Minimizer LONG HAUL Series Service Manual
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Minimizer LONG HAUL Series Service Manual

Truck seat system
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Read and understand this manual before servicing this seat

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Summary of Contents for Minimizer LONG HAUL Series

  • Page 1 Service Manual Read and understand this manual before servicing this seat...
  • Page 2 • Fully inspect and test the equipment to ensure that the repair or service has been properly performed and the equipment will function properly. This manual describes the correct service procedures for the Minimizer Long Haul Seat series. The information in this manual was current at the time of printing and is subject to change without notice or liability.

  • Page 3: Table Of Contents

    Contents General Information ............................. 5 Important Hints ............................5 Seats using Universal Riser: ........................8 Seats using 38.1 Risers: .......................... 9 Seat Cushion Removal (Figure 1) ......................12 Seat Cushion Mounting: ........................12 Sliders for Seat Cushion: ........................12 Sliders Mounting: ..........................12 Covers Seat Frame IPS-Valve, switches for heating, swivel and air-conditioning covers, lever side (5): 14 Switch for seat lowering: ........................
  • Page 4 Bowden cable adjustment: ......................... 31 Swivel ..............................32 Heating seat cushion ..........................34 Heating backrest ............................. 35 Climate Kit Assembly........................... 36 Fan for seat cushion: ..........................37 Electronic unit for Climate System: ......................38 Lever/Bowden cable horizontal suspension ....................39 Armrest removal: ............................

  • Page 5: General Information

    General Information Important Hints Seat repairs should be carried out by service only. technicians The description in chapter 2 explains the removal of sundry seat components. The installation of these seats components generally happens in reverse sequence. Not all fastening parts for hoses and cables (e.g., cable binder) will be mentioned in detail.
  • Page 6 Option A & B Switch Not Shown will be located above feature 10, 11, & 12 switches Option C uses the remote...
  • Page 7 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. Located Here Serial number found in the front middle of the lower frame.

  • Page 8: Seats Using Universal Riser

    Seats using Universal Riser: Disconnect air supply lines and electrical connections. Remove old seat from Truck and keep floor bolts. Position New Universal Riser so holes in riser line up with the holes in floor. Use original floor bolts to secure riser to floor. Remove 4 bolts at bottom corners of suspension.

  • Page 9: Seats Using 38.1 Risers

    Seats using 38.1 Risers: Remove old seat from Truck and keep floor bolts. Disconnect air supply lines and electrical connections. Position New 38.1 Riser so holes in riser line up with the holes in floor. Use original floor bolts to secure riser to floor. Remove 4 bolts at bottom corners of suspension.
  • Page 10 International Wide Bolt Pattern / Volvo / Late model PACCAR Risers Remove old seat from Truck and keep floor bolts. Disconnect air supply lines and electrical connections. Remove 4 bolts at bottom corners of suspension. Position riser to suspension by lining up top riser holes with threaded holes at bottom corners of suspension.

  • Page 12: Seat Cushion Removal (Figure 1)

    Seat Cushion Removal (Figure 1) Lift up lever (1) and pull seat cushion to foremost position. Undo two screws (2) and remove tilt handle (3) from seat cushion (F). Lift up lever (1) and slide sideways towards (A) as shown in the picture below.
  • Page 13 Figure 2...

  • Page 14: Covers Seat Frame Ips-Valve, Switches For Heating, Swivel And Air-Conditioning Covers, Lever Side (5)

    Covers Seat Frame IPS-Valve, switches for heating, swivel and air-conditioning covers, lever side (5): Remove seat cushion. Adjust suspension to highest position and secure it with block between lower suspension axle and front frame. Press nose of shoulder adjustment lever (21) till nose of handle disengages. Pull off handle (21) downwards.

  • Page 16: Backrest Removal

    Backrest Removal Remove shoulder adjustment handle (8) in figure 4 Remove side covers (Both sides) See page 11. Remove plug (7). Remove e-clip (2) and roller (3). Remove cable from cable guide (5). Remove plug (9) from cable guide. Take out e-clip (1), and completely remove cable from guide. Disconnect lumbar airlines (13) and electrical connections (12).

  • Page 17: Lever / Lever Springs For Backrest

    Lever / Lever Springs for Backrest Lever for backrest adjustment and lever springs Remove side cover for seat frame (lever side without loosening hoses) Remove e-clip (1), Remove handle (3) then remove springs (2) and (5) and remove shoulder handle bracket (6). Figure 5 Shoulder adjustment Remove e-clip (7) and roller (8)

  • Page 18: Height Adjustment Handle/Cable

    Height Adjustment Handle/Cable Adjust seat frame tilt to the upmost position. Remove seat cushion. See page 9. Remove nut (2), remove Bowden cable (3) from fastening (4) and pull cable nipple (5) out of valve lever (6) Remove two screws (1), Push Bowden cable (3) out of bearing (7) and pull height adjustment handle and cable (8).

