Minimizer 101358 Service Manual Download Page 9 | Manualshive

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Seats using 38.1 Risers:

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Remove old seat from Truck and keep floor bolts.

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Disconnect air supply lines and electrical connections.

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Position New 38.1 Riser so holes in riser line up with the holes in floor. Use original floor
bolts to secure riser to floor.
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Remove 4 bolts at bottom corners of suspension.

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Position Seat and suspension on top of riser by lining up riser holes with threaded holes
at bottom corners of suspension. Install 6 bolts included with riser up into bottom
corner holes of suspension (Torque to 20 NM +/ - 5NM).

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Summary of Contents for 101358

Page 1: ...Read and understand this manual before servicing this seat Service Manual ...

Page 2: ...the service and repair to Inspect for abnormal wear and damage Choose a repair procedure that will ensure your safety the safety of others and the safe operation of the equipment Fully inspect and test the equipment to ensure that the repair or service has been properly performed and the equipment will function properly This manual describes the correct service procedures for the Minimizer Long Ha...

Page 3: ...ning 14 Backrest Removal 16 Lever Lever Springs for Backrest 17 Lever for backrest adjustment and lever springs 17 Shoulder adjustment 17 Height Adjustment Handle Cable 18 Shock Absorber Adjustment 19 Lever for Tilt Adjustment 20 Adjustment instructions for Bowden cable of tilt adjustment 21 Tooth segment for backrest adjustment 22 Upholstery cover for backrest cushion 23 Cover for seat cushion 24...

Page 4: ...mate Kit Assembly 36 Fan for seat cushion 37 Electronic unit for Climate System 38 Lever Bowden cable horizontal suspension 39 Armrest removal 40 Pneumatic Plans 41 Circuit Diagrams Heating Ventilation 42 Troubleshooting 48 ISRI Extended Warranty 51 Warranty Request Notification Form 52 ...

Page 5: ...curing components into original position Hoses electrical lines and Bowden cables must not be crushed or bent Due to safety reasons pay attention to the correct positioning and to the observance of the tightening torques of the screws and bolts when exchanging component parts including the seat belt anchorage points After each repair a functional test and if pneumatic parts are involved a leak tes...

Page 6: ...Option A B Switch Not Shown will be located above feature 10 11 12 switches Option C uses the remote 6 ...

Page 7: ...the lower frame Located Here Serial number location Serial number and model label are located at the front side of the lower frame of the suspension unit and are visible when lifting up the Bellow Please specify these numbers for spare part orders ...

Page 8: ...l Riser so holes in riser line up with the holes in floor Use original floor bolts to secure riser to floor Remove 4 bolts at bottom corners of suspension Attach angle brackets to front and rear of suspension with bolts included with riser Position on top of riser by lining up bracket holes with weld nuts on riser and install 4 bolts Torque to 20 NM 5NM ...

Page 9: ...es in riser line up with the holes in floor Use original floor bolts to secure riser to floor Remove 4 bolts at bottom corners of suspension Position Seat and suspension on top of riser by lining up riser holes with threaded holes at bottom corners of suspension Install 6 bolts included with riser up into bottom corner holes of suspension Torque to 20 NM 5NM ...

Page 10: ...lectrical connections Remove 4 bolts at bottom corners of suspension Position riser to suspension by lining up top riser holes with threaded holes at bottom corners of suspension Install 6 bolts included with riser up into bottom corner holes of suspension Torque to 20 NM 5NM Position seat into truck and use original floor bolts to secure to floor ...

Page 11: ...11 ...

Page 12: ...the sliders 7 at the rear Push lever 1 upwards don t move cushion and push lever in direction of arrow B Press down on the seat cushions while lining up the four key holes 5 onto the sliders 7 at the front and back Push the cushion in direction of backrest till stop while still pressing down on the complete seat cushion till handle engages Check now if all four sliders 7 are locked in the keyholes...

Page 13: ...13 Figure 2 ...

Page 14: ... screws Undo two plastic rivets 3 Fold backrest completely forwards and remove one screw 4 Remove cover 5 from seat frame Switch for seat lowering Remove screws 7 IPS valve 12 Lift up locking tab 8 safely and Remove air pipe 9 from Y connector 10 Disconnect three hoses from valve unit Undo retainers of valve and push out valve from cover 5 Cover opposite lever side 2 Remove cover 20 in general sen...

Page 15: ...15 ...

