control cord Cord bushing Fuse Power switch Power switch Connector Condenser Screw Screws Screws 1 How to remove the rear cover 1 Unscrew
7. board relay CN202 CN203 CN201 IC301 2 3 1 Printed board pulse CN30 2 1 3 4 7 6 5 4 3 2 1 3 2 1 Printed board main CN3 CN8 CN14 CN4 CN12 CN5 and CN12 available for HEC 904 only CN13 7 6 5 4 3 2 1 CN11 CN10 CN6 CN7 CN5 CN2 CN1 CN9 ON Printed board Connectors Configuration Drawing 15 Motorized Reclining HEC 904 GENERAL The back rest can recline steplessly up to 170 degree maximum by operating RECLINING switch on the remote control Motorized reclining operation 1 The reclining motor rotates both clockwise and counterclockwise to make the cylinder stroke length adjustable 2 The cylinder stroke length is made shorter simultaneously with startup of the reclining motor so that the backrest is pulled and reclines from the frame supporting center by the cylinder Back rest 16 Massage motors HEC 902 GENERAL HEC 904 GENERAL 1 Tapping motor This motor rotates to move the massage balls upward and downward alternately via the driving belt coupled to the motor The motor revolutions is adjustable in three steps so that the patting frequency can be changed over to approximately 360 480 and 600 cycles minute 2 Massage motor This motor rotates to move the massage balls crosswise via the driving belt and gear box coupled to the motor The motor revolutions is adjustable in three steps so that the massaging frequency can
8. chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Tapping motor relations Trouble described left is displayed 15 seconds after the power is turned ON or TAPPING is selected Tapping failure 15 seconds later or 15 seconds after tapping motion 1 Check the Printed board main CN8 and CN14 and the tapping motor junction connector for come off 2 Check the Printed board main CN8 to tapping motor connector harness for disconnection Insert the connector Replace the main harness during tapping 3 Check the Printed board main CN8 output approx DC57 100V If output Replace The tapping motor If no output Replace the Printed board main Tapping mode remains unchanged 15 seconds after tapping motion 4 Check the Printed board relay CN202 connector for come off and pins for come off 5 Check the Printed board pulse CN301 connector for come off and pins for come off 6 Check the Printed board relay CN201 and Printed board main CN13 connectors for come off of each lead wire pin No 2 7 Check the junction harness CN202 CN301 circuit for disconnection or shorting 8 Check the tapping magnet for its mounting direction and fall down 9 Check the Printed board pulse IC 301 for inclination 10 Check the belt TATAKI for dislocation and cut off Inser
9. for come off 2 Check the harness between the Printed board main CN6 and massage motor junction connector for disconnection Insert the connector Replace the main harness during massage 3 Check the Printed board main CN6 output approx DC57 100V If output Replace the massage motor If no output Replace the Printed board main Massaging mode remains unchanged 15 seconds later or 15 seconds after massaging motion 4 Check the Printed board relay CN201 connector and Printed board main CN13 connector for come off of each lead wire pin Pin No 3 brown 4 yellow and 7 white 5 Check the main harness CN201 to CN13 line for disconnection or shorting 6 Check the massaging POSITION and ROTATION magnets for their mounting direction and fall down 7 Check the Printed board relay IC 201 and IC 202 for inclination 8 Check the belt MOMI for dislocation and cut off Insert each lead wire pin Replace the main harness Mount the magnet in normal condition Correct the tilted condition or replace the Printed board relay Mount or replace the belt MOMI Massage motor running 9 When no fault is detected upon checking in the Step 1 8 Replace the Printed board relay or the Printed board main The power lamp the center of the width lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting 10 Problem diagnosis
