REPAIR MANUAL

ISRI 1000/515, 6000/515(517), 6500/515(517)

08/2003
 INDEX / GENERAL

General / Connection data............................…........…....... 1.1.0

Troubleshooting, pneumatics.............................................. 2.1.0
Backrest.............................................................................. 3.1.0
Seat cushion....................................................................... 3.1.0
Seat frame.......................................................................... 3.1.0
Suspension unit.................................................................. 3.1.0
Horizontal adjustment......................................................... 3.1.0
Bellow................................................................................. 3.1.0
Seat-and backrest cover..................................................... 3.2.0
Heating elements................................................................ 3.2.0
Air chambers LS / IPS............................................…......... 3.2.0
Compressor........................................................................ 3.2.0
Latch mechanism for backrest............................................ 3.2.0
Handles for height and slope adjustment........................... 3.2.0
Valve for lumbar support (LWS / IPS)................................. 3.3.0
Air spring ISRI 6500............................................................ 3.3.0
Vertical damper ISRI 6500.................................................. 3.3.0
Valve / Control disk ISRI 6500............................................ 3.3.0
Damper for horizontal suspension...................................... 3.4.0
Vertical damper ISRI 6000.................................................. 3.4.0
Handwheel for weight adjustment ISRI 6000...................... 3.4.0
Tension springs ISRI 6000.................................................. 3.4.0
 GENERAL / CONNECTION DATA

General:
- For sparepart orders please specify seat part number and serial number if
possible.

- Seat repairs have to be carried out by competent staff only.

- The presentation in this booklet shows as a rule the left seat resp. the left
seat side.
On the right seats resp. right seat side the repair will be carried out
accordingly.

- The following pages describe the removal of sundry parts, the installation
generally happens in reverse sequence.

- Pull off compressed air connector before exchanging the control

components.

- After repairs etc. pneum. lines and electrical cables have to be layed and
fixed acc. to original condition.
After each repair a functional test and, if pneumatic parts are involved,
a leaktest has to be effected.

- Hoses and bowden cables must not be creased.

- backrest in forward folded position must not be used as ascent help.

- further details are shown in the explosive drawings of spare parts list.

Connection Data :

Operating pressure range : 7-10 bar

Colour: black = compressed air (P hose)

grey= exhaust air (E hose)

Operating pressure range: 7 .... 10 bar

Heating: operating voltage 12V / 24V

power up ca. 22oC
Cut off ca. 39oC

Subject to technical changes for reasons of further development.

1.1.0
 TROUBLESHOOTING, PNEUMATICS

fault description inspection remedy notice

1 Seat does not go up. check hoses for kinks. remove kink,
if necessary repair it.
airlekage:

valve does not work, exchange valve.

tappet is stuck.

valve, airspring, hoses exchange defective part.

leaky.

2 Seat goes to upmost airspring fully inflated:

position, resp. stays under
pressure. valve does not work, exchange valve.
tappet is stuck.

vitiated air hose is remove kink,

jammed. if necessary repair it.

3 Lumbar support without incoming air hose is remove kink, if necessary

function. jammed. repair it.

LS valve without function. exchange LS valve.

deflation noises exchange faulty part.

(LS valve, resp. Hoses
leaky).

4 Mechanical function foreign body in face of clean and grease face of

working hard. pulley. pulley (attention: grease
faces of roller only at
front side).

5 Seat overshoots. shock absorder oily, exchange shock

investigate on even absorder.
tensile and compressive
force.
Shock absorder
defective.

2.1.0
 SEAT MODULES

Backrest

• Unscrew bolt (1).

• Fold down backrest forward.
• If mounted, disconnect connectors of pneum.- and electric lines.
• Unhook backrest from sideplate (2).

Seat cushion (without seat cushion adjustment)

• Unscrew 2 screws (3) and pull off seat cushion from seat frame
cross tube (4) (clamped).
• Pull apart plug connection of electric cable,if necessary.

Seat cushion(with seat cushion adjustment) - see picture below -

• Move seat cushion to the foremost position.

• Press down stop spring (5) through one of the side - rear latch holes
of one seat cushion slide. At the same time operate the release lever (6).
• Pull seat cushion further forward.

Seat frame

• Remove seat cushion and backrest (s.a.).

• Remove bellow from seat frame.
• Unscrew boltings (8) and (9) (detail X for ISRI 6000).
• Disconnect connectors of pneum.- and electric lines,If necessary.

Suspension unit

• Remove seat cushion (s.a.)

• Remove bellow from the lower frame(13) of the suspension unit.
• Disconnect connectors of pneum.- and electric lines,If necessary.
• Unscrew boltings (8) and (9) of seat frame (7).
• Disassemble horizontal adjustment.

Horizontal adjustment

• Push forward, resp. back, the slides (10) and remove bolts (11)
(detail Y: A- Type slides for ISRI 1000 will be screwed seatsided as
per detail Y to the metal trestle).

Concertina bellow

• Remove seat from vehicle.

• Remove sundry plugs (12) from seat frame (7) and lower frame (13)
of suspension unit, as well as 4 clamps (14) from the seat frame
cross tube (4).

