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Repair Manual MSG 90.6PG Commercial Vehicles, Omnibuses – November 2017

Material no. 1153450_c

1.1

Safety instructions

Page 1 of 3

TABLE OF CONTENTS

1 All inspection, test and repair work must be performed exclusively by adequately trained personnel.

2 All work steps and procedures described are to be performed with consideration to the applicable directives and regulations

stipulated by the relevant local authorities and in compliance with the provisions on health protection, prevention of
accidents and environmental protection.

3 Special notes in this repair manual are highlighted as follows:

WARNING …

indicates

possible risks for persons and their prevention.

ATTENTION ...

indicates

possible damage or destruction of material and their prevention.

Note: ...

introduces an additional explanation for better understanding the work to be carried out.

Installation note: ...

introduces an additional explanation for better understanding the installation work to be carried out.

4 Prior to all repair work, the following work has to be carried out:

•

Disconnect the seat from the power supply.

•

Bleed air out of the compressed-air system.

•

Move the seat down to the end stops.

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Summary of Contents for MSG 90.6PG

Page 1: ...mmercial Vehicles Omnibuses Page 1 of 7 END TABLE OF CONTENTS Preliminary remarks 1 Description 1 1 Safety instructions 1 2 Seat types example of seat models 1 3 Rating plate 2 Diagnosis 2 1 Overview...

Page 2: ...moval and installation seat with climate control system 3 4 Left covering in position for repair removal and attachment 3 5 Entire covering removal and attachment 3 6 Bellows removal and installation...

Page 3: ...e aft isolator removal and installation delivery option 3 16 Bowden pull wire for seat angle adjustment inspection and adjustment 3 17 Bowden pull wire for seat angle adjustment with locking mechanism...

Page 4: ...for electro pneumatic gearshift EPS removal and installation delivery option 3 26 Backrest cover and seat belt removal and installation 3 27 Lap belt removal and installation 3 28 Belt buckle with be...

Page 5: ...pport adjuster removal and installation 3 35 Vertical shock absorber removal and installation 3 36 Air spring removal and installation 3 37 Fore aft isolator removal and installation delivery option 3...

Page 6: ...eat 3 41 Guides removal and installation 3 42 Air hose for compressed air quick coupling removal and installation delivery option 3 43 Seat frame removal and installation 3 44 Seat suspension removal...

Page 7: ...on seat with climate control system 3 51 Cable harness for vehicle connection removal and installation seat with climate control system 3 52 Radial fan for backrest removal and installation seat with...

Page 8: ...technical deviations in work procedures due to different seat models refer to the current text or individual chapters of the manual The functions can either be on the left hand or right hand side of t...

Page 9: ...safety instructions of the specific vehicle manufacturer and those stated in Chapter 1 1 of this repair manual must be strictly observed This repair manual also includes some information on delivery o...

Page 10: ...with cable ties at the defined spots by hand loose Make sure that in the case of a vertical seat adjustment they are not squeezed or distorted when the seat is moved Replace all removed old parts with...

Page 11: ...ause any negative effects in particular with regard to technical safety For this reason GRAMMER AG disclaims liability for any possible damage of this kind We point out explicitly that all work steps...

Page 12: ...ses November 2017 Material no 1153450_c 1 Description Page 1 of 1 END TABLE OF CONTENTS 1 1 Safety instructions 1 2 Seat types example of seat models 1 3 Rating plate Note Please refer to the applicab...

Page 13: ...n prevention of accidents and environmental protection 3 Special notes in this repair manual are highlighted as follows WARNING indicates possible risks for persons and their prevention ATTENTION indi...

Page 14: ...s may only be removed installed contacted when the battery is disconnected and the ignition key removed After an accident the belt tensioner must be checked for external damage defects and for being t...

Page 15: ...of Germany belt tensioners must be detonated prior to scrapping according to the respective regulations for the prevention of industrial accidents This makes it impossible to remove pyrotechnic devic...

Page 16: ...Commercial Vehicles Omnibuses November 2017 Material no 1153450_c 1 2 Seat types example of seat models Page 1 of 1 TABLE OF CONTENTS A Actros B Atego Axor C Bus seat right function with swivel D Kin...

Page 17: ...the following information example A Country of manufacture MADE IN XXXXXXX B Designation MSG 90 6 PG LI C INVENTORY NO 01133179 D Year CW Assembly 0747 049 Year of manufacture 07 2007 Built in week 4...

Page 18: ...C38 Actros seat type A943 Colour code 5C38 G Date of manufacture 27 11 07 H Designation MSG 90 6 PG LI Seat type MSG 90 6 PG Left seat LI I Inventory no GAG no 1051726 Notes When orders are placed the...

Page 19: ...located on the upper right side The rating plate shows the following information example A Inventory no 1 126 814 SPC 050320 B Working pressure p 6 5 10 bar C SERIAL NO 000 381 D L6D Production code...

Page 20: ...shows the following information example A Country of manufacture MADE IN XXXXXXX B Designation MSG 90 6 PG LI C INVENTORY NO 01133179 D Year CW Assembly 0747 049 Year of manufacture 07 2007 Built in w...

Page 21: ...ample F Number A9439105102 00005C38 Atego seat type A973 Colour code 5C38 G Date of manufacture 27 11 07 H Designation MSG 90 6 PG LI Seat type MSG 90 6 PG Left seat LI I Inventory no GAG no 1051726 N...

Page 22: ...located on the upper right side The rating plate shows the following information example A Inventory no 1 126 814 SPC 050320 B Working pressure p 6 5 10 bar C SERIAL NO 000 381 D L6D Production code...

Page 23: ...ate shows the following information example A Country of manufacture MADE IN XXXXXXX B Designation MSG 90 6 PG LI C INVENTORY NO 01133179 D Year CW Assembly 0747 049 Year of manufacture 07 2007 Built...

Page 24: ...us seat type A953 Colour code 5C38 G Date of manufacture 27 11 07 H Designation MSG 90 6 PG LI Seat type MSG 90 6 PG Left seat LI I Inventory no GAG no 1051726 Notes When orders are placed the correct...

Page 25: ...located on the upper right side The rating plate shows the following information example A Inventory no 1 126 814 SPC 050320 B Working pressure p 6 5 10 bar C SERIAL NO 000 381 D L6D Production code...

Page 26: ...pension part behind the bellows The rating plate shows the following information example A Country of manufacture MADE IN XXXXXXX B Designation MSG 90 6 PG LI C INVENTORY NO 01133179 D Year CW Assembl...

Page 27: ...s located on the upper right side The rating plate shows the following information example A Inventory no 1 126 814 SPC 050320 B Working pressure p 6 5 10 bar C SERIAL NO 000 381 D L6D Production code...

Page 28: ...buckle cable if fitted page 14 Cable for electro pneumatic gearshift EPS cable if fitted page 15 2 2 Functional test page 1 6 2 3 Overview of faults page 1 11 Seat moves upwards too slowly page 1 2 S...

Page 29: ...krest does not fold forwards automatically after being unlocked page 10 Backrest cannot be unlocked page 10 Seat fore aft adjustment does not operate after pulling or pushing the lever for the seat fo...

Page 30: ...nism of the fore aft isolator delivery option 4 Lever for seat fore aft adjustment 5a Button for quick lowering of the seat Actros Atego Axor 5b Button for swivel bus seat 6 Lever for vertical shock a...

Page 31: ...intake P 3 Air hose gray for air exhaust R 4 Air hose black for lumbar support and lateral support adjustment A 5 Entire air hose set 1 2 3 4 Note The adhesive tapes are intended to bundle the air ho...

Page 32: ...tment 11 Left chamber of lateral support adjustment 12 Lower chamber of lumbar support 13 Upper chamber of lumbar support 14 Hose connector 15 Valve for upper chamber of lumbar support 16 Valve for lo...

Page 33: ...Connections Z Connection for air hose blue to the air spring P Connection for the air hose black for air intake R Connection for the air hose gray for air exhaust A Connection for the air hose for lum...

Page 34: ...l wire for quick lowering of the seat 5 Upper actuating cams for air intake valve seat lifting 6 Lower actuating cams for air exhaust valve seat lowering 7 Retracting spring of the valve lever for qui...

Page 35: ...lowering of the seat 15 Air hose blue to the air spring Z 16 Air hose black for air intake P 17 Air hose gray for air exhaust R 18 Bowden pull wire for vertical shock absorber adjustment Connections Z...

Page 36: ...cle connection 4 Cable for heater switch 5 Belt tensioner cable cut it off if not required 6 Thermostat in the backrest safety thermostat 7 Heater mat in the backrest 8 Thermostat in the seat cushion...

Page 37: ...ion heater 3 pin 17 Heater cable 18 Belt tensioner Note Pin assignment seen from the back 19 Pin assignment for heater at the plug for vehicle connection 10 contact 3 K3 voltage 24 V rt contact 4 K4 g...

Page 38: ...cushion heater level 2 low at the plug for seat cushion heater 14 contact 1 K1 contact 2 K2 23 Pin assignment for seat cushion heater level 1 high at the plug for seat cushion heater 14 contact 1 K1...

Page 39: ...he cable for heater switch 4 C Electrical connection 3 pin between the heater cable 17 and the cable for seat cushion heater 2 D Electrical connection 2 pin between the cable for seat cushion heater 2...

Page 40: ...t for Actros Atego Axor and bus seat without belt tensioner cable 5 and 9 pin plug for vehicle connection 24 Note Pin assignment seen from the back 25 Pin assignment for heater at the plug for vehicle...

Page 41: ...belt buckle contact corresponds to that for Actros Atego Axor and bus seat without belt tensioner cable 12 with cable for belt buckle contact 26 with socket for belt buckle contact 27 with additional...

Page 42: ...round sw 29 Pin assignment for belt buckle contact at the plug for vehicle connection 10 contact 4 K4 ground sw contact 5 K5 belt warning buzzer bl Electrical plug and socket connection F Electrical c...

Page 43: ...Belt buckle 2 Belt buckle cable 3 Plug for belt buckle cable 4 Socket for belt buckle cable 5 Cable for belt buckle contact 6 Pin assignment for belt buckle contact at the plug of the belt buckle cabl...

Page 44: ...eumatic gearshift EPS cable if fitted 1 Cable for electro pneumatic gearshift EPS cable 2 Plug for EPS cable 3 Socket for EPS cable 4 EPS control element 5 Pin plug for EPS cable 6 Contact socket for...

Page 45: ...ted in chapter 2 1 if not stated otherwise in this text If there is a difference between the result specified status and the actual status please take the measures as described in the chapter Causes r...

Page 46: ...height step The seat moves up gradually until the highest position maximum height is reached The seat can oscillate about 40 mm upward without hitting the stopper while driving See Overview of faults...

Page 47: ...Pull the backrest adjustment handle up while loading and unloading the backrest and then release the handle The backrest latches into the desired position It should not be possible to move the backre...

Page 48: ...um adjustment travel of 180 mm in increments of 10 mm each See Overview of faults Chapter 2 3 13 Release the lever for seat fore aft adjustment The seat locks into place in the selected position It sh...

Page 49: ...yond the end stop of the seat fore aft adjustment The maximum adjustment travel is 100 mm for left hand drive and 150 mm for right hand drive in increments of 10 mm each See Overview of faults Chapter...

Page 50: ...uspension part backwards until the fore aft isolator locks into place with an audible click The upper suspension part cannot be moved in longitudinal horizontal direction See Overview of faults Chapte...

Page 51: ...eshooting Seat moves up too slowly Too low reserve air pressure Bowden pull wire for seat height adjustment is not correctly adjusted Level control is defective Air leaks at the valve tappet Air conne...

Page 52: ...seat does not respond when pulling the lever for seat height adjustment Bowden pull wire for seat height adjustment is not correctly adjusted Bowden pull wire for seat height adjustment is torn Air l...