10. four fixing screws to remove the rear cover Fig 1 2 Replacement of the printed board main 1 Unscrew three fixing screws to remove the cover the printed board main Photo 2 2 Pull out 14 connectors 12 in the case of HEC 902 which are connected to the printed board main and thereafter demount the printed board Photo 3 3 Unscrew two transformer fixing screws to remove the transformer Photo 3 4 Unscrew two reactor fixing screws and one capacitor fixing screw Photo 3 3 Replacement of power switch 1 Unscrew two case fixing screws to remove the power switch Photo 4 In removing shift the switch in arrow direction from the bushing of the remote control cord 2 Open the power fuse case to take out the fuse Photo 5 3 Unscrew two switch holder fixing screws to remove the power switch Photo 5 4 Pull out the auxiliary connector outward which is fitted in the case power switch Photo 5 4 Replacement of power cord 1 Disconnect the power cord connector to remove the cord bushing from the power cord Photo 5 5 Replacement of remote control 1 Remove the bushing from the remote cord Photo 4 2 Unscrew four remote control case fixing screws to open the case Fig 1 3 Unscrew two printed board remote control fixing screws to disconnect the remote control cord connector 18 Replacement procedure HEC 902 GENERAL HEC 904 GENERAL Photo 6 Elevation motor Belt Rolling Pulley SM Scre
11. ce the Printed board main Replace the power transformer Insert the connector and pins Replace the remote control cable Replace the Printed board remote control or Printed board main Remote control relations Trouble described left is displayed immediately or 3 seconds after the power switch is turned ON Immediately or 3 seconds later 1 Check the Printed board main CN11 and Printed board remote control CN101 connector pins for come off Pin No 3 blue 4 yellow and 6 orange 2 Check the remote control cable for disconnection or shorting Blue yellow and orange wires 3 When no fault is detected upon above check Insert the connector pins Replace the remote control cable Replace the Printed board remote control or Printed board main Nothing is displayed The power lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting 9 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Massage motor relations Trouble described left is displayed 15 seconds after the power is turned ON or MASSAGE is selected Massaging failure 15 seconds later or 15 seconds after massaging motion 1 Check the Printed board main CN6 and CN7 and massage motor junction connector
12. check in Step 1 5 Replace the Printed board main Other Trouble described left is displayed No Replace the Printed board main The power lamp the center of the speed lamp the center of the width lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting The power lamp the both edges of the speed lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting 14 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method No trouble is displayed Leg vibrator Leg vibrator fails to start Leg vibrator ON 1 Check that Leg vibrator lamp on the remote control is ON If the lamp OFF Check and replace the Printed board remote control 2 Check the Printed board main CN2 output to be approx DC12V If output Replace the cushion footrest If no output Replace the Printed board main Various Remote control relations Trouble is displayed motion stop from time to time Each function in running 1 Start massaging in AUTO mod and lightly pull the remote control cord to check whether massaging motion stops or trouble is displayed Replace the remote control IC202 IC4 IC201 2 3 1 1 4 3 2 1 2 3 4 5 6 7 Printed
13. d Pulse Reactor Reactor Motor Tapping Motor Massaging Reclining motor Condenser 10 F 250 V Reclining motor Motor Leg vibrator Fuse 250 V 3 15 A Switch Limit switch Limit switch Tapping pulse IC 301 IC 202 Massaging pulse 7 Circuit Diagram HEC 904 GENERAL Printed board Main Printed board Remote control RESET SI 5V SO GND SCLK 8 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Power and remote control relations Nothing is displayed after the power ON Immediate 1 Check current fuse 3 15A for fusion 2 Check Printed board Main CN1 output AC100V 3 Check Printed board Main CN9 output AC100V 4 Check power transformer output CN10 approx 12V 5 Check Printed board main CN11 and Printed board remote control CN101 for connector come off Check pins both No 5 brown and No 7 black or No 1 white and No 2 red for come off 6 Check the remote control cable for disconnection or shorting both brown and black wires or white and red wires 7 When no fault is detected upon checking in Step 1 6 Replace the current fuse 3 15A Check the power switch and power cord and transfomer for normal conductivity and replace them if necessary upon check Repla
