CLAAS GRAMMER seat suspension MSG 97AL Repair manual - PDF DOWNLOAD

June 2013

Repair manual GRAMMER seat suspension MSG 97AL

Page 1 of 5

END TABLE OF CONTENTS Preliminary remarks 1 Description 1.1

Safety instructions

1.2

Rating plate

2 Diagnosis 2.1

Overview of components

2.2

Functional test – Testing the specified status of functions

2.3

Overview of faults – Pointing out possible faults that might occur

2.4

Troubleshooting – Locating the fault

Material no. 1 160 241_e

June 2013

Repair manual GRAMMER seat suspension MSG 97A (L)

Page 2 of 5

END TABLE OF CONTENTS 3 Repair work 3.1

Seat suspension – removal and installation

3.2

Center and rear cover – removal and installation

3.2.1

Center and rear cover – removal and installation (seat suspension with handle on the left)

3.2.2

Center and rear cover – removal and installation (seat suspension with handle at the front)

3.3

Covers on the right and left side – removal and installation

3.4

Bellows – removal and installation

3.4.1

Bellows – removal and installation (seat suspension with handle on the left)

3.4.2

Bellows – removal and installation (seat suspension with handle at the front)

3.5

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation

3.5.1

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left)

3.5.2

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

June 2013

Repair manual GRAMMER seat suspension MSG 97A (L)

Page 3 of 5

END TABLE OF CONTENTS 3.6

Vertical shock absorber – removal and installation

3.7

Locking mechanism for fore/aft isolator – removal and installation

3.7.1

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.7.2

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front)

3.8

Handle for fore/aft isolator – removal and installation

3.8.1

Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.8.2

Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

3.9

Longitudinal horizontal shock absorber – removal and installation

3.10

Fore/aft isolator unit – removal and installation

3.11

Compressor – removal and installation

3.12

Level control – removal and installation

3.13

Level control (micro-switch, outlet valve) – adjustment

3.14

Air hoses – removal and installation

Material no. 1 160 241_e

June 2013

Repair manual GRAMMER seat suspension MSG 97AL

Page 4 of 5

END TABLE OF CONTENTS 3.15

Handle for height adjustment – removal and installation

3.16

Holder for height adjustment – removal and installation

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left) 3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front) 3.17

Bowden pull wires for height adjustment – removal and installation

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) 3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) 3.18

Bowden pull wires for height adjustment – inspection and adjustment

3.19

Air spring – removal and installation

3.20

Additional air supply – removal and installation

Material no. 1 160 241_e

June 2013

Repair manual GRAMMER seat suspension MSG 97AL

Page 5 of 5

END TABLE OF CONTENTS 3.21

Cable harness of vehicle connection – removal and installation

3.22

Cable harness of seat suspension (incl. U-profile) – removal and installation

3.22.1 Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation 3.22.2 Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation 3.23

Upper suspension part – removal and installation

3.24

Lower suspension part – removal and installation

3.25

Swinging structure – disassembly and assembly

3.26

Worn parts – replacement

3.27

Front cover – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

Preliminary remarks

Page 1 of 4 TABLE OF CONTENTS

Notes on these instructions This repair manual includes information and instructions on how to perform repair work on the GRAMMER seat suspension MSG97AL of the following seat models: • Holder for height adjustment, lateral isolator and vertical shock absorber on the left • Holder for height adjustment, lateral isolator and vertical shock absorber at the front • Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part • Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness The repair of the upper seat part is described in the repair manual for the upper seat part S721 - S742, to which a reference is made, if required.

Example: The cable harness for the upper seat part has been inspected and found to be OK (see repair manual for upper seat part).

The seat suspension MSG97AL with vehicle plug integrated at the rear of the upper suspension part forms the basis for illustrations in this repair manual. In the case of technical deviations in work procedures (due to different seat suspension designs), refer to the current text or individual chapters of the manual.

Each chapter starts with a list of all preparatory work to be completed before starting repair. These preparations are described in separate chapters and shall be carried out without the preparatory steps described there.

At the beginning of each description for repair you will find an overview diagram. All parts included in the overview diagrams within one chapter are consecutively numbered starting with "1". Each component is referred to by the same number throughout the document.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

Preliminary remarks

Page 2 of 4 TABLE OF CONTENTS

With the help of these overview diagrams, an experienced technician will gain a quick overview.

For spare part orders, please use the numbers stated in the latest issue of the relevant spare parts catalogue.

The description of the work procedures refers to the removed seat suspension.

Depending on the individual installation situation, some work may also be performed on the installed seat suspension and/or with upper seat part. For this reason, check the environment of the installed seat suspension for this possibility before starting work. The safety instructions of the specific vehicle manufacturer and those stated in Chapter 1 of this repair manual must be strictly observed.

This repair manual also includes some information on delivery options, if these require further explanation. Since the scope of delivery depends on the specific customer order, the actual seat suspension design may deviate from the descriptions and illustrations in this manual.

The illustrated repair steps refer to the seat suspension for left-hand drive. Different work steps are to be performed laterally reversed when repairing vehicle models with right-hand drive.

If not stated otherwise, the directional indications "front, back" and "right, left" refer to the installed seat suspension regarded in the driving direction of the vehicle.

The document layout is suitable for later use of this repair manual via CD-ROM / INTERNET / INTRANET. A navigation line was entered below the heading for this. This navigation line includes the Chapter titles and it allows the user to jump directly to these Chapters after the corresponding hyperlinks have been set.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

Preliminary remarks

Page 3 of 4 TABLE OF CONTENTS

Basic information on the seat suspension The seat suspension is provided with a long-lasting lubrication (approx. 10 years). The lubricating points must be re-greased only after repair work, using an acid-free multi-purpose lubricant.

In the description of the present repair manual, not all fastening parts might be mentioned. After repair, it might be necessary to check fastening parts regarding their factory-made laying, support and securing and to correct them respectively, if required.

Bowden pull wires, cables and air hoses may only be fastened with cable ties at the defined spots by hand (loose). Make sure that Bowden pull wires, cables and air hoses cannot be squeezed or distorted when the seat suspension is adjusted and the seat moved.

Replace all removed old parts with enclosed new ones. If there is no new part included, the old one is to be cleaned and checked for its suitability for re-use. Defective parts and worn parts must be replaced by new ones.

GRAMMER AG rejects any warranty claims if damaged or worn parts and assemblies are not replaced by spare parts released by GRAMMER AG.

Qualified personnel These instructions offer basic information on proper technical seat repair. The contents of the work procedures described are intended for professionally educated technicians with profound product knowledge. This level of knowledge is an imperative requirement when performing the work and procedures described in this document.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

Preliminary remarks

Page 4 of 4 TABLE OF CONTENTS

In order to avoid bodily injury, reduced operational safety of the seat suspension or damage to it resulting from improperly performed work, all information and instructions, in particular the safety instructions stated in Chapter 1, must be read carefully and strictly observed.

As an inevitable matter of fact, GRAMMER AG cannot evaluate all situations and consequences that may bear a risk of injury for the persons involved in the described work procedures. For this reason it is absolutely necessary that every person who carries out repair work at the seat suspension uses his/her professional knowledge to make sure that his/her own safety will not be put at risk and that the selected type of repair will not cause 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 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.

Change notification and copyright The seat suspensions are subject to continuous development. Please understand that we must reserve the right to make changes in shape, equipment and technical design. For this reason, the contents of this repair manual cannot be used to substantiate any possible claims.

Reprint, translation and copies of this manual or parts thereof are admissible only after written approval.

GRAMMER AG ⋅ Postfach 14 54 ⋅ D-92204 Amberg Phone +49 (0) 96 21 / 66-6822 www.grammer.com

Delivery and factory address: GRAMMER AG Köferinger Str. 9-13 ⋅ D-92245 Kümmersbruck Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

1

Description

Page 1 of 1

TABLE OF CONTENTS 1.1

Safety instructions

1.2

Rating plate

Note: Please refer to the applicable seat operating instructions for further details.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

1.1

Safety instructions

Page 1 of 1 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 suspension from the power supply.

• Move the seat suspension down to the end stops.

5 When using oil, grease and other chemical substances, the relevant safety regulations for the handling and use of these products must be observed.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

1.2

Rating plate

Page 1 of 1 TABLE OF CONTENTS

The rating plate is located on the right of the rear cover.

The rating plate shows the following information (example):

A

XXXXXXX

B

MSG 97AL/741

C

1137851

(A) Country of manufacture = MADE IN XXXXXXX (B) DESIGNATION = MSG 97AL/741

SACH-NR.

(C) INVENTORY NO. = 1137851

D

0716 031

(D) Year / CW / Assembly • Year of manufacture • Built in week • Assembly

E

XX 63988700013

= 0716 031 = 07 (2007) = 16 (April) = 031

(E) ORDER NO. = XX 63988700013 • Country indicator = XX Note: When orders are placed, the correct inventory no. (C) on the rating plate is always to be quoted.