Page 53: ...eat height adjustment see Chapter 3 9 Check the air spring Chapter 2 4 step no 3 1 Press down the button for quick lowering of the seat until it is released Seat does not move down seat does not respo...

Page 54: ...on during operation Seat lowers down Seat moves up by itself Seat oscillates Bowden pull wire for seat height adjustment is not correctly adjusted Bowden pull wire for seat height adjustment is torn L...

Page 55: ...own but it automatically returns to its original position Level control is defective Check leveling valve and level control Chapter 2 4 inspection steps 1 1 and 2 1 Seat does not respond when pressing...

Page 56: ...upport adjustment Too low reserve air pressure Respective valve is defective Air hoses are leaky Chamber for lumbar support or lateral support adjustment is leaky Check the compressed air system of th...

Page 57: ...ive Check electrical system of the vehicle Check the plug and socket connection restore it if necessary Check the seat heater Chapter 2 4 inspection step 4 1 Check the seat heater Chapter 2 4 inspecti...

Page 58: ...cient lubrication of the central bearing of the swinging structure Insufficient lubrication of the collar screw and or of the axle of the swinging structure for the fastening of the vertical shock abs...

Page 59: ...place the cylinder for swivel see Chapter 3 47 2 Replace the valve for swivel see Chapter 3 47 3 Check the air hoses for leakage and replace them if necessary see Chapter 3 47 4 Vertical shock absorpt...

Page 60: ...defective Bowden pull wire for backrest adjustment is not correctly adjusted Bowden pull wire for backrest adjustment is torn Backrest locking mechanism is defective Replace the lever for backrest ad...

Page 61: ...re aft adjustment Lever for seat fore aft adjustment is defective Seat fore aft adjustment is defective Replace the lever for seat fore aft adjustment see Chapter 3 40 Replace the seat fore aft adjust...

Page 62: ...d with regard to tightness and found to be OK The air spring has been inspected with regard to tightness and found to be OK Notes Perform the inspection whit the seat being loaded e g by pressing it d...

Page 63: ...mechanical end stop Compressed air leaks at the valve for quick lowering of the seat venting The seat does not move down Proceed with inspection step no 1 3 Replace the level control Chapter 3 38 1 3...

Page 64: ...the control disc for seat height adjustment The seat moves up until the maximum height is reached The seat remains in its original position The seat does not move up Proceed with inspection step no 1...

Page 65: ...ng cam for the air intake valve against the valve tappet of the air intake with your hand The seat moves up The seat does not move up Proceed with inspection step no 1 7 Replace the level control Chap...

Page 66: ...found to be OK The air spring has been inspected with regard to tightness and found to be OK Notes Perform the inspection whit the seat being loaded e g by pressing it down The components mentioned ab...

Page 67: ...oes not move down to the minimum height Proceed with inspection step no 2 3 Replace the level control Chapter 3 38 2 3 Press and lock the button for quick lowering of the seat The seat moves down to t...

Page 68: ...n and apply load to the seat The level control moves the seat to the original position up The level control does not move the seat up to the original position Proceed with inspection step no 2 6 Repla...

Page 69: ...ted with regard to tightness and found to be OK Level control has been inspected and found to be OK Note The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this t...

Page 70: ...Chapter 3 1 Note The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this text Step no Inspect operate Result specified status Troubleshooting 4 1a Disconnect the...

Page 71: ...trical connection A between the Kingman seat and the vehicle Turn the heater switch to heating level 2 high ATTENTION Malfunction The heater can only be checked at heating level 1 below 20 C Measure t...

Page 72: ...e cable for seat cushion heater and the cable for backrest heater Measure the resistance at the contacts in the plug of backrest heater 2 pin K1 yellow K2 black 2 14 10 at approx 20 C 1 93 or 2 35 Pro...

Page 73: ...and found to be OK Note The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this text Step no Inspect operate Result specified status Troubleshooting 5 1 Disconnec...

Page 74: ...elt buckle with belt buckle cable has been inspected and found to be OK Note The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this text Step no Inspect operate...

Page 75: ...S Step no Inspect operate Result specified status Troubleshooting 6 2 Release the belt latch at the belt buckle buzzing Measure the resistance at the contacts in the plug for vehicle connection pin as...

Page 76: ...e belt buckle is open belt latch is not locked into the belt buckle Note The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this text Step no Inspect operate Resu...

Page 77: ...The components mentioned above are illustrated in Chapter 2 1 if not stated otherwise in this text Step no Inspect operate Result specified status Troubleshooting 8 1 Disconnect the electrical connec...

Page 78: ...and installation seat with climate control system 3 4 Left covering in position for repair removal and attachment 3 5 Entire covering removal and attachment 3 6 Bellows removal and installation 3 7 Bo...

Page 79: ...re aft isolator removal and installation delivery option 3 16 Bowden pull wire for seat angle adjustment inspection and adjustment 3 17 Bowden pull wire for seat angle adjustment with locking mechanis...

Page 80: ...t for electro pneumatic gearshift EPS removal and installation delivery option 3 26 Backrest cover and seat belt removal and installation 3 27 Lap belt removal and installation 3 28 Belt buckle with b...

Page 81: ...pport adjuster removal and installation 3 35 Vertical shock absorber removal and installation 3 36 Air spring removal and installation 3 37 Fore aft isolator removal and installation delivery option 3...

Page 82: ...seat 3 41 Guides removal and installation 3 42 Air hose for compressed air quick coupling removal and installation delivery option 3 43 Seat frame removal and installation 3 44 Seat suspension removal...

Page 83: ...ion seat with climate control system 3 51 Cable harness for vehicle connection removal and installation seat with climate control system 3 52 Radial fan for backrest removal and installation seat with...

Page 84: ...ttachment Page 1 of 5 RAISE ATTACH TABLE OF CONTENTS 1 Seat cushion 2 Velcro fastener at the cover of the backrest 4 and the seat cushion 1 3 Bowden pull wire for seat angle adjustment 4 Backrest 5 Sl...

Page 85: ...ill hole from the front arrows at the left in the seat cushion 1 under the spring 7 and unlock the seat cushion 1 by lifting the springs 7 Simultaneously pull the handle for seat depth adjustment 6 in...

Page 86: ...n 1 with cable tie 8 and remove the cable tie 8 5 Undo the Velcro fastener 2 between the backrest 4 and the seat cushion 1 Notes For easy disconnection and reconnection of the electrical connections d...

Page 87: ...ie 11 7 Mark the points where the electrical connections C D are bundled with a cable tie 12 and remove the cable tie 12 Installation note The cable tie 12 must be lead through the cable tie 13 affixe...

Page 88: ...TENTS 9 Seat with climate control system Disconnect the electrical connection between the cable harness for backrest and seat fan cable see Chapter 2 12 10 ATTENTION Damage Place the seat cushion 1 on...

Page 89: ...Page 1 of 4 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Round head screw 2 5 Nm 2 Locking plate 3 Seat cushion 4 Seat plate 5 Housing 6 Lever for seat depth adjustment 7 Lever for seat angle adjustment 8...

Page 90: ...ion 2 Operate the lever for seat angle adjustment 7 and position the latches 13 between two cutouts in the seat frame 12 3 Unscrew two round head screws 1 Installation note Round head screw 1 2 5 Nm 4...

Page 91: ...cushion 3 until the hauling rope 8 is accessible Installation notes When inserting the housing 5 press the locking plate 2 towards the seat plate 4 so that the hook arrow at the lever for seat depth a...

Page 92: ...removal and installation Page 4 of 4 REMOVAL INSTALLATION TABLE OF CONTENTS 8 Pull out the housing 5 with the lever for seat angle adjustment 7 and seat depth adjustment 6 out of the seat cushion 3 9...

Page 93: ...s November 2017 Material no 1153450_c 3 3 Seat cushion cover removal and installation Page 1 of 1 END TABLE OF CONTENTS 3 3 1 Seat cushion cover removal and installation 3 3 2 Seat cushion cover remov...

Page 94: ...hion cover 2 Foam plastic part 3 Cable seat cushion heater 4 Velcro 5 Seat plate 6 Clamp 16 each replace Note No claims for warranty can be accepted if you install the seat cushion covers of other man...

Page 95: ...remove the seat cushion cover 1 from the clamps 6 using a stopping knife 4 ATTENTION Damage The seat cushion cover 1 is secured in the seat pan area with two Velcro fasteners 4 When separating the Vel...

Page 96: ...te 5 and evenly install the seat cushion cover 1 onto the foam part 2 starting from the back to the front 3 Turn back the edge of the seat cushion cover 1 along the slinging strap and evenly push it i...

Page 97: ...at cushion cover 2 Foam plastic part 3 Ventilation cushion fabric inlay 4 Seat plate 5 Clamp 16 each replace 6 Tie strap 7 Lug 8 Cable seat cushion heater 9 Cable for seat fan 10 Cable tie 11 Slinging...

Page 98: ...Chapter 3 1 2 Remove the seat cushion and lever for seat angle and seat depth adjustment Chapter 3 2 Removal 3 Mark the installation position of the 16 clamps 5 at the seat plate 4 and seat cushion co...

Page 99: ...lamps 5 at the seat cushion cover 1 7 Mark the point where the cable for the seat cushion heater 8 and the seat fan cable 9 are bundled with a cable tie 10 and remove the cable tie 10 8 Slightly bend...

Page 100: ...e seat pan area at the back When removing the seat cushion cover 1 make sure that the tie straps 6 do not tear Pull off the seat cushion cover 1 at the foam plastic part 2 10 Place the two lugs 7 vert...

Page 101: ...ons 2 Guide the two lugs 7 at the tie straps 6 out through the slits in the foam plastic part 2 in downward direction then turn until they lie evenly under tension at the foam part 2 3 Evenly install...

Page 102: ...marked location 6 Turn back the edge of the seat upholstery 1 along the slinging strap 11 and push it evenly on both sides into the clamps 5 from the back to the front A A using suitable means such a...

Page 103: ...covering 2 Lever for seat height adjustment 3 Raised countersunk head screw 3 Nm 4 Support 5 Round head screw 1 7 Nm 6 Seat frame 7 Upper snap in hook 8 Lower snap in hook 9 Rear snap in hook 10 Fron...

Page 104: ...for seat height adjustment 2 at the handle support 14 Installation note Raised countersunk head screw 3 3 Nm 3 Unscrew the round head screw 5 Installation note Round head screw 5 1 7 Nm ATTENTION Risk...

Page 105: ...first in downward and then in outward direction 6 Carefully pull the central snap in hook 11 at the left covering 1 out of the seat frame 6 7 Carefully detach the front snap in hook 10 at the left co...

Page 106: ...d head screw 1 7 Nm 6 Left covering 7 Plug for cable for heater switch 8 Air hose for lateral support adjustment 9 Air hose of the upper lumbar support 10 Air hose of the bottom lumbar support 11 Hose...

Page 107: ...k 18 Upper snap in hook 19 Cover delivery option 20 Cross head screw delivery option 3 Nm 21 Lever for fore aft isolator delivery option 22 Hose nozzle 23 Heater switch 24 Holder pin at the center 25...

Page 108: ...repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Seat with operator console and armrest for electro pneumatic gearshift 3 1 Remove the supporting structure for electr...

Page 109: ...ical connection B between the connector 7 and heater switch 23 5 Seat with climate control system Mark two electrical connections N note the color of the cables and disconnect the electrical connectio...

Page 110: ...e air hoses 8 9 10 12 6 Remove three hose clamps 11 at the air hoses 8 9 10 and one hose clamp 22 at the air hose 12 and push towards the back 7 ATTENTION Damage Do not damage air hoses 8 9 10 12 and...

Page 111: ...10 12 according to the marking Push the air hoses 8 9 10 12 completely to the connections arrows of the valve 13 When attaching the new left covering 6 the valves 13 and the heater switch 23 should be...

