Johnson J-5800 Service Manual

J-5800 MASSAGE CHAIR

SERVICE MANUAL

2014/03/17
EV 2

Johnson Health Tech. Co., Ltd.

Summary

 1. Product specification
 2. Engineering mode introduction

 2-1. Motor testing (P1) 2-2. Sensor testing (P2) 2-3. Current testing (P3)

 2-4. Air pressure testing (P4) 2-5. Software version detection model (PU)
 3. Error codes

3-1. OF, 90 3-2. A0 3-3. A1 3-4. A2, A3, B0, B1

3-5. B2, B3, C0, C1 3-6. D0 3-7. E0 3-8. E1, E2 3-9.E3

 4.Common troubleshooting

4.1 Fail to start 4.2 Pushrod motor 4.3 Single air bag

4.4 All air bags 4.5 All air bags 4.6 Machine core

 5. Appendices

 5.1 Replace the machine core 5.2 Software update 5.3 Adjust machine core motor current

 5.4 Complete machine breakdown drawing 5.5 Machine core breakdown drawing

 5.6 Lower control panel breakdown drawing

 Thank you! (Contact us)

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Foreword

Precautions during repairs and faults:

a. When disassembling, unplugging connectors and replacing parts, make
sure to unplug or turn off the power.

b. As semiconductors (IC, etc.) are prone to being damaged by static
electricity, please use human body electrostatic discharge ground wire if it is
required to directly contact the baseplate when performing operations, or
touch the ground wire (ground wires of fridges, washing machines, etc.) with
bare hands to discharge the static electricity of the human body before
carrying out operations.

c. The circuit baseplate mixes high voltage (AC110V, AC220V) and low voltage
(12V, 5V), which may cause electric shock accident; so please do not have
direct contact without preparations.

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1.Product Specifications：

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1.Product Specifications：

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1. When the power is on and manual controller is not yet
actuated, press

MANUAL

MANUAL and

LEG STRETCH

LEG STRETCH on the

manual controller at the same time for 5 seconds and the
controller will display “ - - ”

2. Then press

REPEAT

REPEAT key to enter engineering mode

3. In the engineering mode,“ P0 ” will be displayed

2. Engineering mode introduction:

In the engineering
mode,“ P0 ” will be
displayed

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4 . Use

UP

UP and

DOWN

DOWN to select 8 modes,

including P0~P4+P7+P8+PU

5 . In mode selection state, press

WIDE

WIDE

to enter the mode to operate the
massage chair

6 . After mode selection, use

UP

UP

and

DOWN

DOWN

again to select the element to

be controlled, such as A0~A5

2. Engineering mode introduction:

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7 . After entering the mode, press

STOP

STOP key to return to the

previous layer of menu; this key has the same function as the
ESC key of the computer keyboard

8 . After element selection, use AIR STRENGTH to adjust the

element speed, and the intensity will be displayed as the air
pressure strength, with one to three representing from weak to
strong

2. Engineering mode introduction:

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Key Operation

Emergency stop Return to the previous layer of menu

Up Forward mode selection

down

Reverse mode selection

Wide

Select ok and the air bag moves or motor rotates forward

Narrow

Motor rotates reverse

Power switch Exit engineering mode

Air bag strength (panel) Speed selection (3: high, 2: medium, 1: low)

LCD

LCD Operation

Time window

Display selected element number and corresponding current or
position

Air pressure strength Speed display (3: high, 2: medium, 1:low)

2.

Engineering mode introduction:

Engineering mode introduction:

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— —

P0 : Hand controllertestingmode

P1 : Motor testing mode

P2 : Sensor testing mode

P3 : Current testing mode

P4 : Air bag testing mode

P7 : Automatic testing mode

P8 : Life testing mode

PU : Software version check

2.

