Panasonic EP3203-U1 Service Manual Download

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ORDER NO.HPD0401U11C1

E11

MASSAGE LOUNGER

EP3203-U1

SPECIFICATIONS

Summary of Contents for EP3203-U1

Page 1: ...ORDER NO HPD0401U11C1 E11 MASSAGE LOUNGER EP3203 U1 SPECIFICATIONS SPECIFICATIONS 1 ...

Page 2: ...1 1 COMPONENTS IDENTIFICATION 1 1 Massage lounger 2 ...

Page 3: ...1 2 Controller 3 ...

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 4 ...

Page 5: ... 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 5 ...

Page 6: ...3 TURNING ON THE POWER 6 ...

Page 7: ... on position After each use Be sure to turn the power switch to off To prevent children from using this unit lock the power switch by moving the operating lock switch to the lock position As a further caution unplug the power cord from the power socket after each use Timer When the on off button is pushed a timer begins to prevent overuse After approximately 15 minutes time expires and the massage...

Page 8: ...4 REQUIRED TOOLS 8 ...

Page 9: ...5 ACTUAL WIRING DIAGRAM 5 1 Connecting cord for power source to Sub PCB 9 ...

Page 10: ...6 DISPLAY METHOD OF MASSAGE BLOCK TOTAL USE TIME AND OPERATION TIME 10 ...

Page 11: ...aneously turn on the power switch and continue to hold the buttons for approximately 5 seconds Release after the Focus button lights up 2 Push the Focus button and automatically it lights off Turn off the Power source switch and turn it on again then the adjustment is finished Total use time Display method While pushing the Shiatsu button and the Deep button simultaneously turn on the power switch...

Page 12: ...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 MOTION OF THE CLUTCH AND BELT BASED ON VARIOUS MASSAGER OPERATIONS Massager operation and belt motion 12 ...

Page 13: ...Massager operation and clutch motion 8 CONTROL OF THE AIR MASSAGE OPERATION 13 ...

Page 14: ...d Electromagnetic is Off In ventilation 4 When you operate the electric reclining lift or the electric Ottoman lift while you operate On off button or it is in waiting mode stop the operation of the pump The pressure of electromagnetic valves are maintained And after the operation stop retracting mode from the retracting mode and stop mode or after electric reclining lift or electric Ottoman lift ...

Page 15: ...en 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 15 ...

Page 16: ...he massager has been mounted horizontally an abnormal sound or problem may occur 4 Move it up to the highest position until the massager stops by setting the controller manual operation MASSAGE HEAD ADJUSTMENT button to up 5 Peeping into the square hole of the back frame check the position of the massager to adjust One thread of the up down detection gear gives a stroke change of 4mm When the mass...

Page 17: ... assy to 10mm check by using the up down adjustment button found on the manual operation panel of the controller 7 Using the manual operation of the controller conduct the rolling operation 10 DISASSEMBLY AND ASSEMBLY INSTRUCTION 10 1 Removing the Arm rest and the Controller stand 10 1 1 Removing the Arm rest 1 Unscrew a hex screw 4mm on the bottom of the Arm rest 17 ...

Page 18: ...2 Pull the Arm rest backward 1 and pull it up 2 and take it away 18 ...

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 19 ...

Page 20: ...10 1 2 Removing the Controller stand 1 Take off the Controller and unscrew three Hex screws 4mm of the Controller stand 20 ...

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 21 ...

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Page 23: ...2 Take off the hook with nippers which fixes the Rear cover bottom and the Rear cover fixing plate 23 ...

Page 24: ...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 24 ...

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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 27 ...

Page 28: ...hat 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 Follow the procedure 10 2 1 Removing the Rear cover and 10 2 2 Removing the Under cover 2 Unscrew three srew rivets 28 ...

Page 29: ...29 ...

Page 30: ...nhook 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 30 ...

Page 31: ...e 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 Unscrew four screws of the PC board and remove the PCB cover 31 ...

Page 32: ...3 Unscrew a screw fixing the ground wire and disconnect two connectors 32 ...

Page 33: ...4 Pinch the hook of the Insulated tie and remove it 33 ...

Page 34: ...5 Remove the Connecting cord for power source from the Cover clip 34 ...

Page 35: ...6 Remove Rail piece set at both sides 35 ...

Page 36: ... 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 36 ...

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 37 ...

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 38 ...

Page 39: ...5 Remove the Sub PCB 39 ...

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 40 ...

Page 41: ...41 ...

Page 42: ...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 4 Remove the Ottoman lift pin long and the Snap pin and remove the Ottoman lift 42 ...

Page 43: ...unit It would be easy to remove the Ottoman lift unit if you unload the Massage mechanism block 43 ...

Page 44: ...assage 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 44 ...

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 45 ...

Page 46: ...46 ...

Page 47: ...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 47 ...

Page 48: ...48 ...

Page 49: ... 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 Follow the procedure 10 4 Removing the Under box 49 ...