Page 112: ...kage The right covering 1 is held by snap in hooks and is wedged into the plastic Use suitable screwdrivers to carefully lever the hooks out 9 Carefully detach the snap in hooks at the back 25 on the...

Page 113: ...level of the supports 14 and then pull it in outward direction 12 Carefully pull out the middle snap in hook 24 from the seat support 4 at the right hand covering 1 13 Seat with fore aft isolator 13 1...

Page 114: ...S 14 Carefully detach the front snap in hook 26 at the right hand covering 1 from the support at the front 16 15 Remove the front covering 16 16 Carefully pull the right hand covering 1 over the belt...

Page 115: ...2 Lever for seat fore aft adjustment 3 Seat frame 4 Lower suspension part 5 Seat fore aft adjustment 6 Supporting structure Actros bus seat 7 Bellows pin 8 Cable tie 9 Bowden pull wire for backrest ad...

Page 116: ...ole and armrest for electro pneumatic gearshift 2 1 Remove the cable for the electro pneumatic gearshift EPS cable see Chapter 3 21 Note The EPS cable does not need to be removed at the swinging struc...

Page 117: ...ring Removal and installation 5 Remove ten bellows pins 7 at the lower suspension part 5 6 Mark the point where the Bowden pull wire for backrest adjustment 9 is fastened to the rear of the bellows 1...

Page 118: ...ans of cable ties 11 and remove the cable ties 11 Installation note ATTENTION Malfunction Loosely fix the Bowden pull wire 12 by means of the cable tie 11 at the marked point and make sure it is not d...

Page 119: ...possible 12 Pull the rear part of the bellows 1 downwards over the lower suspension part 4 and the locking rail of the seat fore aft adjustment 5 13 Push the seat forwards over the seat fore aft adjus...

Page 120: ...ering of the seat 2 Rounded head screw inner race 3 Nm 3 Handle rail 4 Lever for quick lowering of the seat 5 Holder for quick lowering of the seat 6 Button for quick lowering of the seat 7 Support ha...

Page 121: ...n in position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the bellows at the rear left of the seat frame see Chapter 3 6 Removal and installation 4 AT...

Page 122: ...lowering of the seat 1 prior to removal Installation note Place the Bowden pull wire for quick lowering of the seat 1 according to the marking 6 Loosen the lock washer 10 at the Bowden pull wire 1 7...

Page 123: ...out of the seat suspension in backward direction 10 Pull out the clip 17 at the seat frame 16 11 Remove the Bowden pull wire 1 from the clip 17 12 Unscrew two rounded head screws 2 and lay the handle...

Page 124: ...m the holder 5 16 Detach the Bowden pull wire 1 at the lever 4 and remove it Installation note Hand the Bowden pull wire 1 into the front drill hole of the lever 4 17 If the button for quick lowering...

Page 125: ...L INSTALLATION TABLE OF CONTENTS 17 2 Unscrew two rounded head screws 15 and remove the button for quick lowering of the seat 6 Installation note Rounded head screw 15 3 Nm 18 If the snap in element 1...

Page 126: ...STMENT TABLE OF CONTENTS 1 Bowden pull wire for seat height adjustment 2 Handle for seat height adjustment 3 Button for quick lowering of the seat 4 Level control 5 Regulating screw 6 Counternut 7 Nut...

Page 127: ...ion 3 Operate the handle for seat height adjustment 2 in both directions as far as possible pulling it upwards pushing it downwards and check it for correct functioning locking in each step for a maxi...

Page 128: ...t adjustment 1 with regard to seat models with left hand or right hand drive The new Bowden pull wire for seat height adjustment 1 must be preadjusted outside the seat 1 With the Bowden pull wire for...

Page 129: ...and use a slide gauge to check the adjustable dimension A between the nipple 8 and the suspension head 9 excess length of the wire Adjustable dimension A 217 mm 3 Loosen the counternut 6 and adjust th...

Page 130: ...te Make sure not to distort the Bowden pull wire for seat height adjustment 1 6 If the Bowden pull wire for seat height adjustment 1 has been removed Hang in the Bowden pull wire for seat height adjus...

Page 131: ...t inspection and adjustment Page 6 of 6 INSPECTION ADJUSTMENT TABLE OF CONTENTS 9 Install the bellows at the rear left of the handle rail see Chapter 3 6 10 Attach the left covering Chapter 3 4 11 Pre...

Page 132: ...TABLE OF CONTENTS 1 Bowden pull wire for seat height adjustment 2 Rounded head screw inner race 3 Nm 3 Handle rail 4 Grooved pin 5 Support 6 Handle support for seat height adjustment 7 Control disc le...

Page 133: ...ter 3 1 2 Remove the left covering Chapter 3 4 3 Remove the bellows at the rear left of the seat frame see Chapter 3 6 Removal and installation 4 WARNING Risk of crushing Bring the seat into the highe...

Page 134: ...rol disc 7 Note For easier removal of the Bowden pull wire 1 press the control disc 7 against the Bowden pull wire 1 strain relief 7 Loosen the lock washer 9 at the Bowden pull wire 1 8 Remove the Bow...

Page 135: ...of 6 REMOVAL INSTALLATION TABLE OF CONTENTS 12 Unscrew two rounded head screws 2 and lay the handle rail 3 down Installation note Rounded head screw 2 3 Nm 13 Loosen the lock washer 10 at the Bowden...

Page 136: ...pull wire 1 between the drum 11 and the handle support for seat height adjustment 6 and remove it Installation notes The Bowden pull wire 1 has to be hung into the guide arrow of the handle support fo...

Page 137: ...e To pull the handle support for seat height adjustment 6 out more easily detach the Bowden pull wire for quick lowering of the seat 13 at the support 5 see Chapter 3 7 18 Re install the components in...

Page 138: ...ment Page 1 of 5 INSPECTION ADJUSTMENT TABLE OF CONTENTS 1 Bowden pull wire for vertical shock absorber adjustment 2 Lever for vertical shock absorber adjustment 3 Vertical shock absorber 4 Adjusting...

Page 139: ...ection 2 Operate the lever for vertical shock absorber adjustment 2 several times in both directions and check the following Check the Bowden pull wire for vertical shock absorber adjustment 1 for eas...

Page 140: ...be set to the middle position line A in relation to the vertical shock absorber 3 The compression spring 5 must tighten the Bowden pull wire for vertical shock absorber adjustment 1 Adjustment Note Th...

Page 141: ...k absorber adjustment 2 to the middle position 4 Loosen the counternut 7 and bring the adjusting lever 4 to the middle position in relation to the vertical shock absorber 3 line A by means of the regu...

Page 142: ...the adjustment with the counternut 7 Note Make sure not to distort the Bowden pull wire for vertical shock absorber adjustment 1 7 Operate the lever for vertical shock absorber adjustment 2 several t...

Page 143: ...Page 1 of 7 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Bowden pull wire for vertical shock absorber adjustment 2 Support 3 Lever for vertical shock absorber adjustment 4 Adjusting lever 5 Fork 6 Compres...

Page 144: ...ion Page 2 of 7 REMOVAL INSTALLATION TABLE OF CONTENTS 14 Axial locking ring replace 15 Compression spring 16 Holder lever for vertical shock absorber 17 Lock washer 18 Holder Bowden pull wire 1 Lift...

Page 145: ...at into the highest position and secure the swinging structure to the front plastic rollers of the lower suspension part by means of appropriate spacers 4 Turn the lever for vertical shock absorber ad...

Page 146: ...ompression spring 6 8 If the bearing 8 is defective 8 1 Pull off the adjusting lever 4 at the pin of the vertical shock absorber 7 8 2 Loosen the lock washer 9 at the axle 10 8 3 Pull off the bearing...

Page 147: ...10 Pull the Bowden pull wire 1 out of the seat suspension in backward direction 11 Pull out the clip 13 at the seat frame 12 12 Remove the Bowden pull wire 1 from the clip 13 13 Remove the Bowden pul...

Page 148: ...ire 1 at the holder 18 16 Hang out the Bowden pull wire 1 at the lever for vertical shock absorber adjustment 3 and remove it Installation notes Hang the Bowden pull wire 1 into the front hole of the...

Page 149: ...l shock absorber adjustment 3 is defective 17 1 Detach two axial locking rings 14 at the holder 16 Installation notes Replace the axial locking ring 14 The axial locking rings 14 must lie flat against...

Page 150: ...CTION ADJUSTMENT TABLE OF CONTENTS 1 Bowden pull wire for backrest adjustment left 2 Bowden pull wire for backrest adjustment right 3 Lock 4 Tooth sheet 5 Retaining spring 6 Bracket for backrest hook...

Page 151: ...for repair Chapter 3 1 Inspection 2 Apply load to the backrest 8 and lock unlock it several times using the lever for backrest adjustment 12 and check the following easy running of the Bowden pull wi...

Page 152: ...ft and right lock 3 The lever for backrest adjustment 12 must lie flat against the holder 13 The gear segment of the lock 3 must fully engage with the tooth sheet 4 no clearance The lock 3 must protru...

Page 153: ...2 3 1 Loosen the counternut 10 and adjust the gear segment of the lock 3 by means of the regulating screw 9 so that there is no clearance between the lock 3 and the tooth sheet 4 Note When releasing...

Page 154: ...ection and adjustment Page 5 of 5 INSPECTION ADJUSTMENT TABLE OF CONTENTS 4 Lock unlock the backrest 8 several times and check the adjustment on both sides readjust if necessary 5 Install the rear cov...

Page 155: ...OVAL INSTALLATION TABLE OF CONTENTS 1 Bowden pull wire for backrest adjustment left 2 Bowden pull wire for backrest adjustment right 3 Backrest 4 Stud 5 Holder 6 Axial locking ring replace 7 Lever for...

Page 156: ...of 6 REMOVAL INSTALLATION TABLE OF CONTENTS 13 Torsion spring 14 Cable tie 15 Clamp 16 Bellows 17 Z section 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Remove the left covering in...

Page 157: ...int where the right Bowden pull wire 2 is fastened to the bellows 16 by means of cable tie 14 and remove the cable tie 14 Installation notes ATTENTION Malfunction Loosely fix the right Bowden pull wir...

Page 158: ...n pull wire 1 at the catch element 11 of the left lock 10 and detach the right Bowden pull wire 2 at the catch element 11 of the right lock 10 Note The hook arrow of the respective Bowden pull wire 1...

Page 159: ...al locking ring 6 Press the axial locking ring 6 onto the stud 4 with the curve pointing to the lever for backrest adjustment 7 11 Pull off the lever for backrest adjustment 7 at the stud 4 12 Detach...

Page 160: ...CONTENTS 13 Loosen the lock washers 8 at the left Bowden pull wire 1 and at the right Bowden pull wire 2 14 Detach the left and right Bowden pull wires 1 2 at the holder 5 Installation note Adjust th...

Page 161: ...ion Page 1 of 5 INSPECTION ADJUSTMENT TABLE OF CONTENTS 1 Lever for fore aft isolator 2 Support 3 Eccentric 4 Bowden pull wire for locking mechanism of the fore aft isolator 5 Lock 6 Longitudinal hole...

Page 162: ...Chapter 3 1 Inspection 2 Turn the lever for the fore aft isolator 1 downwards as far as possible unlocked It should be possible to move the upper suspension part 9 horizontally without getting stuck 3...

Page 163: ...g spring 8 must lock the stop lever 7 into the clamp 10 arrow direction e If necessary slightly move the upper suspension part 9 3 3 The upper part of suspension 9 should not horizontally move after b...

Page 164: ...7 from the clamp 10 against the retracting spring 8 and pull it back until the stop lever forms a line d with the cutout in the upper suspension part 9 4 3 The retracting spring 8 must hold the eccen...