Engineering mode introduction:

Engineering mode introduction:

P0 : Manual controller testing mode

P1 : Motor testing mode

PU : Software version check

P7 : Automatic testing mode

P8 : Life testing mode

P4 : Air bag testing mode

P3 : Current testing mode

P2 : Sensor testing mode

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P1 Motor testing mode

A0 : Up and down movement of machine core

A5 : Machine core pounding motion

A4 : Kneading-Forward and reverse rotation of machine core

A3 : Front and back movement of machine core

A2 : Up and down movement of chair back

A1 : Up and down movement of foot machine

Motor test mode is mainly used to test if each motor works normally and to adjust

chair angle when replacing elements

2-1. Engineering mode: P1

A6 : Forward and back movement of foot machine

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P2 sensor testing

C0 : Up and down movement of machine core

C4 : Kneading-Forward and reverse rotation of machine core

C3 : Front and back movement of machine core

C2 : Up and down movement of chair back

C1 : Up and down movement of foot machine

Sensor testing is mainly used to test and indicate limits and counts. When operating
motor in this mode, LCD time window will display the digit returned by the sensor. When
the digit exceeds 100, the carrying digit will display “massage intensity” (100~500) and
“motion menu”.

LCD sensing position display window will indicate whether the limit switch is triggered

2-2. Engineering mode: P2

C5 : Forward and back movement of foot machine

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Upper limit is

triggered

Tens and ones

of returned

values

Hundreds of

returned values

Current speed

of motor

motion

The left figure shows that the upper
limit is reached when the selected machine
core (C1) rises

When the upper limit light is, it means
that the machine core is unable to move
upward; when the lower limit light is on, the
machine core is unable to move downward

The “Massage Strength” lamp signal 1 of
massage intensity represents 100, 2
represents 200, and so on

“KNEAD” lamp represents 600,”KAT”

lamp represents 700.

We can tell by the above rules that the
returned value on the left figure is time
window (40) + motion menu lamp signal
(700) =740

2-2. Engineering mode: P2

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P3 current testing

D0 : Up and down migration current of machine core

D4 : Kneading-Forward and reverse rotation current of

machine core

D3 : Front and back migration current of machine core

D2 : Up and down migration current of chair back

Current testing is mainly used to test if the motor current is too high

When the returned number exceeds 100, the carrying digit will display “massage intensity”
(100~500)

D3 is a major test item; if the intensity is set to medium (air bag strength 2) and machine core
forward value is greater than 50, it is likely to generate error code D0 because the current is too
high to lower the sensitivity of induction mechanism

2-3. Engineering mode: P3

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P4 air bag testing

1 : shoulder air bag

5 : right arm air bag

3 : right waist air bag

Air bag testing is mainly used to test if the
air bag works normally, the inflation rate is
normal, there is leakage, etc.

It can also distinguish the position of the air
bag to be tested via the pattern on the
manual controller.

6 : left hip air bag

7 : right hip air bag

8 : instep air bag

9 : thigh air bag

10 : calf air bag

11 : air bag below the leg

2 : left waist air bag

12 : air bag above the leg

4 : left arm air bag

2-4. Engineering mode: P4

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Shoulder

Waist

Arm

Hip

Thigh

Upper leg

Calf

Lower leg

Instep

2-4. Engineering mode: P4

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PU software version

U0 : manual controller software

version

U1 : lower control panel

software version

Software version check mode is generally used to confirm current version of massage chair and

confirm again if the update is successful after updating software

a. Press “up” or “down” key to make the time window display “PU” to enter software version check

function

b. Press “ok” function, and the time window displays “U0” to enter manual controller software

version check function

c. Press “air pressure strength” key, and the time window displays in a jumping loop of “v1”-“04”-

“v1”-“04”...... indicating that the manual controller software version is v104

d. Press “up” or “down” key to make the time window display “U1” to enter lower control panel

software version check function

e. Press “air pressure strength” key, and the time window displays in a jumping loop of “v1”-“05”-

“v1”-“05”...... indicating that the lower control panel software version is v105

f. Then, the software version is 104105

2-5. Engineering mode: PU

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• The error codes will appear on the machine’s manual controller and the machine will stop

• Maintenance personnel can judge the fault conditions and anticipate maintenance materials

based on the error code reported by the customer

Error Code

3. Error codes

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Anomaly

code

Code description Cause of anomaly Countermeasures

0F

Inconsistency

between manual

controller model

and master control

panel model

1. Inconsistency between
manual controller model
and lower control panel

2. Inconsistency of software
versions

1. Confirm manual controller model

2. Replace with correct model software and then
confirm if the machine is normal

3. Replace the lower panel and then confirm if
the machine is normal

4. Ask for assistance of original factory

90

Communication

error

Communication
timeout
between manual
controller and lower
control panel

1. Confirm if connection between manual
controller and lower control panel is normal

2. Update software and then confirm if the
machine is normal

3. Replace the manual controller then confirm if
the machine is normal

4. Replace the lower panel and then confirm if
the machine is normal

5. Ask for assistance of original factory

3-1. Error code (0F, 90)