2034

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2

Diagnosis

Page 1 of 3

TABLE OF CONTENTS 2.1

Overview of components (page 1-18) ● ● ● ● ● ●

Level control with micro-switch (page 1-2) Compressor and compressor cable with vehicle plug integrated at the rear of the upper suspension part – pin assignment of electrical connection (page 3-5) Compressor and compressor cable with vehicle plug integrated at the outside of the cable harness – pin assignment of electrical connection (page 6-8) Pneumatic connecting diagram (page 9-10) Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – pin assignment of electrical connection (page 11-14) Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness – pin assignment of electrical connection (page 15-18)

2.2

Functional test – Testing the specified status of functions (page 1-3)

2.3

Overview of faults – Pointing out possible faults that might occur (page 1-8) ● ● ● ●

Seat suspension does not respond when operating the handle for height adjustment in upward direction (page 1) Seat suspension responds when the handle for seat height adjustment is operated, but returns then to its original position (page 2) Seat suspension does not respond when operating the handle for height adjustment in downward direction (page 2) After the height adjustment, the seat lowers for at least 30 mm, but continues to vent automatically after unloading the seat (driver gets off the seat) (page 3)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2

Diagnosis

Page 2 of 3

TABLE OF CONTENTS ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

Seat responds after the height adjustment has been operated, but then returns to its original position (page 3) Seat suspension position changes during operation, deflates and lowers down (page 3) Seat suspension can be set to the highest position, but does not vent anymore (page 4) Seat suspension can be lowered, but does not pump up in the lowest position despite of the handle pulled upwards (page 4) Seat suspension can be lowered, but does not pump up in the lowest position despite of the handle pulled upwards (page 4) Seat moves up automatically (compressor does not switch off) (page 4) Compressor starts running (page 4) Compressor does not start running (page 5) Seat suspension pumps up and remains in the middle position, while the compressor is running (page 5) After having turned the handle for the fore/aft isolator backwards (in order to unlock the fore/aft isolator), the upper suspension part cannot be moved in longitudinal horizontal direction (page 6) After turning the handle for the fore/aft isolator forwards (in order to lock the fore/aft isolator), the upper suspension part can be moved in longitudinal horizontal direction (page 6) There is no noticeable change in the vertical cushioning effect (hard or soft) after the handle for vertical shock absorber adjustment has been turned (page 6) Seat suspension wobbles (page 7) Seat suspension squeaks (page 7) Seat suspension compresses and extends too much and hits the upper and lower end stop (page 8)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2

Diagnosis

Page 3 of 3

TABLE OF CONTENTS 2.4

Troubleshooting – Locating the fault (page 1 - 19) 1 Inspection of the compressor / compressor cable (page 1-7) 1.1 Compressor cable with vehicle plug integrated at the rear of the upper suspension part (page 1-3) 1.2 Compressor cable with vehicle plug integrated at the outside of the cable harness (page 4-7) 2 3 4

Inspection of the level control (page 8-9) Inspection of the micro-switch (page 10-11) Inspection of the air spring and the additional air supply (page 12)

5 Inspection of the cable harness for seat suspension (page 13-19) 5.1 Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part (page 13-14) 5.2 Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness (page 15-19)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 1 of 18 TABLE OF CONTENTS

Level control with micro-switch

9 10

(1) Level control

8

(2) Belt retractor

(9) Contact (K1) for plug (14) (10) Contact (K2) for plug (15)

12

13

19

1

4

18

12 13 B 15 11 A 14

(5) Air hose Hose from the valve for the belt retractor to the belt retractor

(8) Bowden pull wire lever

19

11

(4) Air hose Hose from the valve for the belt retractor to the additional air supply

(7) Retracting spring

17 7

6

(3) Webbing

(6) Air hose: Hose from the outlet valve to the additional air supply

16

1

2

10 9

ro

2

bl

8 7 6

3 5 4

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 2 of 18 TABLE OF CONTENTS

(11) Outlet valve

9 10

16

(12) Valve lever 8

(13) Cam disk (14) Plug (blue cable)

17 7

6

(15) Plug (red cable)

19

11

(16) Micro-switch

(19) Valve tappets

19 18

12 13 B 15 11 A 14

(18) Valve for retractor

13

1

4

(17) Cam switch

12

1

2

10 9

Electrical plug-in connections: (A) Electrical connection between right-angle plug (14) and microswitch (16) (B) Electrical connection between right-angle plug (15) and microswitch (16)

ro

2

bl

8 7 6

3 5 4

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 3 of 18 TABLE OF CONTENTS

Compressor and compressor cable with vehicle plug integrated at the rear of the upper suspension part – pin assignment of electrical connection

3

C 10

9

13 ro

ro

bl

(1) Compressor sw

(2) Compressor cable (in the cable harness for seat suspension) (3) Level control

2

P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

4

14

(4) Plug of cable harness for seat suspension (10-pin)

11

2 12

(5) Right-angle plug (blue cable)

A 4 13

(6) Right-angle plug (black cable)

7 8

6

(7) Nozzle

5

B

(8) Compressed-air hose

3

bl

(9) Plug (blue cable)

sw

(10) Plug (red cable)

1 2

(11) Socket of cable harness for vehicle connection 2

1 2066

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 4 of 18 TABLE OF CONTENTS

(12) Cable harness for vehicle connection (13) Cable harness for seat suspension

9

(14) Pin assignment for compressor at the plug of the cable harness for seat suspension (4) Pin: P1 (ground) and P2 (voltage)

bl

3

C 10

13 ro

ro

sw

2

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

4

14 11

2 12

Electrical plug-in connections:

A 4 13

(A) Electrical connection between cable harness for vehicle connection (12) and cable harness for seat suspension (13)

7 8

6 5

B

sw

2

1 3

bl

(B) Electrical connection between compressor cable (2) and compressor (1) (C) Electrical connection between compressor cable (2) and level control (3)

P10

2

1 2066

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 5 of 18 TABLE OF CONTENTS

Cable colors: ro = red

3

C 10

9

13 ro

ro

sw = black bl

bl = blue

sw

2

P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

4

14 11

2 12

A 4 13

7 8

6 5

B

3

bl sw

2

1 2

1 2066

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 6 of 18 TABLE OF CONTENTS

Compressor and compressor cable with vehicle plug integrated at the outside of the cable harness – pin assignment of electrical connection

ro

C

2

sw 1

bl

10

(3) Plug at the micro-switch (red line)

1

A

6

9

5

(4) Plug at the micro-switch (blue line) B

(5) Level control (6) Cable harness for seat suspension

5

3

(1) Plug (cable harness for seat suspension) (6) (4-pin) (2) Pin assignment for compressor (7) at the plug (1) Pin: P1 (ground) P2 (voltage)

4

P2

P1

8

7

(7) Compressor

7 2874

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 7 of 18 TABLE OF CONTENTS

4

P2

P1

(8) Right-angle plug (black line) Ground at the compressor

ro

5

C 3

(9) Right-angle plug (blue line) Voltage at the compressor

2

(10) Cable to compressor sw 1

Electrical plug and socket connections: (A) Electrical connection (4-pin) between cable harness plug for seat suspension (1) and cable harness socket for vehicle connection (B) Electrical connections (blue and black line) between cable to compressor (10) and compressor (7)

bl

10

1

A

6

9

5 B

8

7

7 2874

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 8 of 18 TABLE OF CONTENTS

4

P2

P1

(C) Electrical connections (blue and red line) between cable to compressor (10) and micro-switch in the level control (5)

ro

5

C 3

2

Cable colours:

sw 1

bl = blue ro = red sw = black

bl

10

1

A

6

9

5 B

8

7

7 2874

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 9 of 18 TABLE OF CONTENTS

Pneumatic connecting diagram 3 5

1

(1) Additional air supply

2

ATTENTION Damage!

Please observe the notes stated in Chapter 3.20 when pulling off the air hoses (2, 3) and the air intake hose (11) at the connections of the additional air supply (1).

6

(2) Air hose (black) Hose from the valve for the belt retractor to the additional air supply (3) Air hose (blue) Hose from the outlet valve to the additional air supply (4) Air hose (black) Hose from the valve for the belt retractor to the belt retractor (5) Level control

4

3

2

7

9 8 10 13 11 12

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 10 of 18 TABLE OF CONTENTS

(6) Air spring

3

(7) Catch spring

5

1

(8) Coupling (air intake hose) 2

(9) Coupling (compressed-air hose) (10) Compressed-air hose: Hose from the air spring (6) to the compressor (13) (11) Air intake hose: Hose from the air spring (6) to the additional air supply (1)

6

4

3

2

(12) Nozzle (13) Compressor 7

9

ATTENTION Damage!

Please observe the notes stated in Chapter 3.11 when pulling off the compressed-air hose (10) at the connection of the compressor (13).