Page 16: ...g 7 Remove e clip 2 and roller 3 Remove cable from cable guide 5 Remove plug 9 from cable guide Take out e clip 1 and completely remove cable from guide Disconnect lumbar airlines 13 and electrical connections 12 Remove clip 10 from control side backrest bolt then remove both 16 bolts Remove backrest from frame Figure 4 ...

Page 17: ...rame lever side without loosening hoses Remove e clip 1 Remove handle 3 then remove springs 2 and 5 and remove shoulder handle bracket 6 Shoulder adjustment Remove e clip 7 and roller 8 Pull out securing plug 10 and remove cable ball 11 from lever pull cable out of cable guide if necessary Remove bolt 12 Figure 5 ...

Page 18: ...shion See page 9 Remove nut 2 remove Bowden cable 3 from fastening 4 and pull cable nipple 5 out of valve lever 6 Remove two screws 1 Push Bowden cable 3 out of bearing 7 and pull height adjustment handle and cable 8 After mounting Adjust valve 6 for height adjustment how do you do this Figure 6 ...

Page 19: ...stment Remove seat cushion see page 9 Remove retaining e clip 1 and lever bowden cable 2 grey out of shock adjustment bracket 3 Unscrew two screws 4 Knock pin 5 out of lever 6 and pull bowden cable out of seat frame Figure 7 ...

Page 20: ...stment to upper position Press down spring 1 unhook from fixation 2 and pull spring out from levers 3 Remove handle for height adjustment 6 Lever bearing 7 out of seat frame and remove Bowden cable black from lever 3 When mounting hook spring 1 at first in lever 3 Press down spring 1 with a screwdriver in area Y and hook spring behind fixation 2 Figure 8 ...

Page 21: ...ent Pull lever for tilt adjustment up Adjust Bowden cable in a way that between lever 1 and plate 2 so no gap is visible The inclination adjustment must release completely and must move noiselessly when pulling the lever no clattering of tooth segments Figure 9 ...

Page 22: ... cushion See page 9 and Backrest See page 13 Remove side cover for seat frame without disconnecting hoses or electrical connections Remove e clip 1 and loosen springs 2 at pin 3 of lever 4 Remove nuts 5 Slide plate 6 off Remove tooth segment 7 Figure 10 ...

Page 23: ... cushion Disconnect three lumbar bolster air lines 1 Disconnect electrical connection on seats with Relaxer or Climate 3 Remove armrest Unhook C Profiles 2 Pull cover upwards gently and loosen from Velcro 6 Remove cardboard Figure 11 ...

Page 24: ...emove seat cushion see page 9 Pry upholstery tuck strip from bottom of seat cushion out of groove 2 running around seat pan 1 Notice Before mounting the cover bend hooks in the groove 2 from the seat pan 1 if necessary Figure 12 ...

Page 25: ...t Don t tighten screws 1 when mounting the foam part The distance between screw head 1 and shackle should come to 1 mm Disconnect three hoses 3 Pull out lumbar assembly from behind cross braces 4 Hint When mounting the air chamber unit take care that chamber carrier plate 2 has to be mounted behind cross braces 4 Figure 13 ...

Page 26: ...sor axle and lower suspension frame Remove lower shock absorber bolt 5 refer to figure 15 lift up shock absorb and move out air spring 4 frontwards Lift up fixing hook 1 safely and Remove air pipe 2 Undo Screw 3 Turn round air spring 2 90 degrees and take it out from lower holder 5 After mounting the new air spring nose must fit to the hole at the upper air spring holder Figure 14 ...

Page 27: ... seat cushion and pull out lower bellow fixation Secure suspension unit at the highest position by a distance block length 75mm Undo nut 1 loosen screw 2 and remove socket 3 Unscrew lower shock absorber fixation 5 Remove retaining washer 6 and lever Bowden cable 7 grey cable out of fastening Figure 15 ...

Page 28: ...f suspension Remove nut 1 remove Bowden cable 2 black from bracket 3 and pull cable nipple 4 out of valve lever 5 Carefully lift up fixing tabs 6 and Remove air pipes 7 yellow and red from valve 11 Unhook spring 8 Turn around valve 11 on scissor tube 12 and pull it off the scissor tube 12 After mounting See page 29 Figure 16 ...

Page 29: ...29 Switch for quick lowering Remove seat cushion Remove plastic cover 1 Unscrew screw 2 Disconnect hoses from connector 6 Unscrew screw and unhook switch 7 in the upper area out of cover Figure 17 ...