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Anomaly

code

Code description Cause of anomaly Countermeasures

A0

Kneading seized

After the software gives
an instruction, the
kneading sensor of
machine core does not
return signal

1. Check if the connecting line contacts poorly

2. Check if the sensor works normally and the
sensor is centered

Kneading sensor

3-2. Error code (A0)

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Anomaly

code

Code description Cause of anomaly Countermeasures

A1

Up and down

seized

After the software gives
an instruction, the up and
down sensor of machine
core does not return
signal

1. Check if the connecting line contacts poorly

2. Check if the sensor works normally and code
plate is centered

Upper and

lower position

sensor

3-3. Error code (A1)

Lower limit

sensor

Upper limit

sensor

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Anomaly

code

Code description Cause of anomaly Countermeasures

A2

Chair back seized

Count of chair back pushrod

does not return signal

1. Check if the chair back structure is seized

2. Check if the chair back pushrod signal line contacts
normally

3. Update software, and then confirm if the machine is
normal

4. Replace the chair back pushrod, and then confirm if
the machine is normal

5. Replace lower panel

A3

Safety switch

triggered

When the machine core

moves up and down, safety

switch is triggered

1. Except in Japan, this anomaly code is shielded in

the software; while only keeping hardware structure,
updating software can eliminate the error

2. Check if the safety switch connecting line contacts

poorly

3. Check if there is any foreign matter in upper and lower

rails resulting seizure

4. Replace machine core

B0

Kneading overload

Kneading motor current is

too high

1.Check if the machine core structure is seized

2. Replace machine core

B1

Pounding overload

Pounding motor current is

too high

1. Check if the machine core structure is seized

2. Replace machine core

3-4. Error code (A2, A3, B0, B1)

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Anomaly

code

Code description Cause of anomaly Countermeasures

B2

Front and back

overload

Front and back motor

current is too high

1. Check if the machine core structure is seized

2. Replace machine core

B3

Up and down

overload

Up and down motor

current is too high

1. Check if the machine core structure is seized

2. Replace machine core

C0

Abnormal

heating

Abnormal heater band

Please refer to warming function anomaly in

troubleshooting (4-6)

C1

Abnormal

thermistor

Abnormal thermistor

Please refer to warming function anomaly in

troubleshooting (4-6)

3-5. Error code (B2, B3, C0, C1)

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Anomaly

code

Code description Cause of anomaly Countermeasures

D0

Empty

Incorrect sitting posture results in
failure to correctly detect when
detecting position

During body type detection, ask
users to place their backs to the
massaging balls as closely as
possible

Lighter weight of users

During body type detection, ask
users to place their backs to the
massaging balls as closely as
possible. When the massaging balls
move forward for detecting, push
backward as strongly as possible

Aged mechanical structures of the
front and back motors of the machine
core. When they move, the current
rises, lowering detection function.
When the user’s weight is light, it may
misjudge that it is empty

1. Slightly loosen the motor set screws.
Refer to 5-3 Adjust machine core’s

advance and retreat current

for procedure

2. Replace machine core (Please refer
to 5-1 )

3-6. Error code (D0)

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Anomaly

code

Code description Cause of anomaly Countermeasures

E0

Abnormal front

and back count

After the software
gives an instruction, the
front and back sensor of
machine core does not
return signal

1.Check if the connecting line contacts poorly

2.Check if the sensor works normally and code plate is
centered

3. Replace machine core

Advance and retreat

sensor

3-7. Error code (E0)

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Anomaly

code

Code description Cause of anomaly

Countermeasures

E1

Chair back count

anomaly

After the software gives an
instruction, chair back pushrod
does not return signal

1. Check if the connecting line contacts poorly

2. It may be interference with chair back structure. Please confirm if
there is interference

3. Use spare parts to connect the main board to confirm if chair
back pushrod is damaged

4. Replace main board

E2

Foot machine count

anomaly

After the software gives an
instruction, foot machine pushrod
does not return signal