14. ed lamps stretch 2 red lamps combi red lamps lighting 13 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Motorized reclining relations HEC 904 only Trouble described left is displayed with no reclining motion When the motorized reclining operation is effected normally 1 Check the Printed board main CN5 connector and pins for come off 2 Check the Printed board main CN5 output to be approx DC90V Insert the connector and pins If output Replace the reclining motor If no output Replace the Printed board main Trouble described left is displayed three minutes after the power ON 3 seconds later 3 Check the Printed board main CN12 connector for come off Insert the connector 4 Pull out the Printed board main CN12 connector and check whether the current is across No 1 to No 2 pin and No 3 to No 4 pin of the motorized recliner side CN12 connector When the both are open Replace the reclining motor 3 seconds later 5 Pull out the Printed board main CN5 connector for shorting No 1 to No 2 circuit of CN12 Turn ON the power switch after shorting Pin No 3 to 4 to check whether trouble is displayed or not occur Replace the Printed board main No occur Replace the reclining motor 6 When no fault is detected upon
15. fixing the Printed board pulse to remove the Printed board Photo 14 11 Replacement of limit switch 1 Unscrew three switch holder fixing screws Photo 15 2 Unscrew two switch fixing screws upper and lower one each After that remove solder from each switch terminal to demount the switch Photo 15 12 How to remove the back rest 1 Turn OFF the power switch after moving the massage unit to the position shown in Photo 16 using UP DOWN ADJUSTMENT on the remote control 2 Unscrew five back rest pair fixing screws to remove the back rest pair Photo 16 13 Replacement of right and left arm 1 Remove the helical spring for the arm Photo 14 2 Unscrew the right arm fixing nut to remove the right arm Also remove the left arm similarly Photo 14 Remove the left arm similarly 21 Replacement procedure HEC 902 GENERAL HEC 904 GENERAL Photo 18 Fig 19 Leg vibrator Pulley S Screw bar Holder Magnet Screws Nut plastic nut Holder screw rod upper Screws Photo 20 Photo 21 Trans cover Holder Screws Transfomer Screws 14 Replacement of screw bar 1 Unscrew two nut plastic nut lock screws Photo 18 2 Unscrew two holder Screw rod upper fixing screws and remove the holder subsequently taking out the massage unit upward Photo 18 3 After temporarily locking the magnet with a pliers or the like unscrew the backside pulley S fixing nut and remove the pulley
16. l condition gt 1 Stop at the highest position upper limit switch ON lower limit switch OFF Pin 1 2 white red of CN203 connector open Pin 3 4 green yellow of CN203 0 close 2 Stop at the middle position Upper limit switch OFF lower limit switch OFF Pin 1 2 white red of CN203 connector 0 close Pin 3 4 green yellow of CN203 0 close 3 Stop at the lowest position Upper limit switch OFF lower limit switch ON Pin 1 2 white red of CN203 connector 0 close Pin 3 4 green yellow of CN203 connector open Replace the connector ass y upper and lower limit switches When STRETCH 2 mode is selected STRETCH 1 motion is effected and trouble described left is displayed 30 seconds after elevation 9 Check the elevation magnet for the mounting direction and fall down 10 Check the Printed board main IC4 for tilt Mount the magnet in normal condition Correct the tilted condition or replace the Printed board main Trouble described left is displayed with no elevating motion The elevation motor running 11 Check the belt ROLLING for dislocation and cut off Mount or replace the belt ROLLING 12 When no fault is detected upon check in Step 1 11 Replace the Printed board relay or pulse or the Printed board main Elevation motor relations The power lamp the center of the speed lamp and massage red lamp tapping red lamps stretch 1 r