Page 165: ...the excess length of the hauling rope 15 or turn the regulating screw 14 towards the nut 12 in order to extend the excess length of the hauling rope 15 Note Make sure not to distort the Bowden pull w...

Page 166: ...LLATION TABLE OF CONTENTS 1 Bowden pull wire for locking mechanism of the fore aft isolator 2 Lock washer 3 Upper suspension part 4 Support 5 Eccentric 6 Stop lever 7 Retracting spring 8 Seat frame 9...

Page 167: ...at with operator console and armrest for electro pneumatic gearshift Remove the operator console for the electro pneumatic gearshift see Chapter 3 25 4 Remove the entire covering Chapter 3 5 Removal a...

Page 168: ...s far as possible to release the Bowden pull wire 1 7 Mark the point where the Bowden pull wire 1 is fastened to the bellows 11 by means of cable ties 10 and remove the cable ties 10 Installation note...

Page 169: ...den pull wire 1 10 Detach the Bowden pull wire 1 at the upper suspension part 3 11 Pull the Bowden pull wire 1 out of the drill holes arrows in the seat frame 8 12 Remove the Bowden pull wire 1 from t...

Page 170: ...spection and adjustment Page 1 of 4 INSPECTION ADJUSTMENT TABLE OF CONTENTS 1 Lever for seat angle adjustment 2 Seat cushion 3 Bowden pull wire for seat angle adjustment 4 Right latch 5 Left latch 6 R...

Page 171: ...ADJUSTMENT TABLE OF CONTENTS Inspection 2 Apply load to the seat frame 9 and lock unlock the lever for seat angle adjustment 1 several times Then check the following easy running of the Bowden pull wi...

Page 172: ...3 of 4 INSPECTION ADJUSTMENT TABLE OF CONTENTS 3 Check the adjustment of the right 4 and left latch 5 in the 8 locking positions The locked latches 4 5 must protrude at least 1 mm from the cutouts arr...

Page 173: ...Loosen the counternut 7 and use the regulating screw 6 to position the latches 4 5 so that they protrude at least 1 mm from the cutouts arrows in the seat frame 9 basic setting 3 Hold the nut 8 in pos...

Page 174: ...llation Page 1 of 9 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Locking mechanism complete 2 Compression spring 3 Housing to grease 4 Catch element to grease 5 Bowden pull wire for seat angle adjustment...

Page 175: ...er 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the front covering see Chapter 3 5 4 Seat with fore aft isolator Remove the cable tie by means of which the Bowden pull wi...

Page 176: ...secure the swinging structure to the front plastic rollers of the lower suspension part by means of appropriate spacers 7 Operate the seat angle adjustment and move the seat to the highest position 8...

Page 177: ...ge 4 of 9 REMOVAL INSTALLATION TABLE OF CONTENTS 10 Remove the cover 9 at the housing 3 11 Remove two latches 6 with mit compression springs 8 from the housing 3 12 Pull the catch element 4 out of the...

Page 178: ...the old one excess length of the wire 2 Apply acid free multi purpose lubricant F to the housing 3 and to the catch element 4 3 Hang the Bowden pull wire 5 into the hole marked with L of the catch el...

Page 179: ...on springs 8 7 Hang in compression springs 8 into the latches 6 and press them into the pockets 12 of the housing 3 8 Checking the installation position The compression springs 8 must press the latche...

Page 180: ...e Bowden pull wire 5 in the housing 3 11 Guide the Bowden pull wire 5 through the cutout 14 in the upper suspension part 11 12 Place the right latch 16 in front of the groove 15 in the upper suspensio...

Page 181: ...Press in the left latch 17 by hand while pressing the cover 9 onto the housing 3 secure and push the entire locking mechanism 1 into the upper suspension part 11 until both latches 16 17 are engaged...

Page 182: ...ession spring 2 under the bearing pins of the catch element 4 17 Adjust the seat angle to the lowest position 18 Install the bellows at the front of the seat frame and hang it in at the two supports s...

Page 183: ...TABLE OF CONTENTS 1 Handle rail 2 Rounded head screw 3 Nm 3 Bowden pull wire for seat height adjustment 4 Bowden pull wire for quick lowering of the seat 5 Bowden pull wire for vertical shock absorber...

Page 184: ...ition and secure the swinging structure to the front plastic rollers of the lower suspension part by means of appropriate spacers 4 Unscrew two rounded head screws 2 and lay the handle rail 1 down Ins...

Page 185: ...see Chapter 3 7 6 If the Bowden pull wire for quick lowering of the seat 4 is not defective Remove the Bowden pull wire for quick lowering of the seat at the handle rail see Chapter 3 7 7 If the Bowde...

Page 186: ...bsorber adjustment 5 is defective Remove the Bowden pull wire for vertical shock absorber adjustment see Chapter 3 11 10 If the Bowden pull wire for vertical shock absorber adjustment 5 is not defecti...

Page 187: ...nibuses November 2017 Material no 1153450_c 3 19 Heater switch removal and installation Page 1 of 1 END TABLE OF CONTENTS 3 19 1 Heater switch removal and installation 3 19 2 Heater switch removal and...

Page 188: ...Heater switch removal and installation Page 1 of 2 RAISE ATTACH TABLE OF CONTENTS 1 Heater switch 2 Left covering 3 Plug for cable for heater switch 1 Lift off the seat cushion in position for repair...

Page 189: ...2 RAISE ATTACH TABLE OF CONTENTS Removal and installation 3 Disconnect the electrical connection B between the connector 3 and heater switch 1 4 Compress the springs arrows at the heater switch 1 and...

Page 190: ...d installation seat with climate control system Page 1 of 2 RAISE ATTACH TABLE OF CONTENTS 1 Heater switch 2 Left covering 3 Plug cable harness for heater switch 1 Lift off the seat cushion in positio...

Page 191: ...electrical connections N note the color of the cables and disconnect the electrical connections N between the six connectors 3 and the heater switch 1 Installation note Re establish the electrical con...

Page 192: ...NSTALLATION TABLE OF CONTENTS 1 Cable for backrest heater 2 Cable for seat cushion heater 3 Cable for heater switch 4 Cable for vehicle connection 5 Belt tensioner cable 6 Heater cable 3 4 7 Belt tens...

Page 193: ...d the cable for vehicle connection 4 B Electrical connection between the heater switch and the cable for heater switch 3 C Electrical connection 3 pin between the heater cable 6 and the cable for seat...

Page 194: ...Remove the left covering in position for repair Chapter 3 4 3 Remove the rear covering see Chapter 3 5 4 Remove the bellows at the rear left of the seat frame see Chapter 3 6 Removal and installation...

Page 195: ...ENTS 6 Seat with belt tensioner 7 6 1 Mark the point where the belt tensioner cable 5 is fastened to the belt roller support 7 by means of cable tie 8 and remove the cable tie 8 6 2 ATTENTION Damage W...

Page 196: ...of cable ties 10 and remove the cable ties 10 Note The belt tensioner cable 5 is only fitted for seats with belt tensioner 7 8 Mark the points where the two electrical connections C D are bundled by m...

Page 197: ...5 to the left at the secondary belt 11 and put it aside Installation note The belt tensioner cable 5 has to be laid in the top seam arrow of the cross member of the seat frame 9 11 Disconnect the elec...

Page 198: ...14 14 Mark the point where the cable for vehicle connection 4 is attached to the level control 16 by means of cable ties 17 and remove the cable ties 17 15 For seat models Atego Axor Mark the point w...

Page 199: ...lation position for the cable for vehicle connection 4 pull the cable for vehicle connection 4 out of the suspension in backward direction and remove it with the cable of the heater switch 3 and the b...

Page 200: ...pneumatic gearshift EPS removal and installation Page 1 of 6 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Cable for electro pneumatic gearshift EPS cable 2 Right covering 3 Seat frame 4 Cable tie 5 Cable...

Page 201: ...position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the operator console for the electro pneumatic gearshift EPS see Chapter 3 25 Removal and install...

Page 202: ...Thread the EPS cable 1 through the right covering 2 6 Remove the entire covering Chapter 3 5 7 Detach the EPS cable 1 at the two spring clips 6 8 Mark the point where the EPS cable 1 is fastened to th...

Page 203: ...pull off the clip 8 at the EPS cable 1 Installation notes WARNING Malfunction Attach the clip 8 at the new EPS cable 1 according to the marking and fasten it by means of a blind rivet 7 in such a way...

Page 204: ...TS 11 For seat model Actros 11 1 Remove the plug of the EPS cable at the pin contact strip see Chapter 3 39 11 2 Mark the point where the EPS cable 1 is fastened to the swinging structure 10 by means...

Page 205: ...models Atego Axor 12 1 Remove the plug of the EPS cable at the pin contact strip see Chapter 3 40 12 2 Mark the points where the EPS cable 1 is fastened or bundled by means of three cable tie 11 and r...

Page 206: ...exhaust R 4 Air hose black for lumbar support and lateral support adjustment A 5 Entire air hose set 1 2 3 4 Note The adhesive tapes are intended to bundle the air hose set 5 and to mark where the cab...

Page 207: ...n Page 2 of 15 REMOVAL INSTALLATION TABLE OF CONTENTS 12 Cable for vehicle connection 13 Cable tie 14 Hose connector T piece 15 Lower suspension part 16 Air spring support swinging structure 17 Z sect...

Page 208: ...that sufficient length of the air hoses 2 3 4 is provided Move the seats to the maximum forward and backward stop of the seat fore aft adjustment The air hoses 2 3 4 must not be squeezed Fasten the ca...

Page 209: ...set for vehicle connection 7 of the seat has to be removed and replaced Note The air hose 1 to the air spring 6 must only be replaced if the air hose 1 is defective The air hoses 1 2 3 4 differ in le...

Page 210: ...t of the seat should be performed upon installation of the air hoses 1 2 3 4 To do this apply 60 kg load to the seat for 24 hours The lowering within this time must not exceed 15 mm 1 Lift off the sea...

Page 211: ...ing at the right covering see Chapter 3 5 4 Remove the bellows at the rear of the lower suspension part see Chapter 3 6 5 Seat with compressed air quick coupling Remove the quick coupling and the air...

Page 212: ...to the front plastic rollers of the lower suspension part by means of appropriate spacers 7 WARNING The pressure in the pneumatic system might cause injury The pneumatic system is to be vented before...

Page 213: ...f the air hose 1 at the connection arrow of the level control 8 Notes For easier removal carefully slit the air hose 1 with a sharp knife Do not use screwdrivers or similar tools to lift off the air h...

Page 214: ...on the side to allow access to the bottom side 8 5 Remove the air hose blue at the air spring see Chapter 3 36 8 6 Pull out the air hose 1 at the air spring support 16 and remove it 9 Remove the air h...

Page 215: ...detach the air hose 4 at the clip 18 11 Mark the installation position of the air hose 4 and guide the air hose 4 inwards at the cut out arrow in the bellows 19 Installation note Lay the air hose 4 ac...

Page 216: ...the level control 8 Notes For easier removal carefully slit the air hoses 2 3 with a sharp knife Do not use a screwdriver or similar tools to lift off the air hoses 2 3 at the connections arrows of t...

Page 217: ...access to the bottom side 17 Mark the installation position of the air hose set for vehicle connection 2 3 4 prior to removal For seat model Actros The air hoses 2 3 are placed in a loop of 180 to the...

Page 218: ...rt 16 by means of four cable ties 13 and remove the cable ties 13 Note If an EPS cable is fitted take into consideration the fastening of the EPS cable at the air hoses 2 3 4 by means of additional ca...

Page 219: ...ter 3 40 19 2 Mark the points where the air hoses 2 3 4 are fastened to the air spring support 16 by means of four cable ties 20 and remove the cable ties 20 19 3 Mark the points where the air hoses 2...

