Minimizer LONG HAUL Series User manual

Read and understand this manual before servicing this seat

Service Manual

2

INTRODUCTION

SERVICE AND REPAIR

Proper service and repair are important to the safe, reliable operation of this seat. Service and

repair should be performed only by responsible technicians who have been properly instructed

and authorized to do so. The procedures recommended in this manual are safe effective

methods for performing service and repair operations.

We could not possibly know, evaluate, and advise the service trade of all conceivable ways in

which service can be done or of the possible hazardous consequences of each way. If you use a

service procedure which is not recommended, be sure that personal safety and equipment

safety will not be jeopardized.

It is the responsibility of the technician performing the service and repair to:

• Inspect for abnormal wear and damage

• Choose a repair procedure that will ensure your safety, the safety of others, and the

safe operation of the equipment

• Fully inspect and test the equipment to ensure that the repair or service has been

properly performed and the equipment will function properly.

This manual describes the correct service procedures for the Minimizer Long Haul Seat series.

The information in this manual was current at the time of printing and is subject to change

without notice or liability.

READ AND UNDERSTAND THIS SERVICE MANUAL

Learn how to service models 101358, 101359, 101360, 101361, 101362 and 101363. Consult

your dealer or service professional if you do not understand the instructions in this manual

and/or need additional information.

KEEP THIS MANUAL

This manual should be considered a permanent part of the seat and be available for reference

when servicing the seat.

3

Contents

General Information ..................................................................................................................................... 5

Important Hints ......................................................................................................................................... 5

Seats using Universal Riser: ................................................................................................................... 8

Seats using 38.1 Risers: .......................................................................................................................... 9

Seat Cushion Removal (Figure 1) ............................................................................................................ 12

Seat Cushion Mounting: ...................................................................................................................... 12

Sliders for Seat Cushion: ..................................................................................................................... 12

Sliders Mounting: ................................................................................................................................ 12

Covers Seat Frame IPS-Valve, switches for heating, swivel and air-conditioning covers, lever side (5): 14

Switch for seat lowering: .................................................................................................................... 14

IPS valve (12): ...................................................................................................................................... 14

Cover, opposite lever side (2): ............................................................................................................ 14

Operating unit air-conditioning: ......................................................................................................... 14

Backrest Removal .................................................................................................................................... 16

Lever / Lever Springs for Backrest .......................................................................................................... 17

Lever for backrest adjustment and lever springs ................................................................................ 17

Shoulder adjustment........................................................................................................................... 17

Height Adjustment Handle/Cable ........................................................................................................... 18

Shock Absorber Adjustment: .............................................................................................................. 19

Lever for Tilt Adjustment ........................................................................................................................ 20

Adjustment instructions for Bowden cable of tilt adjustment ........................................................... 21

Tooth segment for backrest adjustment ................................................................................................ 22

Upholstery cover for backrest cushion ................................................................................................... 23

Cover for seat cushion ............................................................................................................................ 24

Air Chamber for lumbar support ............................................................................................................ 25

Air Spring ................................................................................................................................................. 26

Height Adjustment .................................................................................................................................. 27

Valve Removal for height adjustment .................................................................................................... 28

Switch for quick lowering ........................................................................................................................ 29

Tooth segment for shoulder adjustment (articulating back) .................................................................. 30

Valve adjustment .................................................................................................................................... 31

4

Bowden cable adjustment: ................................................................................................................. 31

Swivel ...................................................................................................................................................... 32

Heating seat cushion ............................................................................................................................... 34

Heating backrest ..................................................................................................................................... 35

Climate Kit Assembly................................................................................................................................... 36

Fan for seat cushion: ............................................................................................................................... 37

Electronic unit for Climate System: ........................................................................................................ 38

Lever/Bowden cable horizontal suspension ............................................................................................... 39

Armrest removal: ........................................................................................................................................ 40

Pneumatic Plans .......................................................................................................................................... 41

Circuit Diagrams Heating/Ventilation ......................................................................................................... 42

Troubleshooting .......................................................................................................................................... 48

ISRI Extended Warranty…………………………………………………………………………………………………………………………51

Warranty Request Notification Form…………………………………………………………………………………………………….52

5

General Information

Important Hints

- Seat repairs should be carried out by service technicians only.

