ISRI 6830KA/ 880 Repair Manual Download

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CONTENTS

chapter

contens

1.1.0

1.3.0

2.1.0

2.2.0

2.3.0

2.4.0

2.5.0

2.6.0

2.7.0

2.8.0

2.9.0

2.10.0

2.11.0

2.12.0

2.13.0

2.14.0

2.15.0

2.16.0

2.17.0

General

Important

hints.....................................................

Serial

number.......................................................

System components

(before each repair read chapter 1 as well)

Complete

seat......................................................

Horizontal

adjustment...........................................

Seat

cushion.........................................................

Sliders...................................................................

Backrest................................................................

Upholstery cover for seat cushion........................

Upholstery cover for backrest...............................

Side covers for seat frame...................................

Switch for lumbar support.....................................

Switch climatic/ heating........................................

Front

cover............................................................

Switch height adjustment (KA).............................

Rear

cover............................................................

Switch height adjustment (KM)............................

Lever for tilt adjustment........................................

Lever for shock absorber......................................

Lever for horizontal suspension...........................

Handle for backrest..............................................

Handle for backrest/ shoulder adjustment............

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

Tooth segment for shoulder adjustment...............

Electronic unit (ECU)...........................................

Rotary position sensor..........................................

Compressor..........................................................

Summary of Contents for 6830KA/ 880

Page 1: ...REPAIR MANUAL ISRI 6830KA 880...

Page 2: ...Subject to technical changes for reasons of further development State 03 2011...

Page 3: ...nt Seat cushion Sliders Backrest Upholstery cover for seat cushion Upholstery cover for backrest Side covers for seat frame Switch for lumbar support Switch climatic heating Frontcover Switch height a...

Page 4: ...c unit climatic heating Fan seat cushion Fan backrest Air chambers lumbar support IPS Cover for belt 3 point belt 2 point belt Elektronikkomponenten Circuit diagrams Overview elecrtrical parts Connect...

Page 5: ...others Before repair read the warning notes in chapter 1 Please read accessorily the operating instruction of the seat to become fami liar with its technical features WARNING CAUTION For cleaning the...

Page 6: ...arts again After each repair a functional test and if pneumatic parts are involved a leak test has to be effected All adjustment mechanism must engage audibly Move levers over the complete operation s...

Page 7: ...d at lever side on the lower frame of the suspension unit and is visible when lifting up the bellows The exact seat type and the seat number can be identified by the serial number Please specify for s...

Page 8: ...e seat to the foremost position and undo screws 2 Pull lever 1 upwards move seat to the rearmost position and undo screws 3 Horizontal adjustment Dismount seat from vehicle Pull lever 1 upwards and mo...

Page 9: ...at cushion s front keyholes 5 onto the sliders at the front and press down cushion in direction of arrow F Push the cushion in direction of backrest till stop while still pressing down the complete se...

Page 10: ...ckrest and unscrew two screws 2 Lever backrest out of the seat frame brackets Possibly remove armrests For version with 3 point belt Unscrew screw 5 long and screw 6 short and move belt cover upwards...

Page 11: ...Disconnect hoses and electrical connector 3 Unhook C profiles 4 see detail A and 5 Pull cover upwards and loosen fixing tapes 6 Remove cardboard if existing For version with 3 point belt Unscrew screw...

Page 12: ...d down backrest completely and undo one screw 5 Remove cover 6 from seat frame Side cover opposite side Remove cover 14 in general sense of side cover level side IPS valve Lift up fixing hook 7 and se...

Page 13: ...t Push seat cushion in foremost position and lift it up see 2 2 0 Undo two screw 1 and lever out front cover 2 Press out rotation switch for height adjustment from behind of the front cover and discon...

Page 14: ...rews 1 and lever out front cover Press out switch for height adjustment 3 from behind of the front cover Unhinge hoses of switch out of clamp 4 Loose air hoses 5 6 7 at the connectors 9 and 10 Therefo...

Page 15: ...4 5 Remove lever for horizontal suspension see 2 10 0 Lever bearing 7 out of seat frame and remove bowden cable from lever 3 Installation tilt adjustment When mounting hook spring 1 at first in lever...

Page 16: ...ber adjustment Demount seat cushion see 2 2 0 Remove retaining washer 1 and lever bowden cable 2 out of fastening 3 Unscrew two screws 4 Knock pin 5 out of lever 6 and pull bowden cable out of seat fr...

Page 17: ...ON Lever for horizontal suspension Demount seat cushion see 2 2 0 Adjust tilt adjustment in highest position Undo two screws 1 Unhook bowden cable 2 out of lever 3 Pull out bowden cable from side cove...