17. ng screws so the round portion shown in Photo 9 is aligned with the holes of the frame and of stay A motor T Photo 9 Adjust and mount the pulley TM so its groove is kept in line with the groove of pulley T Photo 9 Be careful not to allow adhesion of grease to the belt drive unit etc Adhesion of grease thereto would result in malfunction due to slip 19 Replacement procedure HEC 902 GENERAL HEC 904 GENERAL Photo 11 Photo 13 Gear box Screws Screws Photo 12 Ring C 13 Screws Screws Photo 10 massage motor Screws Screws Screws Belt MOMI Belt MOMI Holder MAGNET WIDTH Stay A Motor M Stay HARNESS Screws Cord Blue Pulley MM Screws Frame Stay A Motor M In perfect alignment of the holes Pulley M 8 Replacement of massage motor 1 Disconnect the massage motor cord connector 2 Take off the belt MOMI Photo 10 3 Unscrew one motor fixing screw Photo 10 4 Unscrew two stay A motor M fixing screws to remove the massage motor unit Photo 10 5 Draw the pulley MM out of the massage motor shaft and unscrew three massage motor fixing screws Photo 10 Cautions in reassembling Fix the stay A firmly with two fixing screws so the round portion shown in Photo 11 is aligned with the holes of the frame and stay A motor M Photo 11 Adjust and mount he pulley MM so its groove is kept in line with the groove of the pulley M Photo
18. t the connector and pins Insert the connector and pins Insert each lead wire pin Replace the junction harness Mount the magnet in normal condition Correct the tilted condition or replace the Printed board pulse Mount or replace the belt TATAKI Tapping motor running 11 When no fault is detected upon check in Step 1 Step 10 Replace the Printed board relay or pulse or the Printed board main The power lamp the center of the width lamp and massage red lamp tapping red lamps stretch 1 red lamps stretch 2 red lamps combi red lamps lighting 11 Problem diagnosis chart HEC 902 GENERAL HEC 904 GENERAL Trouble indication pattern Troubled portion Trouble phenomenon Occurrence condition after power ON Check item Counteraction method Elevation motor relations Elevation failure During elevation or 30 seconds later 1 Check the Printed board main CN3 and CN4 connectors for come off and pins for come off 2 Pull out CN3 on the Printed board main and check for the red pin to white pin output and blue pin to white pin output of the Printed board side CN3 to be approx AC100V respectively For checking turn ON the massager from the remote control and keep either vertical adjust button UP or DOWN as pressed Insert the connector and pins If output from the both Replace the elevation motor If either or neither from the both Replace the Printed board main
19. ws Photo 8 Belt TATAKI Tapping motor Screws Cord Red Screws Screws Stay A Motor T Photo 7 1kg 6mm Photo 9 Pulley SM Pulley S Pulley T Pulley TM Screws Cord Blue Pulley TM Screws Frame Stay A Motor T In perfect alignment of the holes Belt Rolling 6 Replacement of elevation motor 1 Disconnect the elevation motor lead wires 2 Remove the belt Rolling and unscrew four motor mounting screws Photo 6 3 Remove the pulley SM from the elevation motor output shaft and unscrew four elevation motor fixing screws Photo 6 Cautions in reassembling Apply the elevation belt to the pulley and adjust the belt tension as shown in Photo 7 Thereafter tighten four motor mounting screws with specific torque Photo 7 Adjust and mount he pulley SM so its groove is kept in line with that of the pulley S Photo 7 Be careful not to allow adhesion of grease to the belt drive unit etc Adhesion of grease thereto would result in malfunction due to slip 7 Replacement of tapping motor 1 Disconnect the tapping motor cord connector 2 Remove the belt TATAKI Photo 8 3 Unscrew one motor fixing screw Photo 8 4 Unscrew two stay A motor T fixing screws and remove the tapping motor unit Photo 8 5 Draw the pulley TM out of the tapping motor shaft and unscrew three tapping motor fixing screws Photo 8 Cautions in reassembling Fix the stay A firmly with two fixi
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