Page 220: ...take into consideration the fastening of the EPS cable at the air hoses 2 3 by means of the cable ties 21 22 and additional cable ties see Chapter 3 21 20 Pull the air hose set for vehicle connection...

Page 221: ...r support lower chamber 2 Air hose for lumbar support upper chamber 3 Air hose for lateral support adjustment 4 Air hose for lumbar support and lateral support adjustment 5 Hose nozzle 6 Left covering...

Page 222: ...n position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 ATTENTION Hydrostatic test The hydraulic test of the suspension should be performed upon installation of...

Page 223: ...er or similar tools to lift off the air hoses 1 2 3 4 at the connections arrows of the valves 7 8 9 Mark the air hoses 1 2 3 4 and cut them off in a clean and straight way directly behind the connecti...

Page 224: ...E OF CONTENTS Notes The air hoses 1 2 3 4 can be cut off only once After cutting mark the air hoses 1 2 3 4 in order not to cut them several times 5 Press the springs arrows on the top and bottom of t...

Page 225: ...and installation delivery option Page 1 of 2 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Backrest 2 Backrest cover 3 Rounded head screw inner race 4 Nm 4 Armrest on the left 5 Micro encapsulated cap scr...

Page 226: ...rews 3 Installation note Rounded head screw 3 4 Nm 2 Unscrew two micro encapsulated cap screws on the left 5 or right 7 and remove the left armrest 4 or right armrest 6 from the backrest 1 Note Slight...

Page 227: ...or EPS console 2 Stud 3 EPS control element 4 Operator console for electro pneumatic gearshift EPS console 5 Cover EPS console 6 Plug EPS cable 7 Cable tie 8 Micro encapsulated cap screw M8 to replace...

Page 228: ...nd installation delivery option Page 2 of 5 REMOVAL INSTALLATION TABLE OF CONTENTS 12 Left armrest bottom 13 Right armrest top 14 Catch element 15 Washer 16 Rounded head screw inner race 12 Nm 17 Pin...

Page 229: ...lug of the EPS cable 6 and the EPS control element 3 2 Unscrew three countersunk screws 22 and remove the control element 3 from the EPS console 4 Installation note Hand tighten the countersunk screw...

Page 230: ...1 and remove the EPS console 4 as well as the washer 19 Installation note Replace the micro encapsulated cap screws 8 9 by new ones 25 Nm Replace the micro encapsulated cap screw 10 by a new one 12 N...

Page 231: ...11 and remove the top of the armrest 13 Installation note Hand tighten the rounded head screw 11 8 2 Drive out the pin 17 at the bottom of the armrest 12 8 3 Drive out the clamping sleeve 18 at the E...

Page 232: ...gon bolt 45 Nm 2 Belt buckle 3 Spacer 4 Spring washer 5 Adjustment washer plastic 6 Safety belt 7 Hexagon bolt 45 Nm 8 Spring washer 9 Belt roller CAUTION Pay attention to the safety notes in Chapter...

Page 233: ...ation Page 2 of 9 REMOVAL INSTALLATION TABLE OF CONTENTS 15 Belt guide 16 Rounded head screw inner race 2 Nm 17 Belt bracket 18 Serrated washer head screw to replace 25 Nm 19 Hexagon bolt 45 Nm 20 Spa...

Page 234: ...3 1 2 Seat with operator console and armrest for electro pneumatic gearshift Remove the supporting structure for electro pneumatic gearshift EPS see Chapter 3 25 3 Remove the left covering in position...

Page 235: ...he five rounded head screws 11 and remove the backrest cover 12 Installation note Rounded head screw 11 4 Nm 6 Unscrew the hexagon bolt 7 and remove the two adjustment washers 5 and the spring washer...

Page 236: ...t roller 9 with belt tensioner 25 WARNING Risk of injury Pay attention to the safety notes in Chapter 1 1 on belt roller 9 with belt tensioners 25 7 1 Mark the point where the belt tensioner cable 28...

Page 237: ...bolt 10 at the support 13 and remove the spring washer 8 Installation notes Hexagon bolt 10 45 Nm For a new safety belt 6 the items hexagon bolt 10 and spring washer 8 are preassembled on the belt ro...

Page 238: ...th climate control system the microphone support 24 must be removed Installation notes Replace the serrated washer head screw 18 25 Nm The hook arrow at the belt bracket 17 must engage into the square...

Page 239: ...ut the safety belt 6 and the belt guide 15 and guide it out of the backrest 23 towards the back 14 Unscrew the hexagon bolt 19 and remove the belt guide 21 with safety belt 6 spacer sleeve 20 and spri...

Page 240: ...Remove the belt buckle with belt buckle cable Chapter 3 28 16 Belt buckle without belt buckle cable Unscrew the hexagon bolt 1 and remove the belt buckle 2 and the spacer 3 Installation notes Hexagon...

Page 241: ...p belt removal and installation Page 1 of 4 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Hexagon bolt 45 Nm 2 Belt buckle 3 Spacer 4 Seat frame 5 Socket 6 Support for belt roller 7 Hexagon bolt 12 Nm 8 Be...

Page 242: ...epair Chapter 3 1 2 Seat with operator console and armrest for electro pneumatic gearshift Remove the operator console for the electro pneumatic gearshift EPS see Chapter 3 25 3 Remove the left coveri...

Page 243: ...n 5 Belt buckle with belt buckle cable Remove the belt buckle with belt buckle cable Chapter 3 28 6 Belt buckle without belt buckle cable Unscrew the hexagon bolt 1 from the seat frame 4 and remove th...

Page 244: ...screw 11 protects the belt roller 8 against distortion Installation note Groove screw 11 12 Nm 8 Unscrew the hexagon bolt 9 and remove the belt roller 8 and the hexagon nut 10 Installation note Hexag...

Page 245: ...val and installation Page 1 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Belt buckle with belt buckle cable 2 Belt buckle cable short 3 Hexagon bolt 45 Nm 4 Spacer 5 Cable tie 6 Bowden pull wire for...

Page 246: ...e the left covering in position for repair Chapter 3 4 3 Remove the entire covering Chapter 3 5 Note For seat models with fore aft isolator remove only the left and right covering Do not remove the fr...

Page 247: ...buckle cable 2 from the clip 8 8 Unscrew the hexagon bolt 3 and remove the belt buckle 1 with the belt buckle cable 2 and the spacer 4 Installation notes Hexagon bolt 3 45 Nm The nose arrow on the bo...

Page 248: ...1153450_c 3 29 Secondary belt removal and installation Page 1 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Webbing secondary belt 2 Seat frame 3 Protective profile 4 Micro encapsulated cap screw to r...

Page 249: ...position for repair Chapter 3 1 2 Seat with operator console and armrest for electro pneumatic gearshift Remove the clip for the EPS cable at the lower suspension part see Chapter 3 21 3 Remove the be...

Page 250: ...lower suspension part 6 6 Pull out the webbing retaining plate 5 at the webbing 1 and remove the webbing 1 Installation notes Both loops of the webbing 1 have to be hung in the webbing retaining plate...

Page 251: ...ht to replace grease 47 Nm 2 Bearing support right hand 3 Micro encapsulated cap screw to replace 25 Nm 4 Hexagon nut welded for end stop 5 Torsion spring right 6 Leaf tooth sheet right to grease 7 Ba...

Page 252: ...contain bolts which are not micro encapsulated a suitable threadlocking compound e g LOCTITE should be used 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Seat with operator console...

Page 253: ...osition for repair Chapter 3 4 5 Remove the covering completely Chapter 3 5 Note For seat models with fore aft isolator remove only the left and right covering Do not remove the covering at the front...

Page 254: ...26 Note Remove the safety belt only at the backrest Do not remove the belt roller and the belt buckle 8 Remove air hoses for lumbar support and lateral support adjustment at the valve unit see Chapte...

Page 255: ...trical connections between cable harness for backrest and cable harness for vehicle connection and between cable harness for backrest and cable harness for heater switch need not be disconnected 9 3 R...

Page 256: ...CONTENTS Removal 10 Unscrew two micro encapsulated cap screws 3 from the right and left hexagon nut 4 Installation note Replace the micro encapsulated cap screw 3 25 Nm 11 Temporarily reinstall the le...

Page 257: ...bolts 1 10 and remove the backrest 7 with the torsion springs 5 9 at the bearing supports 2 11 Notes Hexagon bolts 1 10 have different widths across flats depending on the seat s special equipment e...

Page 258: ...on the bearing supports 2 11 Installation note Apply acid free multi purpose lubricant to the teeth F of the leaf 6 8 Note Perform installation consecutively first on the right 2 and then on the left...

Page 259: ...ll hole c on the leaf 6 of the backrest 7 2 3 Push the leaf 6 with the engaged torsion spring 5 down in front the bearing support 2 and temporarily fasten it with a micro encapsulated hexagon bolt 1 3...

Page 260: ...sh the leaf 8 with the engaged torsion spring 9 down in front the bearing support 11 and temporarily fasten it with a micro encapsulated hexagon bolt 10 4 Tighten the micro encapsulated hexagon bolt 1...

Page 261: ...the micro encapsulated cap screws 3 at the right and left hexagon nut 4 Installation note Replace the micro encapsulated cap screw 3 25 Nm 7 Install air hoses for lumbar support and lateral support ad...

Page 262: ...system Chapter 3 53 8 4 Install radial fan for backrest Chapter 3 52 8 5 Install the cable harness for the brackets see Chapter 3 49 8 6 Pull the backrest cover downward over the foam plastic part and...

Page 263: ...5 12 Attach the left covering Chapter 3 4 13 Seat with armrests For the installation of a new backrest the armrests of the old backrest are installed onto the new backrest see Chapter 3 24 14 Seat wit...

Page 264: ...ibuses November 2017 Material no 1153450_c 3 31 Backrest cover removal and installation Page 1 of 1 END TABLE OF CONTENTS 3 31 1 Backrest cover removal and installation 3 31 2 Backrest cover removal a...

Page 265: ...on Page 1 of 5 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Backrest cover 2 Foam plastic part 3 Velcro 4 Zipper 5 Insertion rod 6 Covering clamps replace 7 Safety belt Note No claims for warranty can be...

Page 266: ...in position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the covering at the back see Chapter 3 5 4 Seat with armrests Remove the armrests Chapter 3 24...

Page 267: ...ote Remove the safety belt only at the backrest Do not remove the belt roller and the belt buckle Removal and installation 7 Bend open the five covering clamps 6 turn off from the backrest 1 and remov...

Page 268: ...4 of backrest cushioning 1 9 Remove the lower and upper insertion rod 5 from the backrest cover 1 10 ATTENTION Damage The backrest cover 1 is secured in the backrest area with two Velcros 3 When separ...

Page 269: ...nstalling a new backrest cover 1 cut in the holes for the belt guide and belt bracket mounting Put the backrest cover 1 to top of the headrest and evenly pull it onto the foam plastic part 2 from top...

Page 270: ...ON TABLE OF CONTENTS 1 Backrest cover 2 Foam plastic part 3 Clamp 4 Ventilation cushion fabric inlay 5 Strip 6 Tie strap 7 Zipper 8 Safety belt 9 Covering clamps replace 10 Insertion rod 11 Cable tie...

Page 271: ...or warranty can be accepted if you install the backrest cushion covers of other manufacturers than GRAMMER AG 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Remove the left covering...

Page 272: ...move the safety belt only at the backrest Do not remove the belt roller and the belt buckle 6 Pull off the lever for backrest adjustment at the bolt see Chapter 3 13 Note Left and right Bowden pull wi...

Page 273: ...TENTION Damage Attach the new covering clamps 9 with the sharp side to the foam part 2 Do not install any covering clamps 9 in the safety belt area 8 arrows Replace the covering clamps 9 9 Mark the po...

Page 274: ...ackrest heater 12 out of the backrest frame 14 in downward direction 13 ATTENTION Damage The backrest cushion cover 1 is kept under tension with a strip 5 at the tie strap 6 in the upper backrest area...