3.1.0
 SEAT MODULES
Cover / heating element for seat cushion

• Remove seat cushion (see 1.1.0).

• Remove cover from circumferential crease (1) of the seat pan.
• Pull off heating element (4) from pad carefully (use a knife for
separation if necessary).
• Fix new heating element with double-faced adhesivetape.

Cover / heating element for backrest

• Remove seat cushion (see 1.1.0).

• Remove backrest cover from C-profile (2) of the backrest frame and
pull upwards.
• Loosen clamps (3) from the wire inside the pad (cut off if necessary).
heating element (5)( s.a.,seat cushion) : do not remove clamps
for cover fixation (3).

Air chambers of lumbar support (LS / IPS) / compressor

LS / IPS
• Remove backrest cover partly (s.a.,without clamp ( 3).
• Disconnect pneumatic lines at connector.
• Loosen backrest pad from the frame partly.
• Remove retaining clips (1) for LS- chambers and, if existing,
retaining plugs (2) for lateral chambers (IPS).

Compressor
• Remove backrest cover partly (s.a.,without clamp ( 3).
• Loosen backrest pad from the frame partly.
• Disconnect pneumatic lines at connector.
• Cut electric cable feeding the compressor.
• Remove screw (4).

Latch mechanism for backrest

• Remove backrest (see 1.1.0).

• Loosen bolting (1) for toothsegment (2).
• For welded versions the exchange is only conditioned feasible
(possibly contact ISRI - service).
• Remove seat cushion (see 1.1.0).
• Remove circlip (4).
• Unhook tension spring (5).
• For screwed versions : unscrew nut (6) and take off parts (8)(9)(10)
and (11).

H.a.S. - handles with accessories

• Pull off handles (1) from levers (2).

• Loosen bellow from seat frame in the area of the levers (2).
• Remove bearing ledge (3) from lever guide of the seat frame
and unhook tension spring (4).

3.2.0
 SEAT MODULES

Valve for lumbar support

LS ( 2 buttons ) IPS ( 3 buttons )

• Remove seat cushion (see 1.1.0).

• Remove slide for seat cushion adjustment on the valveside,
if necessary.
• Take off valve (1) from the housing (2) ( not always possible
without destroying valve and holder).
• Unscrew the screws (3) out of the thread parts (4) and
remove holder.
• Remove clamping sleeve (5) from the hose in the middle (PU,
D = 3 mm).
• Notice: this pneumatic hose is permanently pressurized (air
supply for vehicle).
• Disconnect pneum. lines from the valve connectors.

Air spring

• Remove seat from the vehicle (separate pneum.lines).

• Remove seat cushion (see 1.1.0).
• Secure suspension unit in topmost position.
• Loosen bellow from the lower frame partly. Unscrew bolts (1) and (2).
• Unscrew sleeve nut (3) and pull apart hose (4).
• Pull angle stub (5) out of the air spring.
• Take air spring out of the suspension unit (frontside).
• Do not mount air spring twisted. Loosen screw (1) slightly.
• Release and compress suspension unit under pressure.
• Screw tight bolt (1) while air spring is pressurized.

Vertical damper
• Secure suspension unit in topmost position.
• Remove seat cushion (see 1.1.0).

Valve (1)
• Unscrew sleeve nuts (2) and pull apart hoses.
• Unscrew 2 bolts (3) out of valve (1).

Control disc
• Remove retaining washer (6).
• Notice: consider adjusting instructions for control disk
installation.

Adjusting instruction for control disk

• Remove seat cushion and loosen bellow at the frontside.

• Weight the seat and lower it to a distance of 60mm
(for vehicle seats) resp. 70 mm (for bus seats) between upper
frame (1) and lower frame (2) of the suspension unit.
• Lower the seat slowly a little bit more , until the valve reacts
( beginning of air supply).
• The lowering down to that moment should come to a distance of
18 mm ( 60 mm / 70 mm minus 18 mm).
• If this is not the case , change the adjustment of the screws (A) and
(B) as follows :
• Screw in bolt (A), if more than 18 mm had to be lowered.
• Screw out bolt (A), if it didn‘t come down for 18 mm.
(One turn of the screw and the change of height makes 2 mm.)
• Adjust with bolt (B) aclear distance of 12 mm to bolt (A).

3.3.0
 SEAT MODULES

Damper for horizontal adjustment

• Remove seat cushion (see 1.1.0)

• Bring height adjustment in topmost position.
• Remove 2 retaining washers (1).

Vertical damper / Handwheel

Vertical damper

• Remove seat cushion (see 1.1.0) and loosen bellow partly.

• Unscrew 2 boltings (1) and remove damper (2).

Handwheel

• Remove seat cushion (see 1.1.0) and loosen bellow partly.

• Punch adaptor sleeve (3) out of lug (4) (attainable through
opening in the holder for handwheel).

Tension springs

• Remove seat cushion (see 1.1.0) and loosen bellow partly.

• Secure suspension unit against lowering.
• Adjust handwheel to lowest weight.
• Push off one of the springs (1) from the holder (2) using an
appropriate lever,
• Unhook the second spring.

3.4.0