Cozzia CZ-388 Maintenance Service Manual
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Cozzia CZ-388 Maintenance Service Manual

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CZ-388 Maintenance Service Manual

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Summary of Contents for Cozzia CZ-388

  • Page 1 CZ-388 Maintenance Service Manual...
  • Page 2 Catalog 1: Precautions for inspection and repair 2: CZ-388 massage chair auto-check list 3: Common Troubles and Maintenance Methods list 4: Tools List 5-1: Guidance of Disassemble the backrest Assy 5-2: Guidance of Disassemble the Backrest pad Assy 5-3: Guidance of Disassemble the Seat pad Assy 5-4: Guidance of Disassemble the Side Board 5-5: Guidance of Disassemble the Thigh Massage unit.
  • Page 3 5-19: Guidance of Disassemble the Footrest Extend Assy 5-20: Guidance of Disassemble the Air valves inside the Footrest...
  • Page 4 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. ...
  • Page 5 CZ-388 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.
  • Page 6 1.wideth inspection board is broken 1.change wideth inspection 2.the wire connect to the more than 5 seconds did board activate wideth inspection board is not tested the narrow 2.change backrest auto-check disconnected signal wires.(black and gray) model 3.kneading motor is 3.change kneading motor broken or kneading belt is lost...
  • Page 7 1.change foot rest recline 1.foot rest recline actuator actuator is broken 2.check whether the foot 2.foot rest actuator motor activate can't test signal from foot rest recline actuator motor wire is disconnected auto-check rest recline actuator wire is well connected. 3.the signal wire of foot model 3.check whether the signal...
  • Page 8 3: Common Troubles and Maintenance Methods are listed as following: Serial Phenomenon Description Maintenance Methods The LCD isn’t illuminating: ① Replace Fuse. ①Fuse melts (in the Power Source Box or on ② Replace Power Box. No Function the transformer wire). ③...
  • Page 9 ①Terminal or Wire Poorly Contacts. ①Plug the terminal securely or ②Down-stroke Photo-electricity replace the wires. ②Replace Down-Stroke Sub- Subassembly Fails. ③Up-stroke Photo-electricity assembly. No Rolling. ③Replace Up-Stroke Sub- Subassembly Fails. ④Rolling Motor Fails. assembly. ⑤Main PCB Fails. ④Replace Rolling Motor. ⑤Replace main PCB.
  • Page 10 ①The terminal of the snuffle valves and ①Plug the terminal securely. ②Replace the snuffle valves. wires are poorly connected. No gas charging ②The snuffle valves fail. ③Replace the inflator pump. in the seat-pad. ③The inflator pump fails. ④Replace main PCB. ④Main PCB fails.
  • Page 11 Tools List Tools required Screwdriver size Diagonal cutter Soldering Spanner tools Kit 1,2,3 long nose pliers Test pen Allen Key set Ratchet Tools Set Blower electrical adhesive Electric Driver Cable Ties WIRE CONECTORS tape...
  • Page 12 5-1: Guidance of Disassemble the Backrest Assy A: Locate the pillow at the top, front of the chair. It is attached to the backrest pad via Velcro. Detach it. ( As pictures below show) Locate Velcro The pillow has been Locate the pillow detached B: Locate the zipper head of the backrest pad at the top, back of the chair.
  • Page 13 C: Locate the level lock at bottom of the backrest. Pull the level lock upwards to release from the catch. Fold the backrest forward. ( As pictures below show) Push the backrest Assy Locate the level lock Pull the level lock upwards forwards D: Rest the backrest onto the seat pad Assy.
  • Page 14 5-2: Guidance of Disassemble the Backrest pad Assy 5-1: Guidance of Disassemble the Backrest A: Disassemble the backrest assy. ( Refer to Assy ) B: Locate the air hoses of backrest pad on the back of the backrest pad. Tracking along the air hoses we can find the air hose connecters.
  • Page 15 Then we can detach the backrest pad assy. ( As pictures below show ) Unzip the zipper to the The backrest pad Locate the zipper head has been detached E: Separate the Velcro on the back of backrest pad. We can find a sponge pad inside. We can take it out.
  • Page 16 nose pliers get ride of the close end wire connecters. Then we can detach the heater. ( As pictures below show ) Get ride of the close The heater has been end wire connecters detached Cut the cable tie 5-3: Guidance of Disassemble the Seat pad Assy A: Disassemble the backrest assy.
  • Page 17 wire connecter. Then disconnect it. ( As pictures below show. ) Locate vibration Use diagonal cutter get motor wire ride of the cable tie E: Locate the zipper head of the zipper which between seat pad and footrest upholstery. Thread a small cable tie through the zipper head to unlock the zipper. Then unzip it to the end.