-

- The description in chapter 2 explains the removal of sundry seat components.

The installation of these seats components generally happens in reverse

sequence.

- Not all fastening parts for hoses and cables (e.g., cable binder) will be mentioned

in detail. After repairs it is necessary to locate the hoses and cables, as well as

fastening and securing components, into original position.

- Hoses, electrical lines and Bowden cables must not be crushed or bent.

- Due to safety reasons, pay attention to the correct positioning and to the

observance of the tightening torques of the screws and bolts when exchanging

component parts, including the seat belt anchorage points.

- After each repair, a functional test and, if pneumatic parts are involved, a leak

test should be done.

Critical fastener torques:

M8 =20 Nm +5Nm Suspension to riser

M10 =22 Nm +/-2Nm Seat rails to suspension

Armrest to seat

7/16”UNF-2B =35Nm +5Nm Seat Belt to ICP Bar

- Backrest in forward folded position must not be used as lift help.

Option A & B Switch Not Shown

will be located above feature 10,

11, & 12 switches

Option C uses the remote

6

7

Serial number found in the front middle of the lower frame.

Located Here

Serial number location:

Serial number and model label are located at the front side of the lower frame

of the suspension unit, and are visible when lifting up the Bellow.

Please specify these numbers for spare part orders.

8

Seats using Universal Riser:

- Disconnect air supply lines and electrical connections.

- Remove old seat from Truck and keep floor bolts.

- Position New Universal Riser so holes in riser line up with the holes in floor. Use original

floor bolts to secure riser to floor.

- Remove 4 bolts at bottom corners of suspension.

- Attach angle brackets to front and rear of suspension with bolts included with riser

Position on top of riser by lining up bracket holes with weld nuts on riser and install 4 bolts

(Torque to 20 NM +/ - 5NM)

9

Seats using 38.1 Risers:

- Remove old seat from Truck and keep floor bolts.

- Disconnect air supply lines and electrical connections.

- Position New 38.1 Riser so holes in riser line up with the holes in floor. Use original floor

bolts to secure riser to floor.

- Remove 4 bolts at bottom corners of suspension.

- Position Seat and suspension on top of riser by lining up riser holes with threaded holes

at bottom corners of suspension. Install 6 bolts included with riser up into bottom

corner holes of suspension (Torque to 20 NM +/ - 5NM).

-

10

International Wide Bolt Pattern / Volvo / Late model PACCAR Risers

- Remove old seat from Truck and keep floor bolts.

- Disconnect air supply lines and electrical connections.

- Remove 4 bolts at bottom corners of suspension.

- Position riser to suspension by lining up top riser holes with threaded holes at bottom

corners of suspension. Install 6 bolts included with riser up into bottom corner holes of

suspension (Torque to 20 NM +/ - 5NM).

- Position seat into truck and use original floor bolts to secure to floor.

11

12

Seat Cushion Removal (Figure 1)

- Lift up lever (1) and pull seat cushion to foremost position.

- Undo two screws (2) and remove tilt handle (3) from seat cushion (F).

- Lift up lever (1) and slide sideways towards (A) as shown in the picture below.

- Move seat cushion forwards until seat cushion releases on its own.

- Disconnect electrical feeders for seat cushion heater and ventilation, if necessary.

Seat Cushion Mounting:

- Bowden cable (8) must be positioned between lever (1) and seat cushion ground plate.

- Lay the keyholes (4) of the seat cushion (on the cushion’s bottom side) onto the sliders

(7) at the rear.

- Push lever (1) upwards (don’t move cushion) and push lever in direction of arrow (B)

- Press down on the seat cushions while lining up the four key holes (5) onto the sliders

(7) at the front and back.

- Push the cushion in direction of backrest (till stop) while still pressing down on the

complete seat cushion till handle engages.