Page 50: ...4 Unscrew two screws and take off the Leg slide lever from the Under pipe 50 ...

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 51 ...

Page 52: ...7 Move the Hose clamps and pull off the Hoses and take off the two Rod holders 52 ...

Page 53: ...53 ...

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 54 ...

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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 56 ...

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 57 ...

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Page 60: ...11 Unscrew three screws each at both sides of the Slide guide 60 ...

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 61 ...

Page 62: ...3 Cut off the Insulated tie on the Hose for sole and pull off the Hose from the fabric 62 ...

Page 63: ...4 Remove the Fabric 63 ...

Page 64: ...Caution when installing Be careful of the hole of the Fabric in which the Hose goes in when installing the Fabric 64 ...

Page 65: ...65 ...

Page 66: ...e 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 3 Remove the Hinge pin minis and the Snap pins of the Leg pipe and the Foot pipe 4 Remove the Anchor clips of the Air bags and remove Air bags 66 ...

Page 67: ...10 7 4 Air Ottoman hoses 67 ...

Page 68: ...10 8 Removing the Head rest Back cushion and Massage wheel cover 68 ...

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 69 ...

Page 70: ...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 70 ...

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 71 ...

Page 72: ...e 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 72 ...

Page 73: ...2 Unscrew two screws and remove the Power source box 73 ...

Page 74: ...3 Micro switch Fuses Power cord and switch can be removed Be careful not to break the screw heads 74 ...

Page 75: ...Caution when installing Controller cord and Power cord Refer to the figure when installing cords 75 ...

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 76 ...

Page 77: ...anges 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 Up down sensor gear position adjustment procedure To make an adjustment refer to the Massage mechanism block removing method the back frame is tilted from the chair 77 ...

Page 78: ...ting the controller manual operation Massage head adjustment button to up 4 Peeping into the square hole of the back frame check the position of the massager to adjust One thread of the up down detection gear gives a stroke change of 4mm When the massager has been raised excessively Turn the up down detection gear counterclockwise to adjust When the massager has been lowered excessively Turn the u...

Page 79: ...er 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 Also confirm that each Connecting cords are not extremely tense at the highest position Caution After moving the Massage mechanism block to the highest position install the Rear cover...

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 80 ...

Page 81: ...10 13 Assembly and disassembly of Massage mechanism block 10 13 1 Removing the Up down sensor 81 ...

Page 82: ...ear box B 10 13 2 Removing the Body pressure sensor 1 Disconnect the Connector CN206 4 on the Main PCB 2 Cut off the Insulated tie medium 5 and the Insulated tie small 6 of the lead wires 3 Unscrew a screw 7 of the Intensity gear box B 4 Remove the Body pressure sensor 8 Caution when installing When removing the Body pressure sensor do not pull the Lead wires strongly Handle the PCB carefully Be c...

Page 83: ...s be careful so that Lead wires do not hook anything 10 13 4 Removing the Width sensor 1 Disconnect all the Connectors on the Main PCB 2 Cut off the four Insulated ties medium 2 5 10 18 one small 12 3 Unscrew five screws 13 on the Main PCB installation plate and four screws 14 and three screws 15 4 Cut off two Insulated tie medium 16 of the Air hoses and unscrew two screws 17 5 Take off the Snap p...

Page 84: ... 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 84 ...

Page 85: ...it with the five screws loose of the Main PCB installation plate 10 13 7 Removing the Width motor 1 Disconnect Connectors CN102 CN500 of the Main PCB 2 Cut off one Insulated tie medium and two small 3 Remove the Width belt 4 Unscrew four screws of the Width motor 10 13 8 Removing the Back vibrator 1 Disconnect Connectors CN2102 CN211 of the Main PCB 2 Cut off three Insulated ties medium of the Lea...

Page 86: ...om the Rear frame 2 Unscrew two Hex screws of the Air bags 3 Take off the Snap pins of the Air bags 4 Move the Hose clamps and remove the Air bags from the hoses Caution when installing Be careful of the installation directions of the Hose clamps and the Snap pins Caution when removing It would be easy to remove the Air bags if you set the Massage balls at widest and strongest 86 ...

Page 87: ...ssage mechanism frame Up down driving installation plate and Intensity driving installation plate 3 Lift the Up down block and the Intensity block at the same time and remove the Up down from the Massage mechanism block 4 Unscrew two screws of the Up down sensor installation plate 5 Unscrew three screws of the Up down gear box and the Up down driving installation plate 6 Unscrew four screws of the...

Page 88: ...r block 1 3 1 Unscrew five screws of the Intensity gear box and the Intensity driving installation plate 2 Unscrew two screws of the Intensity gear box and the motor and one screw of the Intensity gear box A B Caution when installing It would be easy if you rotate the Intensity worm shaft by hand when inserting the Intensity motor shaft to the coupling 88 ...

Page 89: ...3 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 2 Unscrew four screws of the Back vibrator left right Caution when installing 89 ...