Page 275: ...new backrest cover 1 cut in the holes for the belt guide and belt bracket mounting Put the backrest cover 1 to the top of the headrest and evenly pull it down onto the foam plastic part 2 When pullin...

Page 276: ...LE OF CONTENTS 1 Bearing support right 2 Bearing support left 3 Seat frame right 4 Rounded head screw 6 Nm 5 Blind rivet 6 Hexagon bolt 7 Retaining spring right 8 Retaining spring left 9 Seat frame le...

Page 277: ...n right 18 Bracket for backrest hook in function left 19 Leaf tooth sheet Delivery option pos 20 24 for seat with operator console and armrest for electro pneumatic gearshift EPS console 20 Support fo...

Page 278: ...elivery of spare parts which are not micro encapsulated an appropriate threadlocking compound e g LOCTITE has to be used 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Seat with oper...

Page 279: ...e entire covering Chapter 3 5 Note For seat models with fore aft isolator remove only the left and right covering Do not remove the front covering 5 Remove the backrest see Chapter 3 30 Notes The seat...

Page 280: ...ON TABLE OF CONTENTS 6 Pull off the lever for backrest adjustment at the stud see Chapter 3 13 Note The left and right Bowden pull wires for backrest adjustment do not have to be detached at the lever...

Page 281: ...5 at the right bearing support 1 9 Unscrew the rounded head screw 4 and remove the right bearing support 1 on the right seat frame 3 with the parts attached to it 7 13 14 15 16 17 10 Bore out the riv...

Page 282: ...ng mechanism 1 Assembly of the right bearing support 1 1 1 Insert two spacers A 14 with their round side into the right and left milling hole of the bearing support A 1 Notes The groove arrows of the...

Page 283: ...upport B 1 Notes The flat side of the lock B 13 must point towards the bearing support B 1 The even and flat side of the lock B 13 must lie on the bottom of the bearing support B 1 The groove B arrow...

Page 284: ...he bearing support C 1 as far as possible Notes Before pushing it through place turn the catch element C 15 in such a way that the nose C arrow at the catch element C 15 can be guided through the groo...

Page 285: ...bracket of the torsion spring D 16 must point towards the bearing support D 1 1 5 Insert the bracket D 17 into the hinge of the bearing support D 1 and hang in the legs of the torsion spring D 16 into...

Page 286: ...15 Notes The long leg of the retaining spring E 7 must point towards the bearing support E 1 and to the back When it is installed the retaining spring 7 must press upwards the engaging surface arrow o...

Page 287: ...ft side of the seat frame 3 9 and fasten them by means of hexagon bolts 6 in installation position for adjustment Note The retaining springs 7 8 must lie flat against the right and left side of the se...

Page 288: ...xagon bolt 6 out again Installation note Rounded head screw 4 6 Nm 7 Install the backrest see Chapter 3 30 8 Hang in the Bowden pull wires for backrest adjustment at the left and right catch elements...

Page 289: ...2 Installation note Rounded head screw 11 6 Nm 11 Fasten the left bearing support 2 with a blind rivet 12 on the left of the seat frame 9 12 Install the complete covering Chapter 3 5 13 Install the l...

Page 290: ...nstallation Page 1 of 5 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Backrest 2 Safety belt 3 Backrest cover 4 Foam plastic part 5 Lumbar support 6 Lattice frame 7 Air hose for upper chamber 8 Air hose fo...

Page 291: ...OF CONTENTS 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Carefully detach the rear covering at the right covering see...

Page 292: ...2 at the left curvature of the backrest 1 6 Bend open the covering clamps 11 in the zipper area 10 and remove them Installation notes ATTENTION Damage Attach the new covering clamps 11 with the point...

Page 293: ...the upper and lower chamber 7 8 should be performed upon installation of the lumbar support 5 8 WARNING Damage Take care not to damage the air hoses for the upper and lower chamber 7 8 Pull off the ai...

Page 294: ...e lumbar support 5 at the lattice frame 6 10 Pull out the lumbar support 5 through the lattice frame 6 in backward direction Installation note Before hanging it into the lattice frame 6 exactly align...

Page 295: ...TION TABLE OF CONTENTS 1 Lateral support adjustment left 2 Backrest frame 3 Foam plastic part to glue with 2 4 Hose connector T piece 5 Air hose left chamber 6 Lateral support adjustment right 7 Air h...

Page 296: ...rests Remove the armrests Chapter 3 24 3 Seat with operator console and armrest for electro pneumatic gearshift Remove the operator console for the electro pneumatic gearshift EPS see Chapter 3 25 4 R...

Page 297: ...3 26 Note Remove the seat belt at the backrest only Do not remove the belt roller and the belt buckle 7 Remove the backrest cover Chapter 3 31 Removal and installation ATTENTION Hydrostatic test The...

Page 298: ...ies 9 and remove the cable ties 9 9 Lateral support adjustment left 1 9 1 Carefully pull off the foam plastic part 3 in the area of the left lateral support adjustment 1 at the backrest frame 2 Instal...

Page 299: ...3 ATTENTION Damage Take care not to damage the air hose for the left chamber 5 Pull off the air hose for the left chamber 5 at the hose connector 4 Installation note Push the air hose for the left ch...

Page 300: ...Carefully pull off the foam plastic part 3 in the area of the left lateral support adjustment 6 at the backrest frame 2 Installation note Glue together the foam plastic part 3 and the backrest frame...

Page 301: ...o damage the air hose for the right chamber 7 Pull off the air hose for the right chamber 7 at the hose connector 8 Installation note Push the air hose for the right chamber 7 completely onto the hose...

Page 302: ...LLATION TABLE OF CONTENTS 1 Vertical shock absorber 2 Collar screw to replace to grease 3 Hexagon nut 25 Nm 4 Bracket swinging structure 5 Washer replace 6 Axle swinging structure to grease 1 Lift off...

Page 303: ...3 WARNING Risk of crushing Bring the seat into the highest position and secure the swinging structure to the front plastic rollers of the lower suspension part by means of appropriate spacers 4 Unscr...

Page 304: ...re collar F of the collar screw 2 Replace the washer 5 6 Move the seat to the middle position in order to be able to pull off the vertical shock absorber 1 at the axle 6 7 Pull off the vertical shock...

Page 305: ...ENTS 1 Air spring 2 Collar screw inner race 5 Nm 3 Upper air spring support swinging structure 4 Lower air spring support swinging structure 5 Thread collar air spring 6 Air hose blue to the air sprin...

Page 306: ...of the quick coupling 7 must be pressed to the very back e g using flat pliers in order to avoid scoring of the air hose 6 Connect the air hose 6 not more than 1 to 2 times Always check the air hose...

Page 307: ...ulic test of the seat should be performed upon installation of the air spring 1 To do this apply 60 kg load to the seat for 24 hours The lowering within this time must not exceed 15 mm 1 Lift off the...

Page 308: ...see Chapter 3 9 4 Remove the cable for vehicle connection at the level control see Chapter 3 20 5 Remove the air hose for lumbar support and lateral support adjustment at the retainer of the level con...

Page 309: ...CONTENTS 7 For seat model Actros Remove the pin contact strip at the supporting structure see Chapter 3 39 Removal and installation 8 WARNING Risk of crushing Bring the seat into the highest position...

Page 310: ...matic system might cause injury The pneumatic system is to be vented before removing the air hose 1 e g by means of the quick lowering 10 Unscrew the collar screw 2 through the mounting hole arrow in...

Page 311: ...llar screw 9 Installation note Collar screw 9 5 Nm 12 Press the retaining ring of the quick coupling 7 against the air spring 1 and pull the air hose 6 out of the air spring 1 Installation notes Inser...

Page 312: ...ing support 3 4 and remove it from the seat in downward direction Note Press the removed level control 11 aside when removing the air spring 1 Installation note Insert the air spring 1 at the lower ai...

Page 313: ...INSTALLATION TABLE OF CONTENTS 1 Stopper 2 Rounded flange head screw inner race 5 Nm 3 Upper suspension part 4 Clamp to grease 5 Rubber spring 6 Swinging structure 7 Tube section to grease 8 Washer 9...

Page 314: ...val and installation 2 To unlock the fore aft isolator turn the lever for the fore aft isolator 13 upwards 3 Move the seat to a high position and secure it WARNING Risk of crushing Secure the obtained...

Page 315: ...LE OF CONTENTS 4 Unscrew two rounded flange head screws 2 Installation note Rounded flange head screw 2 5 Nm 5 Pull off two stoppers 1 at the studs 12 and remove them from the running surfaces 11 of t...

Page 316: ...ENTION Deformation The clamp 4 is mounted between the swinging structure 6 and the upper suspension part 3 To remove the clamp 4 push a screwdriver from the front horizontally between the upper suspen...

Page 317: ...engage in the guide 13 at the upper suspension part 3 Apply acid free multi purpose lubricant to the entire groove F and running surface F of the clamp 4 11 Pull the rubber spring 5 out of the clamp...

Page 318: ...2 Swinging structure 3 Lock washer 4 Centre axle swinging structure 5 Front axle bottom swinging structure 6 Clamp right level control 7 Clamp left level control 8 Bracket level control 9 Air hose bl...

Page 319: ...1 To do this apply 60 kg load to the seat for 24 hours The lowering within this time must not exceed 15 mm Notes When replacing the level control 1 the air hose 9 to the air spring 12 is replaced as w...

Page 320: ...hapter 3 4 3 Detach the front covering at the right covering see Chapter 3 5 4 Remove the bellows at the front of the upper suspension part see Chapter 3 6 and press it down 5 Detach the Bowden pull w...

Page 321: ...3 20 8 Remove the air hose for lumbar support and lateral support adjustment at the retainer of the level control see Chapter 3 22 9 Pull the air hose out of the air spring see Chapter 3 36 10 Pull o...

Page 322: ...the highest position and secure the swinging structure to the front plastic rollers of the lower suspension part by means of appropriate spacers 13 WARNING The pressure in the pneumatic system might...

Page 323: ...lation note During installation make sure that the bracket 8 is hung into the lower front axle 5 of the swinging structure 2 16 Remove the level control 1 from the seat in upward direction Installatio...

Page 324: ...removal and installation Page 1 of 1 END TABLE OF CONTENTS 3 39 Supporting structure removal and installation 3 39 1 Supporting structure and pin contact strip removal and installation Actros 3 39 2 S...

Page 325: ...ounded head screw inner race 5 Nm 4 Micro encapsulated cap screw to replace 25 Nm 5 Plug of the cable for vehicle connection 6 Connection for air intake 7 Connection for air exhaust 8 Plug of EPS cabl...

Page 326: ...ws 3 and lay the pin contact strip 2 down Installation note Rounded head screw 3 5 Nm 2 Push the seat backwards as far as possible and unscrew two micro encapsulated cap screws 4 at the front Installa...

Page 327: ...nnect the electrical connection between the pin contact strip 2 and the plug of the cable for vehicle connection 5 5 2 Pull off the air hose for air intake 10 and air exhaust 9 at the connection for a...

Page 328: ...ego Axor Page 1 of 2 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Supporting structure 2 Micro encapsulated cap screw to replace 25 Nm 3 Lower suspension part 1 Remove the seat fore aft adjustment at the...

Page 329: ...xor Page 2 of 2 REMOVAL INSTALLATION TABLE OF CONTENTS Removal and installation 2 Unscrew four micro encapsulated cap screws 2 Installation note Replace the micro encapsulated cap screw 2 25 Nm 3 Remo...

Page 330: ...e Size and shape of the supporting structure 1 might differ depending on the design or model of the seat 2 Swivel 3 Lever for seat fore aft adjustment 4 Seat fore aft adjustment 5 Plate with mounting...