8 10 13 11 12

2067

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 11 of 18 TABLE OF CONTENTS

Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part – pin assignment of electrical connection:

10

20 P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

(1) Cable harness for seat suspension (2) Plug (blue cable) (3) Plug (red cable)

5 18

19

P3

17

P8

P7

P6

P2

P1

P5

P4

(4) U-profile (5) Plug of cable harness for seat suspension (10-pin)

14 15 16 7

6

(6) Socket of cable harness for vehicle connection

9 10

(7) Cable harness for vehicle connection (8) Cable harness for upper seat part

A

8

(9) Socket of cable harness for upper seat part (10) Plug of cable harness for seat suspension (8-pin) (11) Holding plate

B

5 11 4

3

bl

2

12

ro 1

bl

13 sw 2068

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 12 of 18 TABLE OF CONTENTS

(12) Right-angle plug (blue cable) (13) Right-angle plug (black cable) (14) Pin assignment for compressor at the plug of the cable harness for seat suspension (5) Pin: P1 (ground) and P2 (voltage) (15) Pin assignment for climate control system at the plug of the cable harness for seat suspension (5) Pin: P3 (ground) and P4 (voltage) (16) Pin assignment for lumbar support at the plug of the cable harness for seat suspension (5) Pin: P3 (ground) and P5 (voltage)

10

20 P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

5 18

19

P3

17

P8

P7

P6

P2

P1

P5

P4

14 15 16 7

6 9 10 A

8

B

5 11 4

3

bl

2

12

ro 1

bl

13 sw 2068

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 13 of 18 TABLE OF CONTENTS

(17) Pin assignment for heater at the plug of the cable harness for seat suspension (5) Pin: P3 (ground) and P6 (voltage) (18) Pin assignment for heater at the plug of the cable harness for seat suspension (10) Pin: P6 (ground) and P8 (voltage) (19) Pin assignment for lumbar support at the plug of the cable harness for seat suspension (10) Pin: P6 (ground) and P7 (voltage) (20) Pin assignment for climate control system at the plug of the cable harness for seat suspension (10) Pin: P6 (ground) and P3 (voltage)

10

20 P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

5 18

19

P3

17

P8

P7

P6

P2

P1

P5

P4

14 15 16 7

6 9 10 A

8

B

5 11 4

3

bl

2

12

ro 1

bl

13 sw 2068

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 14 of 18 TABLE OF CONTENTS

Electrical plug-in connections: (A) Electrical connection between cable harness for seat suspension (1) and cable harness for vehicle connection (7)

P10

P11

P12

P7

P8

P9

P4

P5

P6

P1

P2

P3

(B) Electrical connection between cable harness for seat suspension (1) and cable harness for upper seat part (8)

5 18

19

P3

17

P8

P7

P6

P2

P1

P5

P4

14 15 16

Cable colors: ro = red

10

20

7

6 9

sw = black

10

bl = blue A

8

B

5 11 4

3

bl

2

12

ro 1

bl

13 sw 2068

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 15 of 18 TABLE OF CONTENTS

Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness:

P1

P4

(1) Pin assignment for seat occupancy detection system at the cable harness plug for seat suspension (4) Pin: P3 (signal B) P4 (signal A)

3

1

3

A

2

4 P2

P3 5

(2) Pin assignment for voltage supply at the cable harness plug for seat suspension (4) Pin: P1 (ground for compressor and additional load) P2 (voltage for compressor and additional load)

6 B

4

7 16 12

8 10

(3) Plug (cable harness for seat suspension) (4-pin)

7

9 15 14 P3

P2

P1

P5

P4

13

11 P8

P7

P6

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 16 of 18 TABLE OF CONTENTS

(4) Cable harness for seat suspension P1

P4

(5) Plug at the micro-switch (blue line) (6) Plug am Micro-switch (red line) (7) Plug (cable harness for seat suspension) (8-pin)

3

1

3

A

(8) Right-angle plug (blue line) Voltage at the compressor

2

4 P2

P3

(9) Right-angle plug (black line) Ground at the compressor

5 6

(10) Cable to compressor

B

(11) Air hose between compressor and additional air supply

4

7

(12) Holding plate

16 12

8 10

7

9 15 14 P3

P2

P1

P5

P4

13

11 P8

P7

P6

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 17 of 18 TABLE OF CONTENTS

(13) Pin assignment for seat occupancy detection system at the cable harness plug for seat suspension (4) Pin: P1 (signal B) P4 (signal A)

3

1

3

A

(14) Pin assignment for lumbar support at the cable harness plug for seat suspension (4) Pin: P6 (ground) and P7 (voltage)

2

4 P2

P3 5 6 B

(15) Pin assignment for heater at the cable harness plug for seat suspension (4) Pin: P6 (ground) and P8 (voltage) (16) Pin assignment for climate control system at the cable harness plug for seat suspension (4) Pin: P3 (voltage) and P6 (ground)

P1

P4

4

7 16 12

8 10

7

9 15 14 P3

P2

P1

P5

P4

13

11 P8

P7

P6

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.1

Overview of components

Page 18 of 18 TABLE OF CONTENTS

Electrical plug and socket connections:

P1

P4

(A) Electrical connection (4-pin) between cable harness plug for seat suspension (3) and cable harness socket for vehicle connection

3

1

3

A

(B) Electrical connections (blue and black lines) between cable to the Compressor (10) and compressor

2

4 P2

P3 5 6 B

4

7 16 12

8 10

7

9 15 14 P3

P2

P1

P5

P4

13

11 P8

P7

P6

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.2

Functional test – Testing the specified status of functions

Page 1 of 3 TABLE OF CONTENTS

A functional test is used to circumscribe all possible malfunctions; it must be performed before and after repair work on the seat suspension at any rate.

Preconditions for inspection: • Pull and push the weight and height adjustment handle at least five times and move it over the entire range of spring as far as possible.

• The individual functions are activated in compliance with the instructions of the seat operating instructions.

• The electrical system of the vehicle has been inspected and found to be OK and in compliance with the vehicle operating instructions.

• The seat must be vented completely.

• Battery voltage at the seat 12 V (24 V), ignition ON. • Bowden pull wire adjustments have been inspected and found to be OK (see Chapter 3.18).

Note: The components mentioned above are illustrated 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/remedial measures".

Step no.

1

Scope of inspection Function to be operated

Result/Specified state

Seat suspension

No noise.

Apply load to the seat suspension and spring up and down several times.

High lateral stability in horizontal direction.

Notes, cause/remedial measures See Overview of faults (Chap. 2.3).

No noticeable escape of compressed air.

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.2

Functional test – Testing the specified status of functions

Page 2 of 3 TABLE OF CONTENTS

Step no.

2

Notes, cause/remedial measures

Scope of inspection Function to be operated

Result/Specified state

Weight adjustment (level adjustment)

Seat remains in the lowest Briefly lift the handle. position.

Ignition is ON.

Seat moves up to minimum See Overview of faults height.

(Chap. 2.3).

3

4

Height adjustment upwards

Height adjustment in downward direction

Briefly lift the handle.

Seat moves up to minimum See Overview of faults height.

(Chap. 2.3).

Pull the handle upwards as far as possible and keep it in this position (max. 1 minute).

Seat moves up to maximum height.

See Overview of faults (Chap. 2.3).

Release the handle.

After having reached the maximum height, the seat must move down at least 30 mm.

See Overview of faults (Chap. 2.3).

Press the handle down as far as Seat moves down to possible and keep it in this position. minimum height (as far as possible).

See Overview of faults (Chap. 2.3).

Release the handle.

The seat remains in the set Briefly lift the handle. position.

Seat moves up to minimum See Overview of faults height.

(Chap. 2.3).

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.2

Functional test – Testing the specified status of functions

Page 3 of 3 TABLE OF CONTENTS

Step no.

5

Result/Specified state

Fore/aft isolator

Turn the handle for the fore/aft isolator (see chapter 3.8) backwards in order to unlock the fore/aft isolator.

The upper suspension part See Overview of faults can be moved in (Chap. 2.3). longitudinal horizontal direction.

Turn the handle for the fore/aft isolator (see chapter 3.8) forwards in order to lock the fore/aft isolator.

Move the upper suspension part backwards until the fore/aft isolator locks into place with an audible click.

The upper suspension part See Overview of faults cannot be moved in (Chap. 2.3). longitudinal horizontal direction.

6

7

8

Notes, cause/remedial measures

Scope of inspection Function to be operated

Vertical suspension

Turn the handle for vertical shock The seat suspension can See Overview of faults absorber adjustment in backward be moved easily in vertical (Chap. 2.3). direction (see Chapter 3.5) to adjust direction. a "soft" vertical cushioning.

Turn the handle for vertical shock The seat suspension absorber adjustment in forward hardly can be moved in direction (see Chapter 3.5) to adjust vertical direction. a "hard" vertical cushioning.

See Overview of faults (Chap. 2.3).

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 1 of 8

TABLE OF CONTENTS This chapter contains notes on possible faults of the seat suspension. The notes and information provided in Chapter 2.4 "Fault Diagnosis" are intended to ease troubleshooting of faults.

Faults caused due to insufficient maintenance or improper repair are not covered here.

Note: The components mentioned above are illustrated in chapter 2.1, if not stated otherwise in this text.

Fault description

Possible cause

Troubleshooting

Seat suspension does not respond when operating the handle for height adjustment in upward direction

• Compressor is not running.

Check the compressor / compressor cable (Chap. 2.4, step no. 1.1).

• Height adjustment is not operated via the Bowden pull wire

Adjust the Bowden pull wire (see Chapter 3.18).

• Level control is defective.

Check the level control (Chap. 2.4, inspection step 2.1).

• The plug at the micro-switch or compressor is not connected correctly.

Check the plug-in connectors and establish the connection, if necessary.

• Micro-switch is too far from the cam disk.

Adjust the micro-switch (see Chapter 3.13).

WARNING Risk of injury!

Do not operate the cam switch manually, but use an appropriate tool.

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 2 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

• The Bowden pull wire lever is not operated via the Bowden pull wire

Adjust the Bowden pull wire (see Chapter 3.18).

• Bowden pull wire is torn.

Replace the Bowden pull wire (see Chapter 3.17).

• No voltage.

Check the cable harness for seat suspension (Chap. 2.4, inspection step no. 5.1).

Seat suspension responds when the handle for height adjustment is pulled, but then returns to its original position.

• Level control is defective.

Check the level control (Chap. 2.4, inspection step 2.1).

Seat suspension does not respond when operating the handle for height adjustment in downward direction.

• Outlet valve does not respond (Bowden pull wire adjustment has been inspected).

Check the level control (Chap. 2.4, inspection step 2.1).

• Outlet valve / valve lever is too far from the cam disk.

Adjust the outlet valve (see Chapter 3.13).