1. Check if the connecting line contacts poorly

2. It may be interference with foot machine structure. Please
confirm if there is interference

3. Use spare parts to connect the main board to confirm if foot
machine pushrod is damaged

4. Replace main board

Chair back

pushrod

Foot machine

pushrod

3-8. Error code (E1, E2)

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Anomaly

code

Code description Cause of anomaly

Countermeasures

E3

Extend foot machine

count anomaly

After the software gives
an instruction, extend foot
machine pushrod does not
return signal

1. Check if the connecting line contacts poorly

2. It may be interference with chair back structure. Please confirm if
there is interference

3. Use spare parts to connect the main board to confirm if extend
foot machine pushrod is damaged

4. Replace main board

Plug of extend foot

machine pushrod

3-8. Error code (E3)

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• Precautions during repairs and faults:

• a. When disassembling, unplugging connectors and replacing parts, make

sure to unplug or turn off the power.

• b. As semiconductors (IC, etc.) are prone to being damaged by static
electricity, please use human body electrostatic discharge ground wire if it
is required to directly contact the baseplate when performing operations, or
touch the ground wire (ground wires of fridges, washing machines, etc.)
with bare hands to discharge the static electricity of the human body before
carrying out operations.

•

• c. The circuit baseplate mixes high voltage (AC110V, AC220V) and low

voltage (12V, 5V), which may cause electric shock accident; so please do
not have direct contact without preparations.

• When measuring with an electric meter, basic electricity knowledge is
required to avoid short circuits or personal dangers.

4.

Common troubleshooting

Common troubleshooting

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Treatment:

• When the machine fails to start, confirm if the protector is tripped

After reset, the power led turns onit may be motor overload, keep on observing

After reset, the power led turns on and then off immediatelythe circuit system may be short

circuited and requires attention. It is recommended to ask the personnel with electronic
background to check and repair. There may be broken covered wires, short circuits or
breakdown of electronic devices

4-1.

Fail to start

Fail to start

First, turn on the

power supply

Press the protector to reset

its status

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b. Confirm if the power supply and EMC filter board are normal. Measure if AC110V (AC220V

in mainland China) power supply of output end of EMC board is normal

Possible cause: EMC board fuse damage, EMC board damage or poor contact of

connecting line

4-1.

Fail to start

Fail to start

Turn off the

power supply

Remove four set screws (red arrow),

Remove power supply cover (blue arrow)

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The probe is
placed on the
power supply

input end

Switch to AC,

and turn on the

power supply to

confirm voltage

Test if the output

end voltage

conforms to the

input end

After the power is

off, measure if the

fuse is damaged

The main purpose is to measure if the input end voltage has
output voltage (AC110V or AC220V) after passing through the filter;
if there is no voltage, check if the fuse is burned (The power must

be off when measuring the fuse)

When the fuse is not burned, and there is still no output voltage,
replace the filter

4-1.

Fail to start

Fail to start

Fuse

specificatio

n

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c. Confirm if the transformer power supply is normal. Measure transformer output end

voltage: no load AC24-28V, AC12-15V, AC15-18V

Possible cause: the fuse inside the transformer is damaged; replace the transformer.

AC12V AC15V AC24V AC24V

4-1.

Fail to start

Fail to start

Transformer body

Voltage output plug

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d. Record the software for the master control panel and manual controller

again and observe if the indicator light of the master control flashes
normally.

Please refer to 5-2 Software Update

e. Change to the spare manual controller for operation. If it operates

normally, replace the manual controller; if not so, replace the master
control panel

4-1.

Fail to start

Fail to start

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Treatment:

Unplug the power line of the electric pushrod motor which does not work, and
replace with spare pushrod motor (or replace with the electric pushrod which
works normally on the machine) for testing.

Replace master

control panel.

Replace

pushrod.

Still does

not work

Works

normally

4-2.

Pushrod motor does not work

Pushrod motor does not work

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Treatment:

Use engineering mode 2-4:P4 to detect, and refer to the air bag

location diagram

Check if the solenoid valve works normally

Check if each air channel connector leaks/air pipes are

compressed and shut off; connect and fasten again/replace
aged air pipes

4-3.