Page 18: ...2 11 0 BACKREST HANDLE Backrest handle Remove side cover lever side see 2 5 0 Remove retaining washer 1 pull off backrest handle and unhook springs 2 and 3 2 3 1...

Page 19: ...ount spring 2 from lever 3 and lever 6 Pull off lever 3 Demount spring 5 at Pin 4 Lever for shoulder adjustment Remove safety washer 7 and roller 8 Cut cable binder 9 and pull out securing plug 10 Rem...

Page 20: ...krest adjustment Demount seat cushion see 2 2 0 Remove side cover of lever side see 2 5 0 Loosen spring 1 at pin 2 of lever 3 Remove safety clamp 8 Unscrew nuts 4 and take out plate 5 tooth segment 6...

Page 21: ...ove backrest cover and pull it upwards to the shoulder area see 2 4 0 Unscrew bolt 1 nuts 2 and take off plate 3 Unhook spring 4 Undo retaining washer 5 and remove bowden cable 6 from lever 7 Take out...

Page 22: ...ion see 2 2 0 Disconnect plug 1 from electronic unit 2 Secure suspension unit at the highest position by a distance sleeve with a length of 75mm see 1 2 0 Loosen bellows in the lower area till screws...

Page 23: ...on t tighten the nuts the sensor must be still movable Adjustment rotary switch Connect the seat at power supply Positioning a distance piece 10 with an exactly length of 110mm between the frames of t...

Page 24: ...or 1 Cut cable binder 2 and 3 Loosen electrical connection 4 Loosen clip 5 and take out the compressor Instruction of installation When mounting the new compressor the foam part 6 must be placed betwe...

Page 25: ...2 18 0 RELAIS Relais Disconnect plug 1 Unscrew screw 2 and take out relais 3 2 3 1...

Page 26: ...sconnect electrical connection 4 Loosen air connection to the air spring 5 yellow and to the IPS valve 6 transparent at the Y connector 11 Therefor lift up fixing hook 10 carefully and separate air ho...

Page 27: ...osition by a distance sleeve with a length of 75mm see 1 2 0 Undo nut 1 remove screw 2 and take out socket 3 Unscrew lower shock absorber fixation 5 Remove retaining washer 6 and lever bowden cable 7...

Page 28: ...h a length of 75mm see 1 2 0 Lift up fixing hook 2 carefully and demount air pipe 3 Undo screw 4 Remove lower shock absorber fixation and lift it up see 2 18 0 Turn round air spring 5 for 90 and take...

Page 29: ...Shock absorber for horizontal suspension Demount seat cushion see 2 2 0 Secure suspension unit at the highest position by a distance sleeve with a length of 75mm see 1 2 0 Remove securing washers 1 an...

Page 30: ...IC UNIT CLIMATIC HEATING Electronic unit climatic heating Demound seat cushion see 2 2 0 Remove side cover 1 see 2 5 0 Pull off connector 2 from electronic unit 3 Undo screws 4 Tightening toques Pos 4...

Page 31: ...t of groove 2 running around seat ground plate in the area of the seat cushions back half Undo four screws 3 Pull fan unit 4 inclusive congruated tube out of cushion foam Instruction of installation B...

Page 32: ...sealing cup 11 from holder plate Press congruated tube 12 a little unhook it and pull it out of cushion foam Instruction of installation When mounting lay the congruated tube 12 so that it will fit to...

Page 33: ...ses 3 Pull out air chamber from behind cross braces 4 5 Instruction of installation Don t tighten screws 1 when mounting the foam part The distance between screw head and shackle 2 should come to 1mm...

Page 34: ...hort and move belt cover upwards Push retaining bracket 4 and belt tongue 5 through the opening of the belt cover 3 point belt Remove belt cover see above Undo four pins 6 and remove rear cover Unscre...

Page 35: ...5 0 Undo screw 1 and remove belt buckle 2 2 point belt Remove screw 3 und distance bush 4 Demount 2 point belt 5 Instruction of installation The belt buckle must be mounted in an angle of 45 and the...

Page 36: ...rest Fan for backrest Fan for seat cushion Heater for seat cushion Electronic unit Switch for climatic heating Electronic unit height control Reserve for external Rotary sensor Plug 2 Compressor Rotar...

Page 37: ...pressor Connector housing AMP 6 3x0 8 2 pol Housing no AMP 180 907 5 transparent Contact no z B AMP 5 160 446 5 Plug 2 Reserve for external seat contact switch Connector housing AMP 6 3x0 8 2 pol Hous...