• The height adjustment is not operated Replace (see Chapter 3.17) or adjust via the Bowden pull wire. (see Chapter 3.18) the Bowden pull wire.

• Level control is defective.

Replace the level control (see Chapter 3.12).

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2.3

Overview of faults – Pointing out possible faults that might occur

Page 3 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

After the height adjustment, the seat lowers for at least 30 mm, but continues to vent automatically after unloading the seat (driver gets off the seat).

• Level control does not uncouple.

Compress and expand the seat once after getting off the seat.

Seat responds after the height adjustment has been operated, but then returns to its original position.

• Handle has not been operated as far as possible.

Pull or push the handle as far as possible.

• Level control is defective.

Check the level control (Chap. 2.4, inspection step 2.3).

Seat suspension changes its position while driving, deflates and lowers down.

• Air hose connections are leaky.

Check all air hose connections for air leakage and, if necessary, seal leaky connections professionally.

• Air hoses are leaky.

Replace the air hoses (see Chapter 3.14).

• Air spring or additional air supply is leaky.

Check the air spring and the additional air supply (Chap. 2.4, step no. 4.1).

• Level control is leaky (air escapes from the outlet valve).

Adjust the outlet valve (see Chapter 3.13).

• Level control is leaky.

Replace the level control (see Chapter 3.12).

• Compressor is leaky (return valve).

Replace the compressor (see Chapter 3.11).

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2.3

Overview of faults – Pointing out possible faults that might occur

Page 4 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

It is possible to set the seat suspension to the • Outlet valve is too far from the cam highest position, but it does not deflate any disc. longer.

• Level control is defective.

Adjust the outlet valve (see Chapter 3.13).

Seat suspension can be lowered, but does not pump up in the lowest position despite of the handle pulled upwards.

• Micro-switch is too far from the cam disk.

Adjust the micro-switch (see Chapter 3.13).

• Level control is defective.

Check the level control (Chap. 2.4, inspection step 2.1).

Height adjustment upwards: compressor runs, but seat is not lifted.

• Level control is leaky.

Replace the level control (see Chapter 3.12).

Seat moves up automatically (compressor does not switch off).

• Micro-switch is too near to the cam disk.

Adjust the micro-switch (see Chapter 3.13).

• Micro-switch is defective.

Replace the level control (see Chapter 3.12).

• Cable break or short-circuit (e.g. caused by abrasion on the edge of the swinging structure).

Replace the cable harness of the seat suspension (see Chapter 3.22).

Compressor starts running automatically.

Replace the level control (see Chapter 3.12).

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 5 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

Compressor is not running.

• No voltage.

Check the compressor (Chap. 2.4, step no. 1.1).

• Micro-switch is too far from the cam disk.

Adjust the micro-switch (see Chapter 3.13).

- No voltage at the compressor.

• Micro-switch is defective or cam switch is bent.

Check the micro-switch (Chap. 2.4, inspection step no. 3.1).

- Voltage is present at the compressor.

• Compressor is defective.

Replace the compressor (see Chapter 3.11).

- Compressor is running, seat does not move upwards or seat lowers after a short time

• Air hoses are leaky.

Check the air hoses (Chap. 2.4, step no. 4.1).

• Air spring is leaky.

Replace the air spring (Chap. 2.4, step no. 4.2).

• Air tank of additional air supply is leaky.

Check the air tank for the additional air supply (Chap. 2.4, step no. 4.3).

• Compressor is leaky or defective.

Replace the compressor (see Chapter 3.11).

• The sealing ring of the level control is not tight.

Replace the level control (see Chapter 3.12).

Seat suspension pumps up and remains in the middle position, while the compressor is running.

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 6 of 8

TABLE OF CONTENTS Fault description

Possible cause

After having turned the handle for the fore/aft • Linkage rod is detached or broken. isolator backwards (in order to unlock the fore/aft isolator), the upper suspension part cannot be moved in longitudinal horizontal direction.

Troubleshooting Hang in or replace the linkage rod (see Chapter 3.7).

After having turned the handle for the fore/aft • Linkage rod is detached or broken.

Hang in or replace the linkage rod isolator forwards (in order to lock the fore/aft (see Chapter 3.7). isolator), the upper suspension part can be • Tension spring is detached or broken. Hang in or replace the tension spring moved in longitudinal horizontal direction. (see Chapter 3.7).

There is no noticeable change in the vertical • Bowden pull wire for vertical shock cushioning effect (hard or soft) after the absorber adjustment is detached or handle for vertical shock absorber adjustment torn. has been turned.

• Vertical shock absorber is defective.

Hang in or replace the Bowden pull wire for vertical shock absorber adjustment (see Chapter 3.5).

Replace the vertical shock absorber (see Chapter 3.6).

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 7 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

Seat suspension wobbles.

• Fixed bearings or rollers of the swinging structure are defective.

Replace the seat suspension (see Chapter 3.1).

• Swinging structure is defective.

Replace the seat suspension (see Chapter 3.1).

• Insufficient lubrication of the upper and/or lower rollers of the swinging structure.

Apply acid-free multi-purpose lubricant to the guiding rails of the upper suspension part and/or of the lower suspension part at the side surfaces of the rollers (see Chapter 3.23 and/or Chapter 3.24).

• Insufficient lubrication of the studs of the vertical shock absorber.

Apply acid-free multi-purpose lubricant to the stud of vertical shock absorber (see Chapter 3.6).

Seat suspension squeaks.

• Insufficient lubrication of the mounting Apply acid-free multi-purpose surfaces of the longitudinal horizontal lubricant to mounting surfaces of the longitudinal horizontal shock shock absorber. absorber (see Chapter 3.9).

• Insufficient lubrication of the central bearing of the swinging structure.

Apply oil to the central bearing (see Chapter 3.25).

Note: For this purpose, the central bearing does not have to be removed.

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.3

Overview of faults – Pointing out possible faults that might occur

Page 8 of 8

TABLE OF CONTENTS Fault description

Possible cause

Troubleshooting

Seat suspension travels up and down and hits the upper and lower end stop.

• Vertical shock absorber is defective.

Replace the vertical shock absorber (see Chapter 3.6).

• Air spring is leaky.

Check the air spring (see Chapter 2.4, steps no. 4.1 to 4.2).

• Additional air supply is leaky.

Check the additional air supply (see Chapter 2.4, step no. 4.3).

• Air hose connections are leaky.

Check all air hose connections for air leakage and replace the component showing a defective air connection with a new one, if necessary.

• Air hoses are leaky.

Check all air hoses for air leakage and replace a defective air hose, if necessary (see Chapter 3.14).

• Level control is defective.

Check the level control (Chap. 2.4, step no. 2.1).

• Compressor is defective.

Check the compressor (Chap. 2.4, step no. 1.1).

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 1 of 19 TABLE OF CONTENTS

1 Checking compressor / compressor cable 1.1

Compressor cable with vehicle plug integrated at the rear of the upper suspension part

Preconditions for fault diagnosis: •The individual functions are activated in compliance with the instructions of the seat operating instructions.

• The electrical system of the vehicle has been inspected and found to be OK in compliance with the vehicle operating instructions.

• The micro-switch has been inspected and found to be OK. • The compressed-air hose has been inspected with regard to kinks and tightness and found to be OK. • The pneumatic system has been inspected and found to be OK. • Battery voltage 12 V, ignition ON. Note: The components mentioned above are illustrated in Chapter 2.1.

Step no.

1.1

Inspect/Operate

Result/Specified state

Troubleshooting

• Disconnect the electrical connection between the cable harness for vehicle connection and the cable harness of the seat suspension.

• Measure the resistance at the pins P1 and P2 = 0.8 Ω (± 10%) (total resistance of Proceed with inspection in the plug of the cable harness of the seat compressor cable, micro-switch and step no. 1.3. suspension (pin assignment for compressor): compressor) P1

Ω

P2

>> 0,8 Ω (→ ∞) (interruption) or << 0.8 Ω (→ 0) (short-circuit)

Proceed with inspection step no. 1.2.

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2.4

Troubleshooting – Locating the fault

Page 2 of 19 TABLE OF CONTENTS

Step no.

1.2

Inspect/Operate

Troubleshooting

= 0.7 Ω (± 10%) (total resistance of compressor)

Replace the cable harness of the seat suspension (see Chapter 3.22).

>> 0,7 Ω (→ ∞) (interruption) or << 0.7 Ω (→ 0) (short-circuit)

Replace the compressor (see Chapter 3.11).

• Disconnect the electrical connection between compressor cable (right-angle plug) and compressor.

• Measure the resistance at the contacts of the compressor (2-pin): Contact

1.3

Result/Specified state

Ω

contact

• Reconnect the electrical connections and pull Compressor is running and seat the handle for height adjustment upwards. moves upwards.

End of inspection.

Compressor is running and seat does not move upwards; compressor is leaky (return valve).

Replace the compressor (see Chapter 3.11).

Compressor is not running.

Check the fuse and the plug-in connections and replace them, if necessary.

Proceed with inspection step no. 1.4.

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2.4

Troubleshooting – Locating the fault

Page 3 of 19 TABLE OF CONTENTS

Step no.

Inspect/Operate

Result/Specified state

Troubleshooting

Compressor is running.

Proceed with inspection step no. 1.5.

Compressor is not running.

Replace the compressor (see Chapter 3.11).

The leveling valve (3.18 – pos. 21) is operated via the Bowden pull wire, but the seat does not react.

Replace the level control (see Chapter 3.12).

The leveling valve (3.18 – pos. 21) is not operated.

Adjust the Bowden pull wire (see Chapter 3.18) or replace the Bowden pull wire (see Chapter 3.17).