Page 30: ...culating back Remove backrest cover and pull it upwards to the shoulder area Unscrew bolt 1 nuts 2 and take off plate 3 Unhook spring 4 Remove retaining washer 5 and remove Bowden cable 6 from lever 7 Take out lever 7 and tooth segment 8 Figure 18 ...

Page 31: ... cable Black by adjusting nut 1 so that the distance between lever 2 and air spring holder 3 comes to 2mm Bowden cable adjustment Pull handle 5 to the upmost position and adjust Bowden cable Color of valve for height adjustment in that way that lever arm has still a little clearance Figure 19 ...

Page 32: ...cushion See page 9 Disconnect isolator cable shock adjustment cable height adjustment cable and air lines and electric Remove the four screws that hold the slides to the swivel Place upper part of seat in safe location Pivot swivel to side and remove 4 screws holding swivel to suspension ...

Page 33: ...ar the large thru hole as shown in yellow below Swivel unit configured for Swivel unit configured for Driver side left of truck cab Passenger side right of truck cab Take the M8 bolts you just removed from hole position 5 and hole position 9 and move them to the locations shown in red in the image on the right hole positions 2 and hole position 10 as shown above Torque the M8 bolts to 24 foot poun...

Page 34: ...fully from the foam Hint If the heater 4 is not removable without tearing up the foam cut the heater along the broken line X and pull back protective covering from adhesive on the new heater attach new heater on top of old heater Insure new heater is securely adhered to old heater Hint Before mounting the cover bend back hooks at the beading 2 of the ground plate 1 if necessary Figure 20 ...

Page 35: ...nect three air hoses 3 electrical connector 2 and electrical connector if existing Unhook C Profiles 4 Pull off heater 8 carefully from the foam If the heater 8 is not removable without tearing up the foam 4 carefully cut the heater along the broken line X and fix the new heater on top the old heater Figure 21 ...

Page 36: ... screws 7 and one screw 8 out of fan 9 Press in corrugated tube 12 a little unhook it and pull it out of the fan bracket 11 Retain for reuse Remove foam seal from fan bracket 11 Remove backer from new foam seal and stick to new fan Mount corrugated tube into fan bracket 11 Place fan on fan bracket and secure with screws 7 and 8 Place foam on back frame insuring corrugated tube is in back foam chan...

Page 37: ...eat cushion See page 9 Remove four screws retaining fan assembly 3 to seat pan Pull fan assembly 4 from seat pan Hint Before mounting the cover bend hooks in the groove 2 from the ground plate 1 if necessary Corrugated Tube Figure 23 ...

Page 38: ...38 Electronic unit for Climate System Remove seat cushion See Page 9 Remove two top screws from side cover 17 Pull off connector from electronic unit 35 Remove electronic unit 35 Figure 24 ...

Page 39: ...Lever Bowden cable horizontal suspension Remove swivel from suspension Unscrew two screws 1 Remove latch clip 4 Unhook cable from latch 3 from lever 5 Pull lever 5 Bowden cable 2 out of opening 6 Figure 25 ...

Page 40: ...40 Armrest removal Remove 2 bolts 1 and armrest keep bolts Install Cover Plate using the bolts from the armrest ...

Page 41: ...41 Pneumatic Plans ...

Page 42: ...42 Circuit Diagrams Heating Ventilation ...

Page 43: ...43 ...

Page 44: ...44 ...

Page 45: ...45 ...

Page 46: ...46 Revitalizer System Revitalizer Control Revitalizer Motors 2 per seat cushion Revitalizer Motors 4 per backrest Revitalizer Electrical Connection Red Black Wire ...

Page 47: ...47 Revitalizer Wiring Diagram for the driver s seat ...

Page 48: ...48 Troubleshooting ...

Page 49: ...49 ...

Page 50: ...50 ...

Page 51: ...ufacturer or component manufacturer for the fulﬁllment of an applicable warranty refunding the purchase price or some combination of these PRODUCT SPECIFIC TERMS The following terms modify Minimizer LLC general terms stated above in Section 1 for each speciﬁc product component or category listed in this Section 2 Please read this Section carefully and familiarize yourself with the speciﬁc warranty...

Page 52: ...r com lifetime warranty to oﬃcially register your product s and activate your warranty By completing the online form you will have locked in the best warranty in the industry Other Minimizer products like slick plate have their own speciﬁc stated warrantees To ACTIVATE your warranty please complete the form in its entirety MINIMIZER LLC LIFETIME WARRANTY ...

Page 53: ...53 ...

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