- Check now if all four sliders (7) are locked in the keyholes (4 & 5) (no vertical movement

allowed).

- Take note, that the cushion is now locked in horizontal and vertical direction.

Sliders for Seat Cushion:

- Dismantle seat cushion.

- Pull out plastic pin (6) and squeeze out slider (7).

Sliders Mounting:

- Mount sliders (7) at the seat frame.

- Push in pin (6) (level of pin head (6) must be flat to fit the flat of the slider head (7), (see

Section C).

13

Figure 2

14

Covers Seat Frame IPS-Valve, switches for heating, swivel and air-conditioning

covers, lever side (5):

- Remove seat cushion.

- Adjust suspension to highest position and secure it with block between lower

suspension axle and front frame.

- Press nose of shoulder adjustment lever (21) till nose of handle disengages.

- Pull off handle (21) downwards.

- Unscrew screw (1 front screw) and (2) number 2 top screws.

- Undo two plastic rivets (3).

- Fold backrest completely forwards and remove one screw (4).

- Remove cover (5) from seat frame.

Switch for seat lowering:

- Remove screws (7).

IPS valve (12):

- Lift up locking tab (8) safely and Remove air pipe (9) from “Y” connector (10).

- Disconnect three hoses from valve unit.

- Undo retainers of valve and push out valve from cover (5).

Cover, opposite lever side (2):

- Remove cover (20) in general sense of cover.

Operating unit air-conditioning:

- Unhook switch (22) from side cover (5) and unplug connector (23).

Wire diagrams with color codes are found on Pages 42-46 for your convenience.

15

16

Backrest Removal

- Remove shoulder adjustment handle (8) in figure 4

- Remove side covers (Both sides) See page 11.

- Remove plug (7).

- Remove e-clip (2) and roller (3).

- Remove cable from cable guide (5).

- Remove plug (9) from cable guide.

- Take out e-clip (1), and completely remove cable from guide.

- Disconnect lumbar airlines (13) and electrical connections (12).

- Remove clip (10) from control side backrest bolt, then remove both (16) bolts.

- Remove backrest from frame.

Figure 4

17

Lever / Lever Springs for Backrest

Lever for backrest adjustment and lever springs

- Remove side cover for seat frame (lever side without loosening hoses)

- Remove e-clip (1), Remove handle (3) then remove springs (2) and (5) and remove

shoulder handle bracket (6).

Shoulder adjustment

- Remove e-clip (7) and roller (8)

- Pull out securing plug (10) and remove cable ball (11) from lever (pull cable out of cable

guide, if necessary)

- Remove bolt (12)

Figure 5

18

Height Adjustment Handle/Cable

- Adjust seat frame tilt to the upmost position.

- Remove seat cushion. See page 9.

- Remove nut (2), remove Bowden cable (3) from fastening (4) and pull cable nipple (5)

out of valve lever (6)

- Remove two screws (1), Push Bowden cable (3) out of bearing (7) and pull height

adjustment handle and cable (8).

• After mounting: Adjust valve (6) for height adjustment (how do you do this?).

Figure 6

19

Shock Absorber Adjustment:

- Remove seat cushion. (see page 9)

- Remove retaining e-clip (1) and lever bowden cable (2-grey) out of shock adjustment

bracket(3).

- Unscrew two screws (4).

- Knock pin (5) out of lever (6) and pull bowden cable out of seat frame

Figure 7

20

Lever for Tilt Adjustment

- Remove seat cushion.(see page 9)

- Remove side cover without disconnecting hoses (yellow, red and clear).

- Adjust seat frame tilt adjustment to upper position.

- Press down spring (1), unhook from fixation (2) and pull spring out from levers (3).

- Remove handle for height adjustment (6).

- Lever bearing (7) out of seat frame and remove Bowden cable (black) from lever (3)

- When mounting, hook spring (1) at first in lever (3).

- Press down spring (1) with a screwdriver in area “Y” and hook spring behind fixation (2).

Figure 8

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Minimizer LONG HAUL Series User manual

Minimizer LONG HAUL Series User manual

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