Page 331: ...ssible 2 Unscrew two micro encapsulated cap screws 6 at the front and remove the washers 8 and hexagon nuts 7 Installation note Replace the micro encapsulated cap screw 6 25 Nm 3 Push the seat forward...

Page 332: ...OF CONTENTS 5 Unscrew four micro encapsulated cap screws 6 at the rear and remove hexagon nuts 7 washers 8 and the plates with mounting holes 5 6 Remove the supporting structure 1 at the locking rail...

Page 333: ...fore aft adjustment removal and installation Page 1 of 1 END TABLE OF CONTENTS 3 40 1 Seat fore aft adjustment removal and installation Actros 3 40 2 Seat fore aft adjustment and pin contact strip re...

Page 334: ...ge 1 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Lever for seat fore aft adjustment 2 Locking rail to grease 3 Adjusting rail 4 Seat fore aft adjustment 2 3 5 Micro encapsulated cap screw to replace...

Page 335: ...he supporting structure see Chapter 3 39 Note The pin contact strip does not need to be removed from the supporting structure Removal and installation 2 Push the seat forwards as far as possible 3 Uns...

Page 336: ...the adjusting rails 3 Installation note Replace the micro encapsulated cap screw 7 25 Nm 6 Remove the seat fore aft adjustment 4 with the lever for fore aft adjustment 1 at the lower suspension part...

Page 337: ...justment complete 2 3 4 5 2 Lever for seat fore aft adjustment 3 Locking rail to grease 4 Adjusting rail 5 Base plate 6 Pin contact strip 7 Supporting structure 8 Micro encapsulated cap screw to repla...

Page 338: ...N TABLE OF CONTENTS 13 Rounded head screw inner race 2 6 Nm 14 Plug of the cable for vehicle connection 15 Connection for air exhaust 16 Connection for air intake 17 Plug of EPS cable delivery option...

Page 339: ...ed head screw 13 2 6 Nm 2 Push the pin contact strip 6 to the right to unhook the two noses arrows at the base plate 5 3 Remove the pin contact strip 6 at the base plate 5 and put it aside Note In lef...

Page 340: ...console and armrest for electro pneumatic gearshift Unscrew two micro encapsulated cap screws 8 at the front Installation note Replace the micro encapsulated cap screw 8 25 Nm 6 Seat with operator con...

Page 341: ...9 11 are accessible via the mounting holes arrows at the bottom in the base plate 5 8 Unscrew two micro encapsulated cap screws 9 Installation note Replace the micro encapsulated cap screw 9 25 Nm 9 U...

Page 342: ...the plug of the cable for vehicle connection 14 11 2 Pull off the air hose for air intake 19 and air exhaust 18 at the connection for air intake 16 and air exhaust 15 11 3 Seat with operator console...

Page 343: ...3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Lever for seat fore aft adjustment 2 Locking rail to grease 3 Adjusting rail 4 Seat fore aft adjustment 2 3 5 Micro encapsulated cap screw to replace 25 Nm...

Page 344: ...sh the seat fore aft adjustment 4 forwards as far as possible 4 Unscrew two micro encapsulated cap screws 5 at the front and remove two hexagon nuts 6 Installation note Replace the micro encapsulated...

Page 345: ...nuts 6 Installation note Replace the micro encapsulated cap screw 5 25 Nm 7 Remove the seat fore aft adjustment 4 with the lever for fore aft adjustment 1 at the swivel 8 Installation note Apply acid...

Page 346: ...mber 2017 Material no 1153450_c 3 41 Guides removal and installation Page 1 of 2 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Guide to grease 2 Blind rivet 3 Seat frame 1 Lift off the seat cushion in posi...

Page 347: ...ONTENTS Removal and installation 2 Bore off four rivet heads at the guides 1 and drive out the blind rivets 2 3 Remove four guides 1 at the seat frame 3 Installation note Apply acid free multi purpose...

Page 348: ...for compressed air quick coupling 2 Compressed air quick coupling 3 Supporting structure 4 Retaining ring 5 Hose nozzle 6 Hose connector T piece 7 Cable tie WARNING Hydrostatic test The hydraulic tes...

Page 349: ...stallation 1 WARNING The pressure in the pneumatic system might cause injury The pneumatic system is to be vented before removing the air hose 1 e g by means of the quick lowering 2 Mark the point whe...

Page 350: ...ir hose 1 6 Push the retaining ring 4 of the compressed air quick coupling 2 completely backwards arrow direction and pull the air hose 1 out of the compressed air quick coupling 2 Installation notes...

Page 351: ...ame 2 Stud to grease 3 Blind rivet 4 Support 5 Blind rivet 6 Rounded head screw inner race 3 Nm 7 Protective profile 8 Clip for cable and Bowden pull wire 9 Z section 10 Blind rivet 11 Guide to grease...

Page 352: ...16 Eccentric 17 Blind rivet 18 Support Bowden pull wire 19 Blind rivet 20 Clamp Bowden pull wire 21 Clamp EPS cable 22 Handle rail 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Rem...

Page 353: ...3 25 4 Remove the covering completely Chapter 3 5 5 Remove the bellows at the upper suspension part and at the supports see Chapter 3 6 and press it down 6 Remove the Bowden pull wire and the lever f...

Page 354: ...the lap belt Chapter 3 27 10 Remove the belt buckle with the belt buckle cable Chapter 3 28 11 Remove the secondary belt Chapter 3 29 12 Remove the backrest Chapter 3 30 13 Remove the bearing support...

Page 355: ...cture to the front plastic rollers of the lower suspension part by means of appropriate spacers 15 Unscrew two rounded head screws 6 and lay the handle rail 22 down Installation note Rounded head scre...

Page 356: ...ree multi purpose lubricant to the entire surface F of the studs 2 19 Remove the seat frame 1 in upward direction Installation notes For installation of a new seat frame 1 Convert assembles that do no...

Page 357: ...horizontally and in the right position onto the upper suspension part 12 20 Removal of further assemblies 20 1 Bore off four rivet heads drive out the blind rivets 3 at the seat frame 1 and remove two...

Page 358: ...our rivet heads drive out the blind rivets 17 at the seat frame 1 and remove the support 15 with the eccentric 16 20 6 Bore off the rivet head drive out the blind rivet 19 at the seat frame 1 and remo...

Page 359: ...CONTENTS 1 Seat suspension 2 Seat frame 3 Stud to grease 4 Blind rivet 5 Clearance spacer 6 Backrest 7 Countersunk screw inner race 25 Nm 8 Support belt roller 9 Holder Bowden pull wire 10 Rounded hea...

Page 360: ...2 Remove the seat cushion and the lever for seat angle and seat depth adjustment Chapter 3 2 3 Remove the left covering in position for repair Chapter 3 4 4 Seat with operator console and armrest for...

Page 361: ...alve lever and retainer see Chapter 3 7 and pull it out in backward direction 8 Remove the Bowden pull wire for seat height adjustment at the level control control disc and at the holder see Chapter 3...

Page 362: ...chanism of the fore aft isolator Chapter 3 15 10 2 Remove the fore aft isolator Chapter 3 37 11 Remove the Bowden pull wire for seat angle adjustment with the locking mechanism Chapter 3 17 Note Remov...

Page 363: ...rt upper suspension part see Chapter 3 26 lead it upwards at the webbing and secure it 14 Remove the air hose for lumbar support and lateral support adjustment at the valve unit see Chapter 3 23 15 De...

Page 364: ...lt tensioner cable at the clip see Chapter 3 20 18 Remove the secondary belt Chapter 3 29 19 Remove the supporting structure Chapter 3 39 20 Remove the seat fore aft adjustment Chapter 3 40 Removal an...

Page 365: ...ad screw 10 and remove the support 9 at the seat suspension 1 Installation note Rounded head screw 10 2 7 Nm 23 Bore off two rivet heads and drive out the blind rivets 4 at the seat frame 2 24 Pull tw...

Page 366: ...just the clearance between the seat frame 2 and the seat suspension 1 by means of clearance washers 5 Place the seat frame 2 horizontally in the right position onto the seat suspension 1 26 Remove the...

Page 367: ...ding rail face side to be greased 4 Buffer 5 Collar screw inner race 7 Nm 6 Stopper 7 Buffer 8 Hexagon nut 9 Buffer spacer 10 Micro encapsulated cap screw to replace 25 Nm 11 Clearance spacer thicknes...

Page 368: ...6 Threaded bolt 17 Rounded flange head screw inner race 5 Nm 18 Stopper 19 Rounded head screw inner race 2 7 Nm 20 Holder Bowden pull wire 21 Centre bearing to grease Note If the swinging structure 2...

Page 369: ...see Chapter 3 11 2 Compression spring 1x see Chapter 3 11 3 Fixing 1x see Chapter 3 11 4 Collar screw 1x 25 Nm see Chapter 3 35 5 Hexagon nut 1x see Chapter 3 35 Hexagon nut 4x see Chapter 3 45 6 Was...

Page 370: ...3 45 11 Fixed bearing 4x see Chapter 3 45 12 Sleeve tube piece 4x see Chapter 3 45 13 Buffer 2x see Chapter 3 45 14 Clearance spacer 8x see Chapter 3 45 15 Buffer spacer 2x see Chapter 3 45 16 Plasti...

Page 371: ...al and installation driver s seat with swivel e g bus seat Page 1 of 1 END TABLE OF CONTENTS 3 47 1 Swivel and linkage rod removal and installation 3 47 2 Cylinder for swivel removal and installation...

Page 372: ...complete 2 Micro encapsulated cap screw to replace 25 Nm 3 Supporting structure for swivel 4 Lower suspension part 5 Micro encapsulated cap screw to replace 25 Nm 6 Cylinder 7 Air hose to the cylinder...

Page 373: ...inkage rod removal and installation Page 2 of 4 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Position the backrest vertically and put the seat onto the backrest 2 Remove the supporting structure Chapter 3...

Page 374: ...tch the air hose to the cylinder 7 and take care not to damage the hose connection to the cylinder 6 Unscrew six micro encapsulated cap screws 2 and remove the swivel 1 at the supporting structure for...

Page 375: ...ighten the rounded head screw 11 7 Detach the wire bracket 12 at the cylinder 6 and remove the swivel 1 8 Removal of the supporting structure for the swivel 3 Unscrew six micro encapsulated cap screws...

Page 376: ...e to the cylinder 2 Cylinder for the swivel 3 Rounded head screw inner race to hand tighten 4 Wire bracket 5 Hose nozzle 6 Connection fixed throttle ATTENTION Hydrostatic test The hydraulic test of th...

Page 377: ...eat onto the backrest 2 Remove the supporting structure Chapter 3 39 3 Remove the swivel see Chapter 3 47 Note Do not remove the fore aft adjustment at the swivel Removal and installation 4 WARNING Th...

Page 378: ...crewdriver or similar tools to lift off the air hose 1 at the connection 6 of the cylinder 2 Cut off the air hose 1 in a clean and straight way directly behind the connection 6 of the cylinder 2 by me...

Page 379: ...7 Pull off the hose nozzle 5 at the air hose 1 8 Unscrew the rounded head screw 3 Installation note Hand tighten the rounded head screw 3 2 6 Nm 9 Detach the wire bracket 4 at the cylinder 2 and remo...

Page 380: ...OVAL INSTALLATION TABLE OF CONTENTS 1 Button for swivel 2 Handle rail 3 Holder for button of swivel 4 Grooved pin to grease 5 Rounded head screw inner race 3 Nm 6 Lever of button for swivel 7 Valve su...

Page 381: ...repair Chapter 3 4 Removal and installation 3 Drive out the grooved pin 4 at the lever 6 and at the holder 3 in back ward direction and remove the lever 6 with the button for the swivel 1 Installatio...

Page 382: ...rounded head screw 5 and pull out the valve for the swivel 8 with the valve support 7 at the holder 3 Installation note Rounded head screw 5 3 Nm 6 WARNING The pressure in the pneumatic system might...