Page 90: ...he gears bitten incorrectly it may cause the crack of the gears 10 13 13 Removing the Up down shaft Up down shaft bolt Work with the Massage mechanism block unloaded 1 Unscrew the Up down shaft bolt with the 13mm diameter box driver and a screwdriver Caution when installing Tightening the Up down shaft bolt too tightly may break the bolt Be sure to use the torque wrench and tighten the bolt with t...

Page 91: ...11 ACTUAL WIRING DIAGRAM 11 1 Air Ottoman 91 ...

Page 92: ...92 ...

Page 93: ...12 CHECKING 93 ...

Page 94: ...12 1 Controller Massage mechanism block 94 ...

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Page 97: ...97 ...

Page 98: ...12 2 Air bags 98 ...

Page 99: ...99 ...

Page 100: ...e 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 100 ...

Page 101: ...ressure 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 Caution Be careful not to bend hoses while checking 101 ...

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 102 ...

Page 103: ...itch 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 103 ...

Page 104: ...104 ...

Page 105: ...105 ...

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 106 ...

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Page 108: ...14 EXPLODED VIEW 108 ...

Page 109: ...15 REPLACEMENT PARTS LIST NOTES 109 ...

Page 110: ...W CUP S K4 10 6 22 WEP780L0447 COVER CLIP 1 23 WEP3200L0277 HOSE CLIP 1J98 1 24 WEP3200K1587 PARALLEL LINK 1 25 WEP3200L1157 LIFT BUSHING 4 26 WEP3200L0937 HINGE PIN MINI D 2 27 WEP596N0357 SNAP PIN 12 28 WEP3200K1567 LEG SLIDE LEVER 1 29 WEP3200K1627 WIRE FIXING PLATE 1 30 WEP2000L0927 HINGE PIN B 2 31 WEP757L6987 POLYETHYLENE WASHER 2 32 WEP2000L6987 WASHER 4 33 WEP2100L6937 U NUT 2 34 WEP3200L0...

Page 111: ...R CORD 1 74 WEP3203K2068 CONNECTING CORD FOR POWER SOURCE B 1 75 WEP3200L0077 POWER SOURCE BOX LID 1 76 WEP3203K2078 CONNECTING CORD FOR CONTROLLER 1 77 WEP2000L0717 ROD HOLDER C 1 78 WEP3203K3108 UNDER BOX TOP RIGHT 1 79 WEP3203K3118 UNDER BOX TOP LEFT 1 80 WEP3200L3757 EDGE GUARD 1 81 WEP596L9567 SCREW CUP S K4 10 10 82 WEP3200L0757 HOSE 2 ROW UNDER A 1 83 WEP3200L0817 HOSE 2 ROW UNDER B 1 84 WE...

Page 112: ...WEP3203K3148 MASSAGE WHEEL COVER 1 122 WEP3200L0857 CENTER HOOK 1 123 WEP757L9687 SCREW T4 16 8 124 WEP3200K3177 REAR COVER TOP 1 125 WEP2200L9697 SCREW P T4 16 2 126 WEP3203K3158 REAR COVER BOTTOM 1 127 WEP3203K3648 SEAT 1 128 WEP3203K3168 UNDER COVER RIGHT 1 129 WEP3203K3178 UNDER COVER LEFT 1 130 WEP596K0457 RIVET 12 131 WEP2110K0447 RIVET 2 132 WEP3200K0567 INSULATED TIE OS170 FT7 2 133 WEP005...

Page 113: ...1 173 WEP3200L1777 INTENSITY GEAR BOX A 1 174 WEP3200L0237 INTENTISTY SHAFT PLATE 1 175 WEP3200L1487 INTENSITY SHAFT BLOCK 1 176 WEP3200L0407 WIDTH STOPPER 2 177 WEP596L9137 SCREW CUP 2 K4 14 2 178 WEP3200L1377 INTENSITY WORM SHAFT 1 179 WEP3200L1167 BUSHING 2 180 WEP3200L1177 SPRING SLIDE PLATE 1 181 WEP3200L1207 STOPPER RING 1 182 WEP3200L1187 COUPLING 1 183 WEP3200L1217 SPACER 0 6 2 184 WEP3200...

Page 114: ...CREW S M4 45 5 220 WEP2200L9697 SCREW P T4 16 6 221 WEP760N9607 SCREW K4 10 2 222 WEP590L6017 SCREW CUP S K3 6 5 223 WEP573L6627 SCREW CUP S K 4 6 16 224 WEP2110L0427 RIVET 21M2 4 225 WEP3200L0437 PLATE STOPPER RIGHT 1 226 WEP3200L0447 PLATE STOPPER LEFT 1 227 WEP3200L0417 PLATE STOPPER COVER 2 228 WEP3200L0387 PROTECTION CLOTH 1 229 WEP3200K0457 BRUSHCLIP 1 230 WEP3200L0037 PCB INSTALLATION BOARD...

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Panasonic EP3203-U1, Service Manual

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