  • Page 18 F: Take the seat pad cover off. Then we can see air bags and vibration motor. ( As pictures below show) Locate the vibration motor Locate air bags Seat pad cover G: Disconnect the air hose and we can detach the air bag. ( As pictures below show ) Locate air hose connecter 5-4: Guidance of Disassemble the Side Board.
  • Page 19 Locate the two hexagon Remove the screw bolts Remove the screw bolts screw bolts E: Locate the air hose connecter of the side board. Disconnect it. Then we can detach the side board. ( As pictures below show. ) Locate hose connecter.
  • Page 20 C: Disconnect the air hose then detach the thigh massage assy. ( As pictures below show ) Locate hose The thigh massage has connecters been taken off D: Separate the Velcro then remove the cover of thigh massage assy. (As pictures below show ) Velcro been Cover of thigh massage...
  • Page 21 5-6: Replacing rear cover of backrest& front cover of backrest. Guidance of disassemble the backrest assy) A：Detach the backrest assy. ( Refer to B: Locate the zipper heads at the bottom of the backrest assy. Unzip these two zippers to the end.
  • Page 22 Next  front cover of backrest Hold it pull up Backrest hardware 5-7: Guidance of Disassemble up & down limit sensor. A: Detach the rear cover of backrest. Then we can find up & down limit sensor. ( Refer to front cover of backrest &...
  • Page 23 C: Use long nose pliers slacken and remove the screw nuts. Limit sensor been Remove the screw nuts. detached. D: Use long nose pliers get ride of the glue, then disconnect the connecter. Get rid off the glue. The limit sensor has been taken off.
  • Page 24 B: Take off the kneading belt first. Kneading belt has been taken off. C: Use diagonal cutter get ride of the cable ties which fasten the mechanism wires. Locate cable ties. Cable tie has been taken off. D: Use diagonal cutter peel the heat-shrinkable T bush slowly. ( As picture below show.) Be careful, don’t cut the wire Heat-shrinkable T bush has been peel off.
  • Page 25 F: Slacken and remove the screws which fixing the kneading motor, then we can detach the kneading motor. Kneading motor has been detached. 5-9: Guidance of Disassemble the Counting sensor of Rolling motor. A: Detach the rear cover of backrest. Then we can find counting sensor of rolling motor.( Refer front cover of backrest &...
  • Page 26 B: Use diagonal cutter get ride of the cable ties which fasten the mechanism wires. Cable ties have Locate cable ties. been taken off. C: Use diagonal cutter peel the heat-shrinkable T bush slowly. ( As picture below show.) Heat-shrinkable T bush has Be careful, don’t cut the wire been peel off.
  • Page 27 E: Use long nose pliers take off the close end wire connector of counting sensor of rolling motor. ( As pictures below show.) F: Use long nose pliers get ride of the glue, and pry-out the counting sensor. Get rid off the glue. The glue has been cleaned.
  • Page 28 B: Remove the 2 screws (red O) which secure the Upper part of the Gear box as shown in Fig1. C: Remove the 2 screws (red O) which secure the Lower part of the Gear box as shown in Fig2. D: Hold firmly on the Gear Box to prevent from falling (red □) as shown in Fig 3.
  • Page 29 B: There are four screws fixing the top bar. ( As pictures below show.) C: Use a long nose pliers hold the screw nut firmly, then slacken and remove the screw. After the four screw has been removed, then we can take the top bar off. ( As picture below show.) D: There are two stoppers inside the guide rail.
  • Page 30 Locate cable ties. Cable tie has been taken off. F: Use diagonal cutter peel the heat-shrinkable T bush slowly. ( As picture below show.) Heat-shrinkable T bush has Be careful, don’t cut the wire been peel off. G: Use long nose pliers remove all the close-end wire connecters Locate close-end wire connecters.
  • Page 31 5-12: Guidance of disassemble the Rolling motor Assembly Replacing massage mechanism A: Detach the massage mechanism. ( Refer to Massage mechanism has been detached. B: Use a strong screw driver slacken and remove the screws which fixing the rolling motor unit to the mechanism frame.
  • Page 32 C: Now the rolling motor unit can be taken off. 5-13: Guidance of Disassemble the Remote control A: Disassemble the backrest assy. ( Refer to 5-1: Guidance of disassemble the backrest assy.) B: Locate the two cable ties which secure the remote control wire. Use diagonal cutter to get rid of these two cable ties.
  • Page 33 D: Slacken and remove the wire connecter cap, then we can disconnect it and detach the remote control. ( As pictures below show ) The connecter has been Remote control has disconnected been detached...
  • Page 34 5-14: Guidance of Disassemble the Main PCB & Zero-Gravity actuator PCB A: Disassemble the backrest assy. ( Refer to 5-1: Guidance of disassemble the backrest assy.) B: Locate the main PCB box assy at bottom. Use screw driver slacken and remove the two screws which fixing the main PCB box assy to the frame.( As pictures below show ) Locate the two screws C: Pull the main PCB box out a few.