Page 383: ...se a screwdriver or similar tools to lift off the air hoses 10 11 at the connections arrows of the valve 8 Mark the air hoses 10 11 ad cut them off in a clean and straight way directly behind the conn...

Page 384: ...Page 5 of 5 REMOVAL INSTALLATION TABLE OF CONTENTS Notes The air hoses 10 11 can be cut off only once After cutting mark the air hoses 10 11 in order not to cut them several times 9 Remove the valve f...

Page 385: ...Hose nozzle 3 Cable tie 4 Hose connector reducer 5 Hose nozzle 6 Air hose short 7 Air hose long 8 Air hose to the cylinder 9 Air hose for lumbar support lateral support adjustment and swivel 10 Air ho...

Page 386: ...CONTENTS 15 Retainer 16 Level control 17 Cable tie 18 Bellows 19 Cable tie 20 Air spring support WARNING Hydrostatic test The hydraulic test of the seat should be performed upon installation of the ai...

Page 387: ...1 2 Remove the right covering in position for repair Chapter 3 4 3 Carefully detach the rear covering at the left covering see Chapter 3 5 4 Detach the bellows at the supports see Chapter 3 6 5 Remove...

Page 388: ...ve for lateral support adjustment see Chapter 3 23 Removal and installation 8 WARNING Risk of crushing Bring the seat into the highest position and secure the swinging structure to the front plastic r...

Page 389: ...the Bowden pull wire 12 for vertical shock absorber adjustment by means of cable tie 3 and remove the cable tie 3 11 Pull off the hose nozzles 2 5 and push them backwards over the air hoses 6 7 8 9 1...

Page 390: ...screwdriver or similar tools to lift off the air hoses 6 7 8 9 10 at the connections arrows and connection pieces 4 11 Installation note Push the air hoses 6 7 8 9 10 completely onto the connections a...

Page 391: ...the cable ties 17 17 Detach the air hoses 8 9 at the retainer 15 of the level control 16 18 Mark the points where the air hoses 8 9 are fastened to the air spring support 20 by means of cable ties 19...

Page 392: ...5 at the air hose 9 22 Pull out the air hoses 8 9 in upward direction through the seat suspension and then in backward direction arrow at the bellows 18 and remove them 23 Re install the components in...

Page 393: ...CONTENTS 1 Bowden pull wire for optional backrest adjustment 2 Baffle 3 Lever for backrest adjustment 4 Seat frame left 5 Backrest 6 Countersunk screw hexagon socket screw 12 Nm 7 Cable tie 8 Bowden...

Page 394: ...stallation delivery option Page 2 of 8 REMOVAL INSTALLATION TABLE OF CONTENTS 14 Angle plate 15 Handle for optional backrest adjustment 16 Holder for Bowden pull wire 17 Blind rivet 18 Blind rivet 19...

Page 395: ...ON Noise When driving out the blind rivets make sure that the residues of the blind rivets do not fall into the seat 1 Remove the backrest cover see Chapter 3 26 2 Lift off the seat cushion in positio...

Page 396: ...ustment at the stud see Chapter 3 13 6 Detach the left and right Bowden pull wire for backrest adjustment at the lever for backrest adjustment see Chapter 3 13 Removal and installation 7 Mark the poin...

Page 397: ...e 4 Installation note Countersunk screw 6 12 Nm 9 Detach the Bowden pull wire for optional backrest adjustment 1 at the baffle 2 and remove the baffle 2 Installation note The nose arrow of the baffle...

Page 398: ...1 Loosen the lock washer 21 at the Bowden pull wire for optional backrest adjustment 1 12 Detach the Bowden pull wire for optional backrest adjustment 1 at the bearing 10 13 Bore off the rivet head an...

Page 399: ...lstery 20 16 Pull the Bowden pull wire for optional backrest adjustment 1 out of the backrest cover 20 in downward direction and remove it Installation note The Bowden pull wire for optional backrest...

Page 400: ...plate 14 20 Pull off the handle for optional backrest adjustment 15 at the lever 23 21 Pull the lever 23 out of the angle plate 14 22 Bore off the rivet head drive the blind rivet 17 out of the bearin...

Page 401: ...EMOVAL INSTALLATION TABLE OF CONTENTS 1 Cable harness for backrest 2 Cable for microphone 3 Cable for backrest heater 4 Cable tie 5 Cable tie 6 Cable tie 7 Cable for seat fan 8 Cable seat cushion heat...

Page 402: ...ion seat with climate control system Page 2 of 8 REMOVAL INSTALLATION TABLE OF CONTENTS 14 Air hose 15 Cable harness for heater switch 16 Backrest frame 17 Cable tie 18 Cable tie 19 Cable of backrest...

Page 403: ...lectrical connection between seat cushion heater 8 and backrest heater cable 3 J Electrical connection between cable harness for backrest 1 and seat fan cable 7 K Electrical connection between cable h...

Page 404: ...ove the left covering in position for repair Chapter 3 4 3 Remove the covering at the back see Chapter 3 5 4 Remove the backrest cover see Chapter 3 26 5 Remove the covering clamps and upper insertion...

Page 405: ...trol module for climate control system see Chapter 3 53 Removal and installation 8 Mark the points where the cable harness for the backrest 1 is attached to the backrest heater cable 3 and to the micr...

Page 406: ...cable tie 6 and remove the cable tie 6 Installation note The cable tie 6 must be guided trough the cable tie 5 fastened at the seat support 9 11 Mark the points where the electrical connections K L ar...

Page 407: ...one cable 2 are fastened to the backrest frame 16 with cable ties 17 and remove the cable ties 17 14 Mark the points where the cable harness for the backrest 1 the microphone cable 2 and the electrica...

Page 408: ...LATION TABLE OF CONTENTS 15 Disconnect the electrical connection M between cable harness for backrest 1 and backrest fan cable 19 16 Pull the cable harness for the backrest 1 out of the backrest frame...

Page 409: ...rness for heater switch 2 Plug cable harness for heater switch 3 Heater switch 4 Air hose for lumbar support and lateral support adjustment 5 Seat frame 6 Cable tie 7 Cable harness for backrest 8 Cabl...

Page 410: ...4 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the covering at the back...

Page 411: ...sconnect the electrical connections N between the six connectors 2 and the heater switch 3 Installation notes Re establish the electrical connections N according to the markings Lay the cable harness...

Page 412: ...the cable tie 8 Installation note The cable tie 8 must be guided trough the cable tie 6 fastened at the seat support 5 8 Disconnect the electrical connection K between cable harness of the heater swi...

Page 413: ...icle connection 2 Cable harness for backrest 3 Cable harness for heater switch 4 Microphone contact cable in cable harness for vehicle connection 5 Belt buckle contact cable in cable harness for vehic...

Page 414: ...and installation seat with climate control system Page 2 of 8 REMOVAL INSTALLATION TABLE OF CONTENTS 14 Cable clamp 15 Cable tie 16 Plug belt buckle cable 17 Cable for signal 18 Cable tie 19 Level co...

Page 415: ...s for vehicle connection 1 F Electrical connection between belt buckle contact cable 5 and belt buckle cable 5 K Electrical connection between cable harness for backrest 2 and cable harness for the he...

Page 416: ...r repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the covering at the back see Chapter 3 5 Removal and installation 4 WARNING Risk of crushing Bring the seat...

Page 417: ...tallation instructions of the vehicle manufacturer 6 Mark the points where the electrical connections K L are bundled with a cable tie 11 and remove the cable tie 11 Installation note The cable tie 11...

Page 418: ...remove the cable ties 12 Installation note The microphone contact cable 4 and the signal cable 17 are also fastened with the two left cable ties 12 9 Pull out cable clamp 10 at the seat support 13 an...

Page 419: ...to the seat support 13 with two cable ties 15 and remove the cable ties 15 Installation note The cable for the belt buckle contact 5 is placed in the bottom seam arrow of the seat support 13 13 Discon...

Page 420: ...n 1 from the large opening of the swivel 9 and the seat suspension towards the top 16 Pull out the cable harness for vehicle connection 1 from the opening arrow in the bellows 8 towards the back and r...

Page 421: ...and installation seat with climate control system Page 1 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Radial fan for backrest 2 Support in foam part for backrest 3 Cable for microphone 4 Flat head sc...

Page 422: ...ckrest cover see Chapter 3 31 and pull apart in the range of the radial fan 1 in order to make the radial fan 1 and the electrical connection M accessible Removal and installation 3 Mark the points wh...

Page 423: ...ystem Page 3 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 4 Disconnect the electrical connection M between cable harness for backrest 7 and backrest fan cable 6 5 Unscrew the two flat head screws 4 at...

Page 424: ...ntrol system removal and installation seat with climate control system Page 1 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Control module for the climate system 2 Backrest frame 3 Blind rivet 4 Cable...

Page 425: ...system Page 2 of 3 REMOVAL INSTALLATION TABLE OF CONTENTS 1 Remove the backrest cover see Chapter 3 26 2 Remove the covering clamp and upper insertion rods at the backrest cover see Chapter 3 31 3 Op...

Page 426: ...ctor 7 and disconnect the electrical connection P between the cable harness for the backrest 4 and the control module for the climate control system 1 Note To unlock press down the catcher 6 at the co...

Page 427: ...TABLE OF CONTENTS 1 Cable for microphone 2 Microphone support 3 Backrest 4 Serrated washer head screw to replace 25 Nm 5 Cable tie 6 Belt bracket 7 Backrest cover 8 Cable tie 9 Backrest frame 10 Cable...

Page 428: ...INSTALLATION TABLE OF CONTENTS 1 Lift off the seat cushion in position for repair Chapter 3 1 2 Remove the left covering in position for repair Chapter 3 4 3 Remove the covering at the back see Chapt...

Page 429: ...points where the microphone cable 1 is attached to the backrest heater 14 and to the cable harness for the backrest 10 by means of two cable ties 13 and remove the cable ties 13 8 Mark the points wher...

Page 430: ...stened to the backrest frame 9 with cable ties 8 and remove the cable ties 8 10 Fold the backrest 3 forwards 11 Unscrew the serrated washer head screw 4 and put aside the microphone support 2 on the b...

Page 431: ...where the microphone cable 1 is fastened at the microphone support 2 with cable tie 5 and remove the cable tie 5 Installation note The locking head of the cable tie 5 must be located inside between mi...

Page 432: ...VAL INSTALLATION TABLE OF CONTENTS 1 Microphone support 2 Cable for microphone 3 Backrest 4 Serrated washer head screw to replace 25 Nm 5 Cable tie 6 Belt bracket 7 Adapter plate for microphone 8 Roun...

Page 433: ...and installation 3 Fold the backrest 3 forwards 4 Unscrew the serrated washer head screw 4 and put aside the microphone support 1 on the backrest 3 Note After unscrewing the serrated washer head scre...

Page 434: ...microphone support 1 with cable tie 5 and remove the cable tie 5 Installation note The locking head of the cable tie 5 must be located inside between microphone support 1 and backrest 3 6 Remove the...

Page 435: ...ABLE OF CONTENTS 1 Backrest 2 Bearing support right hand 3 Catch element 4 Lock 5 Washer 6 Spacer at the bearing support opposite the lever white 7 Spacer at the bearing support lever side black 8 Bea...

Page 436: ...k see Chapter 3 5 4 Fold the backrest forwards Inspection of play 5 Determine clearance between bearing support 2 8 and lock 4 with a feeler gauge with no load on the backrest 1 Play 0 to 0 15 mm No a...

Page 437: ...nd adjustment Page 3 of 3 INSPECTION ADJUSTMENT TABLE OF CONTENTS Adjusting play 6 Remove the catch element 3 and lock 4 see Chapter 3 29 7 Push washer 5 between lock 4 and spacer 6 7 based on the res...

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