1.4 WARNING Risk of injury!

Do not operate the cam switch manually, but use an appropriate tool.

Use a screwdriver to adjust or to readjust the micro-switch (see Chapter 3.13).

1.5

Pull the handle for height adjustment upwards as far as possible.

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 4 of 19 TABLE OF CONTENTS

1.2

Compressor cable with vehicle plug integrated at the outside of the cable harness

Preconditions for fault diagnosis: • The individual functions are activated in compliance with the instructions of the seat operating instructions.

• The electrical system of the vehicle has been inspected and found to be OK in compliance with the vehicle operating instructions.

• Electrical connection at the components produced according to instruction and locked, if possible.

• Cable harness for seat suspension has been inspected with regard to arcing spots and broken leads (kinks) and found to be OK. • Ignition switched off (no voltage that might cause a current flow must be applied to the seat suspension).

• The micro-switch has been inspected and found to be OK. • Pneumatic air system has been inspected and found to be OK. • Bellows at the upper suspension part removed (see Chapter 3.3) and pressed down.

Note:

The components mentioned above are illustrated in Chapter 2.1, if not stated otherwise in this text.

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2.4

Troubleshooting – Locating the fault

Page 5 of 19 TABLE OF CONTENTS

Step no.

1.1

Inspect/operate

Result/Specified status

Troubleshooting

• Disconnect the electrical connection (E) between the cable harness plug for seat suspension and the cable harness socket for vehicle connection.

• Connect the multimeter to pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

• Pull up the handle for height adjustment and measure the resistance at the pins P3 and P4: P3

Ω

P4

= 1.5 Ω (± ± 10%) (total resistance of Proceed with inspection step compressor cable, micro-switch and no. 1.4. compressor) >> 1,5 Ω (→ ∞) (interruption) or << 1,5 Ω (→ 0) (short-circuit)

Proceed with inspection step no. 1.2.

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2.4

Troubleshooting – Locating the fault

Page 6 of 19 TABLE OF CONTENTS

Step no.

1.2

Inspect/operate

Result/Specified status

Troubleshooting

• Disconnect the electrical connection (B) between the right-angle plugs (black and blue cables) and the compressor.

• Pull up the handle for height adjustment and measure the resistance at the pins P3 and P4: P3

Ω

P4

= ∞ Ω (resistance of the line to the Proceed with inspection step no. 1.3. compressor) << ∞ Ω (→ 0) (short-circuit)

Replace the cable harness for seat suspension (see Chapter 3.22).

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Troubleshooting – Locating the fault

Page 7 of 19 TABLE OF CONTENTS

Step no.

Inspect/operate

1.3

• Bridge contacts of the right-angle plugs.

Result/Specified status

Troubleshooting

<< 1 Ω (resistance of the line to the compressor)

Replace compressor (see Chapter 3.8).

>> 1 Ω (→ → ∞) (interruption)

Replace the cable harness for seat suspension (see Chapter 3.22).

• Pull up the handle for height adjustment and measure the resistance at the pins P3 and P4: P3

1.4

Ω

P4

•Reconnect the electrical connection (A and B). Compressor is running and seat suspension moves upwards.

• Switch the ignition on Compressor is running and seat • Pull up the handle for height adjustment. suspension does not move upwards; compressor is leaky (return valve).

End of inspection.

Replace the compressor (see Chapter 3.11).

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 8 of 19 TABLE OF CONTENTS

2 Inspection of the level control Preconditions for fault diagnosis: •The individual functions are activated in compliance with the instructions of the seat operating instructions.

• The electrical system of the vehicle has been inspected and found to be OK and in compliance with the vehicle operating instructions.

• The compressed-air hoses have been inspected with regard to kinks and tightness and found to be OK. • The compressor has been inspected and found to be OK. • The Bowden pull wires for height adjustment have been inspected and found to be OK. • Battery voltage 12 V (24 V), ignition ON. Note: The components mentioned above are illustrated in Chapter 2.1.

Step no.

Inspect/Operate

Result/Specified state

Troubleshooting

2.1

Press the height adjustment handle down.

The outlet valve (3.13 – pos. 2) is operated via the Bowden pull wire; air escapes at the outlet valve.

Proceed with inspection step no. 2.3.

The outlet valve (3.13 – pos. 2) is Replace the level control operated via the Bowden pull wire; (see Chapter 3.12). there is no air escaping at the outlet valve (valve tappets are stuck).

The outlet valve (3.13 – pos. 2) is not operated.

Adjust the outlet valve (see Chapter 3.13) and check it again. Proceed with inspection step no. 2.2.

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2.4

Troubleshooting – Locating the fault

Page 9 of 19 TABLE OF CONTENTS

Step no.

Inspect/Operate

Result/Specified state

Troubleshooting

2.2

Press the height adjustment handle down.

The outlet valve (3.18 – pos. 16) is operated via the Bowden pull wire; air escapes at the outlet valve.

Proceed with inspection step no. 2.3.

The outlet valve (3.18 – pos. 16) is not operated.

Adjust the Bowden pull wire (see Chapter 3.18).

The seat suspension moves upwards.

Proceed with inspection step no. 2.4.

The seat suspension does not move upwards.

Check the compressor (Chap. 2.4, step no. 1.1).

2.3 WARNING Risk of injury!

Due not operate the cam switch at the microswitch manually, but operate it carefully by means of an appropriate tool.

Replace the level control (see Chapter 3.12).

2.4

Pull the handle for height adjustment upwards as far as possible and release it.

The seat suspension moves upwards and remains in the adjusted position.

End of inspection.

The seat suspension moves Replace the level control upwards and does not remain in the (see Chapter 3.12). adjusted position.

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2.4

Troubleshooting – Locating the fault

Page 10 of 19 TABLE OF CONTENTS

3 Inspection of the micro-switch Preconditions for fault diagnosis: • The electrical system of the vehicle has been inspected and found to be OK in compliance with the vehicle operating instructions.

• Level control has been inspected and found to be OK. • The Bowden pull wire for height adjustment (upwards) have been inspected and found to be OK. Note: The components mentioned above are illustrated in Chapter 2.1.

Step no.

3.1

Inspect/Operate

Result/Specified state

Troubleshooting

>> 1 Ω (→ ∞) (interruption)

Proceed with inspection step no. 3.2.

• Disconnect the electrical connections between the right-angle plug (red cable) and the micro-switch as well as between the rightangle plug (blue cable) and the micro-switch.

• Measure the resistance at the contacts K1 and K2 of the micro-switch: K1

Ω

K2

≤ 1 Ω (→ 0) (short-circuit)

Micro-switch is defective.

Replace the level control (see Chapter 3.12).

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Troubleshooting – Locating the fault

Page 11 of 19 TABLE OF CONTENTS

Step no.

Inspect/Operate

3.2

• Pull up the handle for height adjustment.

Result/Specified state

Troubleshooting

= 0.2 Ω (± 10%) (total resistance of micro-switch)

End of inspection.

>> 0,2 Ω (→ ∞) (interruption) or << 0.2 Ω (→ 0) (short-circuit)

Micro-switch is defective.

Replace the level control (see Chapter 3.12).

• Measure the resistance at the contacts K1 and K2 of the micro-switch: K1

Ω

K2

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2.4

Troubleshooting – Locating the fault

Page 12 of 19 TABLE OF CONTENTS

4 Inspection of the air spring and the additional air supply Preconditions for fault diagnosis: • Air intake hose, compressed-air hose and air hoses have been inspected with regard to kinks and tightness and found to be OK. Note: The components mentioned above are illustrated in Chapter 2.1.

Step no.

4.1

Inspect/Operate

Result/Specified state

Troubleshooting

Apply load to the seat.

Air hose is leaky.

Replace the air hose (see Chapter 3.14).

Professionally seal the connection or replace it (see Chapter 3.14).

Proceed with inspection step no. 4.3.

Replace the air spring (see Chapter 3.19).

Replace the additional air supply (see Chapter 3.20).

Proceed with inspection step no. 4.4.

Adjust the outlet valve (see Chapter 3.13).

Replace the level control (see Chapter 3.12).

End of inspection.

Air hose connection is leaky.

4.2

Check the air spring for visible damage and tightness.

Air spring is tight.

Air spring is leaky.

4.3

Apply load to the seat.

Air escapes at the additional air supply.

The additional air supply is tight.

4.4

Apply load to the seat.

Air escapes at the level control.

The level control is tight.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 13 of 19 TABLE OF CONTENTS

5 Inspection of the cable harness for seat suspension 5.1

Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part

Preconditions for fault diagnosis: • The electrical system of the vehicle has been inspected and found to be OK and in compliance with the vehicle operating instructions.

• The compressor / compressor cable have been inspected and found to be OK. Note: The components mentioned above are illustrated in Chapter 2.1.

Step Inspect/Operate Result/Specified state Troubleshooting no.

5.1

• Disconnect the electrical connection between the cable harness for vehicle connection and the cable harness of the seat suspension.

• Bridge the pins P6 and P8 in the plug of the cable harness for the seat suspension (8-pin).

• Measure the resistance at the pins P3 and P6 in the plug of the cable harness for the seat suspension (10-pin) (pin assignment for the heater): P3

Ω

P6

<< 1 Ω (→ 0)

Proceed with inspection step no. 5.2.

≥ 1 Ω (interruption)

Replace the cable harness of the seat suspension (see Chapter 3.22).

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 14 of 19 TABLE OF CONTENTS

Step no.