  • Page 35 E: Locate the 6pcs main PCB supporters which secure the main PCB. Use long nose pliers nip the head of the main PCB supporter to unlock the main PCB. Meanwhile pull the main PCB up with your finger. Then we can release the main PCB. ( As pictures below show ) Locate the 6pcs main PCB supporters Unlock the Pull the main...
  • Page 36 Main PCB connection Diagram: TRANSFORMER OUTPUT: POWER IN: TRANSFORMER INPUT: AC 20.5V AC 110V AC 110V Backrest motors: Rolling motor, tapping motor, INFLATOR PUMP: kneading motor AC 110V Footrest extend TRANSFORMER OUTPUT: DC24V AC 10.5V Connect to extra PCB Backrest actuator DC24V DC24V Footrest actuator...
  • Page 37 5-15: Guidance of Disassemble the Transformer A: Disassemble the backrest assy. ( Refer to 5-1: Guidance of disassemble the backrest assy.) B: Locate the main PCB box assy at bottom. Use screw driver slacken and remove the two screws which fixing the main PCB box assy to the frame.( As pictures below show ) Locate the two screws C: Pull the main PCB box out a few.
  • Page 38 E: Locate the transformer wire connecters on the main PCB. Then disconnect them. ( As pictures below show ) Locate the transformer wire connecters F: Use spanner slacken and remove the hexagon bolt which secure the transformer. Then we can detach the transformer. ( As pictures below show ) Locate hexagon transformer...
  • Page 39 5-16: Guidance of Disassemble the Air valve A: Disassemble the backrest assy. ( Refer to 5-1: Guidance of disassemble the backrest assy.) B: Locate the main PCB box assy at bottom. Use screw driver slacken and remove the two screws which fixing the main PCB box assy to the frame.( As pictures below show ) Locate the two screws C: Pull the main PCB box out a few.
  • Page 40 E: Use long nose pliers remove the two clips which secure the air hose. Then disconnect the air hose. ( As pictures below show ) The two clips have been The two air hose have removed been disconnected F: Locate the four screws which secure the air valve. Use screw driver slacken and remove them.
  • Page 41 5-17: Guidance of Disassemble the Inflator pump. A: Disassemble the backrest assy. ( Refer to 5-1: Guidance of disassemble the backrest assy.) B: Locate the main PCB box assy at bottom. Use screw driver slacken and remove the two screws which fixing the main PCB box assy to the frame.( As pictures below show ) Locate the two screws C: Pull the main PCB box out a few.
  • Page 42 E: Locate the inflator pump wire connecter on the main PCB. Use diagonal cutter get ride of the cable ties which secure the inflator pump wire harness. Then disconnect the connecter. ( As pictures below show ) Locate the wire Locate the cable connecter ties...
  • Page 43 5-18: Guidance of Disassemble the Footrest assy. A: Unzip the zipper between seat pad and footrest cover. Slacken and remove the screws which secure the lower front cover. Then remove it. ( As pictures below show ) Unzip the zipper to Lower front cover has Locate the screws the end...
  • Page 44 D: Use long nose pliers remove the pin and the bolt which attach the footrest to the steel tube. Then we can detach the footrest ASSY. ( As pictures below show ) Locate the pin and bolt Footrest been detached 5-19: Guidance of Disassemble the Footrest Extend Assy A: Disassemble the footrest.
  • Page 45 C: Use diagonal cutter get ride of the cable tie which fasten the motor wire. ( As pictures below show ) Locate cable ties D: Get ride of insulated tape first. Then use long nose pliers get ride of the close-end wire connecters.
  • Page 46 Use spanner hold on the Use screw and screw screw nut meanwhile use nut to hold on the screw driver slacken the Locate the screws footrest extend ASSY screw G: Slacken and remove the four screws which fixing the feed screw nut. Then we can take footrest extend ASSY off.
  • Page 47 5-20: Guidance of Disassemble the Air valves inside the Footrest Attention: If only change the air valves we don’t have to detach the footrest assy. We can rise the footrest and do it. A: Use screw driver slacken and remove the two screws which securing the rubber support. ( As pictures below show ) Locate the rubber supports The rubber supports has...
  • Page 48 Locate the zipper head. Locate the 6pcs screws Locate the air valves Unzip the zipper to the which secure inside the footrest plastic board D: Use diagonal cutter get ride of the cable tie which secure the wire harness. Then find the air valve wire connecter.
  • Page 49 F: Locate the four screws which secure the air valve. Remove these screws. Locate the side air hose of the air valve. Disconnect it at the “T” connecter. Then we can detach it. ( As pictures below show ) Locate the four screws Locate “T”...

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