  • Page 19: Shock Absorber Adjustment

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

  • Page 20: Lever For Tilt Adjustment

    Lever for Tilt Adjustment Remove seat cushion.(see page 9) Remove side cover without disconnecting hoses (yellow, red and clear). Adjust seat frame tilt adjustment to upper position. Press down spring (1), unhook from fixation (2) and pull spring out from levers (3). Remove handle for height adjustment (6).

  • Page 21: Adjustment Instructions For Bowden Cable Of Tilt Adjustment

    Adjustment instructions for Bowden cable of tilt adjustment 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).

  • Page 22: Tooth Segment For Backrest Adjustment

    Tooth segment for backrest adjustment Remove seat 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.

  • Page 23: Upholstery Cover For Backrest Cushion

    Upholstery cover for backrest 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: Cover For Seat Cushion

    Cover for seat cushion Remove 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: Air Chamber For Lumbar Support

    Air Chamber for lumbar support Remove backrest cover partially. Unscrew four screws (1) and loosen foam part from frame. Hint: 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).

  • Page 26: Air Spring

    Air Spring Remove seat cushion. (see page 9) Pull out Bellow fixation in front and side area. Secure suspension unit (4) at the highest position with block (length: 75mm) between the scissor 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.

  • Page 27: Height Adjustment

    Height Adjustment When exchanging the shock absorber, all parts of the kit must be exchanged! Remove 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).

  • Page 28: Valve Removal For Height Adjustment

    Valve Removal for height adjustment Remove seat from vehicle, lay seat on its back side, access to valve is through bottom of 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 –...

  • Page 29: Switch For Quick Lowering

    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: Tooth Segment For Shoulder Adjustment (Articulating Back)

    Tooth segment for shoulder adjustment (articulating 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).

  • Page 31: Valve Adjustment

    Valve adjustment Lower seat and adjust Height Adjustment to upper position. Adjust Bowden cable (Black) by adjusting nut (1) so that the distance between lever (2) and air spring holder (3) comes to 2mm Figure 19 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...

  • Page 32: Swivel

    Swivel Remove pneumatic (2) and electrical lines. Remove seat from vehicle. Remove seat 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.
  • Page 33 Swivel Changeover Seats come from the factory with the swivel unit configured for the left side of the truck cab. If the seat is to be installed on the right side of a vehicle, the swivel unit must be reconfigured: Remove the seat cushion assembly.

  • Page 34: Heating Seat Cushion

    Heating seat cushion Remove seat cushion. (See Page 9) Lever seat cushion cover out of beading (2) running around seat ground plate (1). Disconnect electrical connection (3). Pull off heater (4) carefully 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.

  • Page 35: Heating Backrest

    Heating backrest Remove seat cushion.(See Page 9) Pull cover (7) upwards while loosening fixing tapes (6). Disconnect 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.

  • Page 36: Climate Kit Assembly

    Climate Kit Assembly Disconnect three air hoses (1) and two electrical connector (heater and fan) Unhook C-Profiles (2). Pull cover upwards while loosening fixing Velcro (6). Remove cardboard. Remove Foam from Backrest frame Disconnect electrical connection (10) and take out fan (9). Remove two screws (7) and one screw (8) out of fan (9).

  • Page 37: Fan For Seat Cushion

    Fan for seat cushion: Remove seat 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.

  • Page 38: Electronic Unit For Climate System

    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

    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: Armrest Removal

    Armrest removal: Remove 2 bolts (#1 ) and armrest (keep bolts) Install Cover Plate using the bolts from the armrest.

  • Page 41: Pneumatic Plans

    Pneumatic Plans...

  • Page 42: Circuit Diagrams Heating/Ventilation

    Circuit Diagrams Heating/Ventilation...
  • Page 46 Revitalizer System Revitalizer Motors (4 per backrest) Revitalizer Control Revitalizer Motors (2 per seat cushion) Revitalizer Electrical Connection (Red & Black Wire)
  • Page 47 Revitalizer Wiring Diagram for the driver’s seat...

  • Page 48: Troubleshooting

    Troubleshooting...

  • Page 51: Isri Extended Warranty

    Limitations” described in Section 3 and to any additional conditions or limitations listed in Section 2 for each product, component or category. The warranties stated herein are in lieu of all other warranties, obligations or liabilities on the part of Minimizer LLC.. Minimizer LLC.

  • Page 52: Warranty Request Notification Form

    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.

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