5.2

Inspect/Operate

Troubleshooting

<< 1 Ω (→ 0)

Proceed with inspection step no. 5.3.

≥ 1 Ω (interruption)

Replace the cable harness of the seat suspension (see Chapter 3.22).

<< 1 Ω (→ 0)

End of inspection.

≥ 1 Ω (interruption)

Replace the cable harness of the seat suspension (see Chapter 3.22).

• Bridge the pins P6 and P7 in the plug of the cable harness for the seat suspension (8-pin).

• Measure the resistance at the pins P3 and P5 in the plug of the cable harness for the seat suspension (10-pin) (pin assignment for the lumbar support): P3

5.3

Result/Specified state

Ω

P5

• Bridge the pins P6 and P3 in the plug of the cable harness for the seat suspension (8-pin).

• Measure the resistance at the pins P3 and P4 in the plug of the cable harness for the seat suspension (10-pin) (pin assignment for the climate control system): P3

Ω

P4

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 15 of 19 TABLE OF CONTENTS

5.2

Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness

Preconditions for fault diagnosis: • The individual functions are activated in compliance with the instructions of the seat operating instructions.

• The electrical system of the vehicle has been inspected and found to be OK in compliance with the vehicle operating instructions.

• Electrical connection at the components produced according to instruction and locked, if possible.

• Cable harness for seat suspension has been inspected with regard to arcing spots and broken leads (kinks) and found to be OK. • Ignition switched off (no voltage that might cause a current flow must be applied to the seat suspension).

• Upper seat part removed at the seat suspension.

• The micro-switch has been inspected and found to be OK. • Compressor and current path have been inspected and found to be OK. • Pneumatic air system 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.

Descriptions of the work required during the diagnosis can be found in Chapter 3.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 16 of 19 TABLE OF CONTENTS

Step no.

5.1

Inspect/operate

Result/Specified status

Troubleshooting

= ∞ Ω

Proceed with inspection step no. 5.2.

<< ∞ Ω (→ 0) (short-circuit)

Replace the cable harness for seat suspension (see Chapter 3.22).

• Disconnect the electrical connection (E) between the cable harness plug for seat suspension and the cable harness socket for vehicle connection.

• Connect the multimeter to pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

• Measure the resistance at the pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

P3

Ω

P4

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 17 of 19 TABLE OF CONTENTS

Step no.

5.2

Inspect/operate

Result/Specified status

Troubleshooting

<< 1 Ω (R→ → 0) (pass)

Proceed with step no. 5.3.

>> 1 Ω (R→∞) (interruption)

Replace the cable harness for seat suspension (see Chapter 3.22).

<< 1 Ω (R→ → 0) (pass)

Proceed with step no. 5.4.

>> 1 Ω (R→∞) (interruption)

Replace the cable harness for seat suspension (see Chapter 3.22).

• Bridge the pins P6 and P8 in the plug of the cable harness for seat suspension (8-pin) (pin assignment for the heater).

• Measure the resistance at the pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

P3

5.3

Ω

P4

• Bridge the pins P6 and P7 in the plug of the cable harness for seat suspension (8-pin) (pin assignment for the lumbar support).

• Measure the resistance at the pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

P3

Ω

P4

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 18 of 19 TABLE OF CONTENTS

Step no.

5.4

Inspect/operate

Result/Specified status

Troubleshooting

<< 1 Ω (R→ → 0) (pass)

Proceed with inspection step no. 5.5.

>> 1 Ω (R→∞) (interruption)

Replace the cable harness for seat suspension (see Chapter 3.22).

• Bridge the pins P3 and P6 in the plug of the cable harness for seat suspension (8-pin) (pin assignment for the climate control system).

• Measure the resistance at the pins P3 and P4 in the cable harness plug for seat suspension (4-pin).

P3

Ω

P4

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

2.4

Troubleshooting – Locating the fault

Page 19 of 19 TABLE OF CONTENTS

Step no.

5.5

Inspect/operate

Result/Specified status

Troubleshooting

<< 1 Ω (R→ → 0) (pass)

End of inspection.

>> 1 Ω (R→∞) (interruption)

Replace the cable harness for seat suspension (see Chapter 3.22).

• Measure resistance between the pins P1 and P2 in the cable harness plug for seat suspension (4-pin) and the pins P1 and P4 in the cable harness plug for the seat suspension (8-pin) (pin assignment for seat occupancy detection system): P1 P2

Ω Ω

P4 P1

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3

Repair work

Page 1 of 4

TABLE OF CONTENTS 3.1

Seat suspension – removal and installation

3.2

Center and rear cover – removal and installation

3.2.1

Center and rear cover – removal and installation (seat suspension with handle on the left)

3.2.2

Center and rear cover – removal and installation (seat suspension with handle at the front)

3.3

Covers on the right and left side – removal and installation

3.4

Bellows – removal and installation

3.4.1

Bellows – removal and installation (seat suspension with handle on the left)

3.4.2

Bellows – removal and installation (seat suspension with handle at the front)

3.5

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation

3.5.1

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left)

3.5.2

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3

Repair work

Page 2 of 4

TABLE OF CONTENTS 3.6

Vertical shock absorber – removal and installation

3.7

Locking mechanism for fore/aft isolator – removal and installation

3.7.1

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.7.2

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front)

3.8

Handle for fore/aft isolator – removal and installation

3.8.1

Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.8.2

Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

3.9

Longitudinal horizontal shock absorber – removal and installation

3.10

Fore/aft isolator unit – removal and installation

3.11

Compressor – removal and installation

3.12

Level control – removal and installation

3.13

Level control (micro-switch, outlet valve) – adjustment

3.14

Air hoses – removal and installation

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3

Repair work

Page 3 of 4

TABLE OF CONTENTS 3.15

Handle for height adjustment – removal and installation

3.16

Holder for height adjustment – removal and installation

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left) 3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front) 3.17

Bowden pull wires for height adjustment – removal and installation

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) 3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) 3.18

Bowden pull wires for height adjustment – inspection and adjustment

3.19

Air spring – removal and installation

3.20

Additional air supply – removal and installation

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3

Repair work

Page 4 of 4

TABLE OF CONTENTS 3.21

Cable harness of vehicle connection – removal and installation

3.22

Cable harness of seat suspension (incl. U-profile) – removal and installation

3.22.1 Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation 3.22.2 Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation 3.23

Upper suspension part – removal and installation

3.24

Lower suspension part – removal and installation

3.25

Swinging structure – disassembly and assembly

3.26

Worn parts – replacement

3.27

Front cover – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.1

Seat suspension – removal and installation

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Seat suspension

4

(2) Upper seat part

7

(3) Fore/aft adjustment (4) Micro-encapsulated cap screw .................. to replace, 25 Nm (5) Cable harness for upper seat part

4

3

3

4

4

4

(6) Cable tie (7) Center cover

4

3

(8) Socket (cable harness for upper seat part)

2

(9) Plug (cable harness of seat suspension)

3

5 6 7

6

7

Note: For the removal of the seat suspension (1) on the vehicle, ask the vehicle manufacturer for the necessary assembly work to be carried out.

5

8 9

1 2037

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.1

Seat suspension – removal and installation

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation

4 7

1 Push the fore/aft adjustment (3) backwards as far as possible.

2 Mark the screw positioning diagram and unscrew two micro-encapsulated cap screws (4) at the front of the fore/aft adjustment (3).

Installation notes: • Replace the micro-encapsulated cap screw (4), 25 Nm. • Check the fore/aft adjuster (3) for correct locking in any position.

4

3

3

4

4

4 4

3 2

3

3 Push the fore/aft adjustment (3) as far forward as possible.

5 6 7

6

7 5

8 9

1 2037

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.1

Seat suspension – removal and installation

Page 3 of 4

REMOVAL / INSTALLATION 4 Mark the screw positioning diagram and unscrew two micro-encapsulated cap screws (4) at the rear of the fore/aft adjustment (3).

Installation notes: • Replace the micro-encapsulated cap screw (4), 25 Nm. • Install the fore/aft adjustment (3) according to the marking.

TABLE OF CONTENTS

4 7

4

3

3

4

4

4 4

3

5 Disconnect the electrical connection between the socket of the cable harness for the upper seat part (8) and the plug of the cable harness for seat suspension (9).

2 3

5 6 7

6 Mark the point where the cable harness of the upper seat part (5) is fastened to the center cover (7) by means of a cable tie (6) and remove the cable tie (6).

6

7 5

8 9

1 2037

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.1

Seat suspension – removal and installation

Page 4 of 4

REMOVAL / INSTALLATION 7 Lift off the upper seat part (2) at the seat suspension (1) and put it aside.

Note: When laying it down, make sure that the cable harness of the upper seat part (5) is not overstretched.

Installation note: To prevent the cable harness of the upper seat part (5) from being squeezed and rubbed, the cable harness (5) should be placed in a slackness loop (round arrow) between the seat suspension (1) and the upper seat part (2).

TABLE OF CONTENTS

4 7

4

3

3

4

4

4 4

3 2

3

8 Remove the seat suspension (1).

5 6 7

9 Re-install the components in the reverse order of their removal.

6

7 5

8 9

1 2037

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2

Center and rear cover – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.2.1

Center and rear cover – removal and installation (seat suspension with handle on the left)

3.2.2

Center and rear cover – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2.1 Center and rear cover – removal and installation (seat suspension with handle on the left)

Page 1 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Center cover

3

(2) Rear cover (3) Bellows pin (4) U-profile

2

2 3

1 3 5

(5) Hook

4

5 6

(6) Bellows (7) Upper suspension part 4

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

6 7

2035

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2.1 Center and rear cover – removal and installation (seat suspension with handle on the left)

Page 2 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 2 Pull out two bellows pins (3) at the front.