Page 38: ...E BU Pin 13 BK Pin 14 Supply Supply heating Plus valve Plus compressor Ground elektronic unit Ground rotary position sensor Ground switch height adj Signal switch height adj Plus switch height adj Jum...

Page 39: ...BU RD BU Pin 9 Pin 10 RD WH RD WH Pin 11 Pin 12 BN RD BN Pin 3 Pin 4 RD YE BK Pin 5 Pin 6 Seat cushion heating Page 3 15 0 BU BN BU Pin 1 Pin 2 BN Pin 3 RD WH Pin 4 Fan for seat cushion Page 3 14 0 RD...

Page 40: ...tion of electronic unit When the driver starts the readjustment of the seat height the electronic unit 1 measures the seat height by using of the rotary sensor 2 and compares it with the adjusted heig...

Page 41: ...hes for 0 5 seconds a Puch LS button above inflating b Use of rotary switch for height adjustment c Changing the seat occupancy seat contact switch Error code When the LED of the electronic unit is fl...

Page 42: ...oltage is connected Correction Check magnetic valve cable harness BC 6 Fault supply voltage Meaning The power supply decreases under 10V compressor and valve are out of action Correction Check supply...

Page 43: ...ances at the cable harness Resistance 82W 5 220W 5 390W 5 680W 5 1 2kW 5 2 0kW 5 3 9kW 5 option only switches with 7 steps Level 6 7 Level 5 Level 1 Checking signal voltage Ignition switches on rotary...

Page 44: ...t Electric connection Checking of pneumatical function Disconnect the plug of the compressor and connect a battery with external voltage from 24V respectively 12V for 12V systems The compressor blows...

Page 45: ...3 YE BK U Pin 3 Pin 2 Alternative at the electronic unit Pin 9 RD YE Pin 12 YE BK Reference 0 25V to 4 75V Checking signal rotary sensor mounted Ignition switched on rotation sensor connected Pin 3 YE...

Page 46: ...of the compressor and connect a battery with external voltage from 24V respectively 12V for 12V systems The valve opens and let release the air from the air spring The seat lowers Checking resistor Di...

Page 47: ...g of the electronic unit at the cable harness and measures the resistance Alternative at the electronic unit intern Pin 14 BK Signal Pin 13 BU Signal R W 8 R 0W Checking resistance of seat contact swi...

Page 48: ...Ventilation level 1 Ventilation level 2 Ventilation level 3 0 V LED 2 0 3 0 V 3 9 V 5 0 V 6 1 V 7 4 V blue red Level 2 Level 1 Level 3 Heating Ventilation Off Only short circuit or interruption to bo...

Page 49: ...RD WH Pin 2 BN Supply voltage switch climatic heating Pin 1 BK WH Pin 4 BN Heating UBAT Off 0 Ventilation UBAT Off Heating Ventilation Switch setting Pin 2 Pin 1 Pin 2 BN Pin 1 RD WH Backrest heating...

Page 50: ...g Aus 0 V Checking backrest heating 18 1 18 2 R 19 2W 10 Supply heating connected heating on Supply voltage heating Aus 0 V NTC 17 1 17 4 17 2 17 3 W W NTC 17 1 17 4 17 2 17 3 Seat cushion heating 30...

Page 51: ...10 5 V ca 16 V ca 24 V LED blue red Level 2 Level 1 Level 3 Heating Ventilation Off A Electric connection Checking supply fans backrest seat cushion UBAT 26 V Checking supply fans backrest seat cushi...

Page 52: ...N 0 75 RD YE 0 50 BU 0 75 BN GN 0 50 BN WH 0 50 RD YE 0 50 YE BK 0 50 1 2 BN 1 50 1 1 BK 1 50 BN 1 00 0 75 BN YE BU 0 75 Compressor 24V Magnetic valve 24V Switch LS Rotary Sensor BU 0 75 BK 0 50 9 1 9...

Page 53: ...BU 0 75 NTC 17 2 17 1 Ignition 15 3 0 75 BK 14 1 BU BN 0 75 BN 0 75 RD BK 0 75 17 3 17 4 Heating seat cushion BN 0 75 Heating backrest 18 2 BN 0 75 BN 0 75 BN 0 75 20 1 20 2 20 1 20 2 RD BU 0 75 BN 0...

Page 54: ...ted During drive operation bumps can cause a lift off for the driver from the seat and that seat contact switch is not able to identify the driver for a short time These changings shall not start the...

Page 55: ...ISRINGHAUSEN GmbH Co KG ISRINGHAUSEN Ring 58 32657 Lemgo Germany Tel 49 0 5261 210 0 Fax 49 0 5261 210 310 info isri de www isri de...

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ISRI 6830KA/ 880, Repair Manual

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