Individual air bag can not be

Individual air bag can not be

inflated or inflated sufficiently

inflated or inflated sufficiently

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Treatment:

a. First, rule out that the internal thermal protection of air pump is caused

by long-time operation

b. Judge whether the air pump works or not by listening to its sound.

c. Check if the solenoid valve works normally. No: Check air valve

connecting line or replace master control panel

No: check air pump

power supply

Normal (AC24-28V)

Replace air pump

Replace master

control panel

Normal

Abnormal

4-4.

All air bags do not work

All air bags do not work

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Treatment:

First, rule out that the internal thermal protection of motor is caused by long-time

operation
Use manual mode to force the motor to start, checking if it can be started.
Enter P2 (refer to2-2) to check if the SENSOR corresponding to the poor motor triggers the

limit,

For example, when the front and back machine core motors cannot move forward, it is
required to note that if the front limit lamp signal is triggered; when the front limit lamp is
on, it represents that the lower control panel thinks that the machine core is at its foremost
position and cannot go more forward

When the lamp signal
is on, it represents
the front limit is
triggered

When the lamp signal
is on, it represents the
back limit is triggered

Sensor mode

Machine core

forward and

backward

4-5.

Machine core motor does

Machine core motor does

not work

not work

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d. When using the engineering mode (e.g. P1) to drive the poor motor, use the electric meter to

measure if the motor corresponding plug on the machine core signal adapter board has DC24V
output?

24V no  check motor power line power line PASS  replace master control panel

24V yes  replace machine core (or replace machine core motor; kneading motor is not

suitable for field replacement; refer to Appendix I for the replacement of machine core）

4-5.

Machine core motor does

Machine core motor does

not work

not work

Up and

down motor

Retreating

motor

Pounding

motor

Kneading

motor

Machine core

adapter board

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• J6800, J5800 and J5600 use the same machine core, and so the
replacement method is the same; the only difference exists in
outer shell disassembly sequence

• Prepare materials as follows:

• Prepare tools: screw driver, cable tie, diagonal cutting plier and

needle-nose plier

5-1.

Replace machine core

Replace machine core

Machine core unit

1 set

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1. Turn off the power supply, and remove the outer
shell’s 4 screws (4 screws indicated by red solid
lines + 2 screws indicated by red dashed lines ).

1

5-1.

Replace machine core

Replace machine core

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5-1.

Replace machine core

Replace machine core

2. Enter the engineering mode A0 (refer to 2-1),
elevate the machine core to the proper height
and cut the cable tie fixing the signal line

3. Use Phillips screwdriver to loosen the ground
wire screws of the signal line

2

3

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Loosen upper two screws

without removing them

4. Loosen the supplementary piece
screws of the upper rail

5. Use the manual controller to operate

the machine core (refer to 2-1) to adjust

the position

6. Move the machine core roller to the
upper position to prepare for removal

4

Remove lower two screws

5-1.

Replace machine core

Replace machine core

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7. Be careful that the roller on the left side may
eject; assist with hands

8. Make the rollers on the upper sides off the
rails

9. Elevate until breaking away from rack
engaging state

10. Unplug the power line and signal connecting
line

11. Use both hands to remove the disengaged
machine core

5-1.

Replace machine core

Replace machine core

7

8

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12. Install the new machine core in the reverse
sequence of removal

13. It should be noted that plastic gaskets are
needed for the right-side roller of the new
machine core and such materials can be
obtained from the old core

14. It should be noted that spring and metal
gaskets are needed for the left-side roller
and such materials can be obtained from
the old core

13

14

5-1.

Replace machine core

Replace machine core

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15. After the machine core is installed, tighten the rail
fixing piece

16. Lock the signal line ground wire on the set screws
of the adapter board. The picture shows that the
ground wire is not locked

17. And use the cable tie to fix the connecting line on
the machine core metal plate. If the tie specification
is small, use two or more ties for fixing. There are
holes for fixing the ties indicated by red circles

Note: When the signal line is not securely fixed, it may

lead to occasional anomalies due to the loosened

signal line during the operation

16

17

5-1.

Replace machine core

Replace machine core

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18. After the installation is completed, elevate
the machine core to the upper limit and
confirm that the sensor works normally,
and adjust the metal plate properly to the
center position (about 2 mm from both
sides)

19. Lower the machine core to the lower limit
and confirm that the sensor works normally,
and adjust the metal plate properly to the
center position

18

19

5-1.