3 Pull out the bellows pin (3) at the rear.

Note: The rear cover (2) is fastened together with the center cover (1).

3 2

2 3

1 3 5

4

5 6

4 Remove the center cover (1).

4

5 Detach the hook (5) of the rear cover (2) at the U-profile (4) and remove the rear cover (2).

Installation note: Make sure that the bellows (6) runs underneath the rear cover (2).

6 7

6 Re-install the components in the reverse order of their removal.

2035

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2.2 Center and rear cover – removal and installation (seat suspension with handle at the front)

Page 1 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Center cover 3

(2) Rear cover

2 2

(3) Bellows pin

3

(4) U-profile

1 3

(5) Hook

5

4

5 6

(6) Bellows (7) Upper suspension part (8) Bowden pull wire for height adjustment in upward direction

4

(9) Bowden pull wire for vertical shock absorber adjustment

6

9

7

(10) Front cover

1 8

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

9 10

10

8

2378

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2.2 Center and rear cover – removal and installation (seat suspension with handle at the front)

Page 2 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 3

2 Pull out the bellows pin (3) at the rear.

Note: The rear cover (2) is fastened together with the center cover (1).

2 2

3

1 3

5

4

5 6

3 Detach the hook (5) of the rear cover (2) at the U-profile (4) and remove the rear cover (2).

Installation note: Make sure that the bellows (6) runs underneath the rear cover (2).

4 6

9

7

4 Pull out two bellows pins (3) at the front.

1 8

9 10

10

8

2378

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.2.2 Center and rear cover – removal and installation (seat suspension with handle at the front)

Page 3 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

5 Detach the Bowden pull wire for the upper height adjustment (8) and the Bowden pull wire for vertical shock absorber adjustment (9) at the grooves (arrows) of the center cover (1).

3

2 2

3

1 3

5

4

5 6

6 Remove the center cover (1).

7 Re-install the components in the reverse order of their removal.

4 6

9

7 1 8

9 10

10

8

2378

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.3

Covers on the right and left side – removal and installation

Page 1 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Cover (left and right) (2) Blind rivet (3) Bowden pull wire for height adjustment

2

2

1

2

(4) Bellows (5) Upper suspension part 2 1

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

WARNING Risk of injury!

3

5

Always install the left and right covers (1) as they provide protection against crushing at the seat fore/aft adjustment.

3 4 2036

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.3

Covers on the right and left side – removal and installation

Page 2 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 2 Bore out two rivet heads each, drive out the blind rivets (2) and remove the left and right covers (1).

Installation notes: ● ATTENTION Damage!

Make sure not to squeeze the Bowden pull wires for height adjustment (3) when installing the left cover (1). ● Make sure that the bellows (4) runs underneath the left and right covers (1).

Note: The Bowden pull wires for height adjustment (3) are protected by the left cover (1).

2

2

1

2

2 1

3

5

3 Re-install the components in the reverse order of their removal.

3 4 2036

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4

Bellows – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.4.1

Bellows – removal and installation (seat suspension with handle on the left)

3.4.2

Bellows – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.1 Bellows – removal and installation (seat suspension with handle on the left)

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Bellows (2) Upper suspension part

1

13

(3) Cover (left and right) (4) Cable harness for vehicle connection

12

(5) Bellows pin (6) U-profile

12 12

(7) Hook

12

12

12

(8) Handle for vertical shock absorber adjustment (9) Handle for height adjustment

3

4

55 12

(10) Handle for fore/aft isolator

6

55

12

12

(11) Lower suspension part

12

12

(12) Keyhole nubs 3

(13) Wire insert 2

1

10 11

9

7

8

12

12 12 12 12

1 12 2038

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.1 Bellows – removal and installation (seat suspension with handle on the left)

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the rear cover (see Chapter 3.2).

1

13

Removal and installation 12

2 Pull out two bellows pins (5) at the U-profile (6).

12

3 Take off eleven keyhole nubs (12) at the upper suspension part (2).

12

12

12

12

4 Detach the bellows (1) at the hook (7).

3

4

55 12 6

55

12

12 12

12

3 2

1

10 11

9

7

8

12

12 12 12 12

1 12 2038

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.1 Bellows – removal and installation (seat suspension with handle on the left)

Page 3 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

5 Pull the bellows (1) over the handles for vertical shock absorber adjustment (8), height adjustment (9) and fore/aft isolator (10).

Installation note: When installing a new bellows (1), tear open the predetermined breaking points for the handles (8, 9, 10) in the bellows (1) if there are no pre-cut apertures.

1

13

12

12 12

12

12

12

6 Detach eleven keyhole nubs (12) at the lower suspension part (11).

3

4

55 12 6

55

12

12 12

12

3 2

1

10 11

9

7

8

12

12 12 12 12

1 12 2038

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.1 Bellows – removal and installation (seat suspension with handle on the left)

Page 4 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

7 Pull the bellows (1) in downward direction over the lower suspension part (11) and remove it.

Installation notes: • Push the bellows (1) under the left and right covers (3).

• Guide the cable harness for vehicle connection (4) between the bellows (1) and the upper suspension part (2) at the rear right.

1

13

12

12 12

12

12

8 If the wire insert (13) is defective: Remove the wire insert (13) at the bellows (1).

Installation notes: • Install wire insert (13) in the middle fold of the bellows (1).

• The welding joint (arrow) of the wire insert (13) must be located on the right of the bellows (1).

3

4

12

55 12 6

55

12

12 12

12

3 2

9 Re-install the components in the reverse order of their removal.

1

10 11

9

7

8

12

12 12 12 12

1 12 2038

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.2 Bellows – removal and installation (seat suspension with handle at the front)

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Bellows (2) Bellows pin

1

12

(3) Handle for vertical shock absorber adjustment (4) Upper suspension part

11

(5) Cover (left and right) (6) Cable harness for vehicle connection

11

11 11

(7) U-profile (8) Hook

6

5

(9) Lower suspension part

11

22

4

(10) Handle for fore/aft isolator (11) Keyhole nubs

11

11

7 11

5

3

22

11

11

11

(12) Wire insert 2 2

11 2 9

2 1

10

8

2 2 2 2

11

1 2379

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.2 Bellows – removal and installation (seat suspension with handle at the front)

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the rear cover (see Chapter 3.2).

1

12

Removal and installation 11

2 Pull out two bellows pins (2) at the U-profile (7).

11

3 Pull out six bellows pins (2) at the front of the upper suspension part (4).

11

11

11

4 Detach seven keyhole nubs (11) at the upper suspension part (4).

6

5

11

22

4

11

7

5 Detach the bellows (1) at the hook (8).

11

5

3

22

11

11

11

2 2

11 2 9

2 1

10

8

2 2 2 2

11

1 2379

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.2 Bellows – removal and installation (seat suspension with handle at the front)

Page 3 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Pull the bellows (1) over the handles for vertical shock absorber adjustment (3) and fore/aft isolator (10).

Installation note: When installing a new bellows (1), tear open the predetermined breaking points for the handles (3, 10) in the bellows (1) if there are no pre-cut apertures.

1

12

11

11

11

7 Detach eleven keyhole nubs (11) at the lower suspension part (9).

11

11 6

5

11

22

4

11

7 11

5

3

22

11

11

11

2 2

11 2 9

2 1

10

8

2 2 2 2

11

1 2379

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.4.2 Bellows – removal and installation (seat suspension with handle at the front)

Page 4 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

8 Pull the bellows (1) in downward direction over the lower suspension part (9) and remove it.

Installation notes: • Push the bellows (1) under the left and right covers (5).

• Lead through the cable harness for vehicle connection (6) between the bellows (1) and the upper suspension part (4) at the rear right.

1

12

11

11

11

11

11

9 If the wire insert (12) is defective: Remove the wire insert (12) at the bellows (1).

Installation notes: • Install wire insert (12) in the middle fold of the bellows (1).

• The welding joint (arrow) of the wire insert (12) must be located on the right of the bellows (1).

10 Re-install the components in the reverse order of their removal.

6

5

11

22

4

11

7 11

5

3

22

11

11

11

2 2

11 2 9

2 1

10

8

2 2 2 2

11

1 2379

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.5.1

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left)

3.5.2

Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.1 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION (1) Bowden pull wire for vertical shock absorber adjustment

Page 1 of 5

TABLE OF CONTENTS 5

1 4

(2) Upper suspension part

5

6

1

6

1

7

(3) Handle for vertical shock absorber adjustment

7

8

8

4

(4) Bearing (5) Compression spring (6) Fork (7) Fixing (8) Vertical shock absorber

2 1

(9) Support (10) Rounded head screw (inner race).......................... 2.5 Nm (11) L-bar (at the upper suspension part) ................................. to grease

14 13 9

(12) Catch spring (13) Bowden pull wire for height adjustment.

(14) Cable harness for seat suspension

1 F

3

11 3

2 12

10 2039

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.1 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

Page 2 of 5

TABLE OF CONTENTS 5

1 4

2 Remove the center and rear covers (Chap. 3.2).

5

6

1

6

1

7 7

8

8

4

3 Take off the bellows from the upper part of suspension (see Chapter 3.4).

Removal and installation 2 1

4

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

14 13 9

1 F

3

11 3

2 12

10 2039

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.1 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 5 Unscrew the rounded head screw (10) from the handle for vertical shock absorber adjustment (3).