Replace machine core

Replace machine core

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• Prepare the flash drive and software

• J5800 software includes 2 parts

(all *.BIN files):

• A. Manual controller application software jconsole.bin

• B. Lower control panel application software jfitness.bin

• It is recommended to install the software in the flash drive below 8GB to avoid that the

lower control panel cannot read the flash drive

• It is recommended to store only the file folder jfitness in the flash drive to improve
recording success

5-2.

Software update

Software update

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Operational method:

a. Enter the engineering mode PU (refer to 2-5 engineering mode:PU) to confirm that if the software

version needs update

b. While the machine’s power is off, insert the flash drive with new software files to the USB line.

c. Press "start/stop" key on the manual controller to turn on the machine power switch (press the manual

controller power switch continuously)

d. Then, you will see the pounding lamp is on. Press the power key continuously and then you will see that

the pounding lamp keeps flashing

e. You will hear the relay’s motion sound 5 seconds after the pounding lamp stops flashing, and the update

is completed. Unplug the flash drive and test again by restarting the machine

5-2.

Software update

Software update

USB connector is hidden under the cushion

I: On / O: Off; when the power is
on, the power switch light is on

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1

• 1. Before adjusting the machine
core’s advance and retreat current,
confirm the current value first: Enter
the engineering mode (please refer to
2-3) D0 to elevate the machine core to
the half height (and confirm that the
chair back is empty or not loaded; any
load will affect the numerical value)

• Proper height is indicated by the green
portion in the picture; the cushion or
leather cover, as indicated by the red
portion, may affect the numerical value

Proper

height

range

5-3.

Adjust the machine core

Adjust the machine core’’s s

advance and retreat current

advance and retreat current

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2. Then from P3->select D3

3. Press the “Air Strength” to select 2

4. Press the roller postion “wide” to make the machine core
move forward. At this time, a number will appear and confirm
that the number is not greater than 30

5. If it is greater than 30, adjust through the following steps;

2

3

4

5

5-3.

Adjust the machine core

Adjust the machine core’’s s

advance and retreat current

advance and retreat current

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Steps as follows

1. Remove 6 screws on the outer shell of the massage chair’s rear cover

2. Enter the engineering mode A0 (refer to 2-1) to elevate the machine
core to the proper height

Prepare tools:
3mm Allen key, 7mm open-end wrench, screwdriver and flathead screwdriver

5-3.

Adjust the machine core

Adjust the machine core’’s s

advance and retreat current

advance and retreat current

Johnson Health Tech. Co., Ltd.

3. Loosen the screw nuts of the machine core’s advance and retreat motor set screws

4. Use the Allen key to loosen the screws for 1/4 circle

5. Tighten the nuts. Then use the Allen key to fix the screws to avoid turning screws when fixing
the nuts

6. Do the same for the other 3 screws. A total of 4 screws require the adjustment

7. After the adjustment, enter the engineering mode D3 to check if the number is lowered to
below 30

8. If the number is lower than 50, the adjustment is completed and machine is restored; if not,
loosen for another 1/4 circle

9. If the adjustment is more than 2 circles, the replacement of machine core is recommended

5-3.

Adjust the machine core

Adjust the machine core’’s s

advance and retreat current

advance and retreat current

4

3

Johnson Health Tech. Co., Ltd.

Right armrest

Manual

controller

Foot machine

unit

Foot

pushrod

Chair back unit

Seat Pad

Machine core

unit

Lower control

panel unit

Left armrest

Chair back

pushrod

5-4. Complete machine breakdown drawing

Johnson Health Tech. Co., Ltd.

Up and down

motor

Front and back

motor

Kneading motor

Upper and lower

limits and upper

and lower numbers

Advance and

retreat sensor

Adapter board

Kneading

sensor

Pounding motor

5-5. Machine core breakdown drawing

Johnson Health Tech. Co., Ltd.

Air valve

5-6. Lower control panel breakdown

drawing

Air pump

Transformer

Lower control

panel

Johnson Health Tech. Co., Ltd.

Thank You

WELLNESS CS Contact Information

Nicholas Beese

p:

1-877-217-2862

Email:[e-mail]