Installation note: Rounded head screw (10), 2.5 Nm. 6 Pull off the handle for vertical shock absorber adjustment (3) at the L-bar (11).

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the top and bottom side of the L-bar (11).

7 Detach the Bowden pull wire (1) at the handle for vertical shock absorber adjustment (3) and remove the handle for vertical shock absorber adjustment (3).

Note: Hang the Bowden pull wire (1) into the front hole of the handle for vertical shock absorber adjustment (3).

Page 3 of 5

TABLE OF CONTENTS 5

1 4

5

6

1

6

1

7 7

8

8

4

2 1

14 13 9

1 F

3

11 3

2 12

10 2039

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.1 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 8 Push off the Bowden pull wire (1) at the support (9) in downward direction.

TABLE OF CONTENTS 5

1 4

9 Remove the catch spring (12) at the L-bar (11).

5

6

1

6

1

7 7

8

8

4

10 Pull off the fixing (7) at the adjusting lever of the vertical shock absorber (8).

11 Compress the compression spring (5) (arrow direction) and take off the hauling rope of the Bowden pull wire (1) at the bearing (4).

Page 4 of 5

2 1

12 Remove the fixing (7) at the fork (6).

13 Take off the Bowden pull wire (1) at the fork (6) and remove the fork (6) and the compression spring (5).

14 13 9

1 F

3

11 3

2 12

10 2039

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.1 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 14 Mark the installation position of the Bowden pull wire (1) and remove the Bowden pull wire (1) from the seat suspension in upward direction.

Installation notes: • Install the Bowden pull wire (1) according to the marking.

• The Bowden pull wire (1) must be placed between the upper suspension part (2), the Bowden pull wire for height adjustment (13) and the cable harness of the seat suspension (14).

Page 5 of 5

TABLE OF CONTENTS 5

1 4

5

6

1

6

1

7 7

8

8

4

2 1

15 Re-install the components in the reverse order of their removal.

14 13 9

1 F

3

11 3

2 12

10 2039

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.2 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 1 of 5

TABLE OF CONTENTS

(1) Bowden pull wire for vertical shock absorber adjustment

5 2

(2) Handle for vertical shock absorber adjustment

10

3

11

1

1

4 12

(3) Upper suspension part F

(4) Rounded head screw (inner race).......................... 2.5 Nm F 6 7

(5) Catch spring (6) L-bar (at the upper suspension part) ................................. to grease

13

9

1

8

3

(7) Rounded head screw (inner race).......................... 2.5 Nm 1

(8) Support

9

(9) Bearing 1

(10) Compression spring (11) Fork

2

10 11 12 13

(12) Fixing (13) Vertical shock absorber

2380

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.2 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

5

10

3

2

1 12

3 Detach the bellows at the front of the upper suspension part (see Chapter 3.4).

F F 6 7

13

9

1

8

Removal and installation

3

WARNING Risk of crushing!

1 9

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

11

1

4

2 Remove the center and rear covers (Chap. 3.2).

4

Page 2 of 5

1 2

10 11 12 13

2380

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.2 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

TABLE OF CONTENTS

5 Turn the handle for vertical shock absorber adjustment (2) to the right to release the tension of the Bowden pull wire (1).

5

10

3

2

11

1

1

4 12

6 Unscrew the rounded head screw (4) at the handle for vertical shock absorber adjustment (2).

Installation note: Rounded head screw (4), 2.5 Nm.

F 6 7

13

9

F

7 Pull off the handle for vertical shock absorber adjustment (2) at the L-bar (6).

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the front and rear side of the L-bar (6).

8 Detach the Bowden pull wire (1) at the handle for vertical shock absorber adjustment (2) and remove the handle for vertical shock absorber adjustment (2).

Page 3 of 5

1

8

3

1 9 1 2

10 11 12 13

2380

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.2 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION 9

TABLE OF CONTENTS

Pull off the catch spring (5) at the L-bar (6).

5

10

3

2

11

1

1

4

10 Unscrew the rounded head screw (7) at the support (8).

Installation note: Rounded head screw (7), 2.5 Nm.

12

F 6 7

13

9

F

11 Pull off the support (8) at the upper suspension part (3).

Note: The pin (arrow) at the support (8) must engage in the drill hole (arrow) of the upper suspension part (3).

1

8

3

1

12 Detach the Bowden pull wire (1) from the support (8).

13 Pull off the fixing (12) at the adjusting lever of the vertical shock absorber (13).

Page 4 of 5

9 1 2

10 11 12 13

2380

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.5.2 Bowden pull wire and handle for vertical shock absorber adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

TABLE OF CONTENTS

14 Compress the compression spring (10) (arrow direction) and take off the hauling rope of the Bowden pull wire (1) at the bearing (9).

5

10

3

2

11

1

1

4 12

15 Remove the fixing (12) at the fork (11).

F 6 7

13

9

F

16 Detach the Bowden pull wire (1) at the fork (11) and remove the fork (11) and the compression spring (10).

17 Mark the installation position of the Bowden pull wire (1) and pull the Bowden pull wire (1) out of the upper suspension part (3) in upward direction.

Installation note: Install the Bowden pull wire (1) according to the marking.

Page 5 of 5

1

8

3

1 9 1 2

10 11 12 13

18 Re-install the components in the reverse order of their removal.

2380

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.6

Vertical shock absorber – removal and installation

Page 1 of 5

REMOVAL / INSTALLATION (1) Bowden pull wire for vertical shock absorber adjustment (2) Swinging structure

TABLE OF CONTENTS

1

4

5

5

6

6

1 7

1

(3) Vertical shock absorber

3

(4) Bearing

7

4

(5) Compression spring

3

(6) Fork (7) Fixing (8) Stud ................................. to grease (9) Lock washer

1

(10) Stud ................................. to grease

9

(11) Lock washer

10

4 F

3

11

F 2

2

8 2040

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.6

Vertical shock absorber – removal and installation

Page 2 of 5

REMOVAL / INSTALLATION 1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

2 Remove the center and rear covers (Chap. 3.2).

TABLE OF CONTENTS

1

4

5

5

6 7

1 3

3 Take off the bellows at the lower suspension part (see Chapter 3.4), push it upwards and fix it in this position.

Removal and installation

7

4

3

1

9

4

6

1

10

4 F

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

3

11

F 2

2

8 2040

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.6

Vertical shock absorber – removal and installation

Page 3 of 5

REMOVAL / INSTALLATION 5 Pull off the fixing (7) at the adjusting lever of the vertical shock absorber (3).

TABLE OF CONTENTS

1

4

5

5

6

6

1 7

1

6 Compress the compression spring (5) (arrow direction) and take off the hauling rope of the Bowden pull wire for vertical shock absorber adjustment (1) at the bearing (4).

3 7

4

3

7 Remove the fixing (7) at the fork (6).

8 Take off the Bowden pull wire for vertical shock absorber adjustment (1) at the fork (6) and remove the fork (6) and the compression spring (5).

1

9

10

4 F

3

9 Loosen the lock washer (9) at the stud (8).

11

F 2

2

8 2040

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.6

Vertical shock absorber – removal and installation

Page 4 of 5

REMOVAL / INSTALLATION 10 Pull out the stud (8) from the swinging structure (2), from the vertical shock absorber (3) and from the bearing (4).

Installation note: Apply acid-free multi-purpose lubricant to the entire surface (F) of the stud (8).

TABLE OF CONTENTS

1

4

5

5

6

6

1 7

1 3 7

4

3

11 Loosen the lock washer (11) at the stud (10).

12 Pull out the stud (10) from the swinging structure (2) and from the vertical shock absorber (3).

Installation note: Apply acid-free multi-purpose lubricant to the entire surface (F) of the stud (10).

1

9

10

4 F

3

11

F 2

2

8 2040

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.6

Vertical shock absorber – removal and installation

Page 5 of 5

REMOVAL / INSTALLATION 13 Remove the vertical shock absorber (3) in upward direction and remove the bearing (4).

Installation note: When installing the vertical shock absorber (3), the marking must point upwards.

TABLE OF CONTENTS

1

4

5

5

6

6

1 7

1 3 7

4

3

14 Re-install the components in the reverse order of their removal.

1

9

10

4 F

3

11

F 2

2

8 2040

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7

Locking mechanism for fore/aft isolator – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.7.1

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.7.2

Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.1 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 1 of 5

TABLE OF CONTENTS

(1) Upper suspension part (2) Handle for fore/aft isolator

1 6 F

(5) Clamping sleeve

11

(6) Linkage rod (8) Tension spring

12

13 F

(11) Flange head screw............ 2.25 Nm

4 5

10

F

F

F

3

9

(9) Tension spring (10) Linkage rod

2

3

11

(4) Rounded head screw .......... 2.5 Nm

(7) Stop lever......................... to grease

F

1

(3) L-bar (at the upper suspension part) ................................. to grease

8

2 1

7 F

F

6

5

4

(12) Stop lever......................... to grease (13) Tension spring

2 2041

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.1 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 2 of 5

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

1 F

1

2 Remove the center and rear covers (Chap. 3.2).

6

2

3

11

3 Detach the bellows at the upper suspension part (see Chapter 3.4).

F 11

Removal and installation

12

13 F

4

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

4 5

10

F

F

F

3

9 8

2 1

7 F

F

6

5

4

5 Tilt the seat suspension to the right.

2 2041

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.1 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Mark the screw positioning diagram for fitting as well as the installation position of the tension springs (8, 9, 13).

Installation note: Install the tension springs (8, 9, 13) according to the marking.

7 Detach the tension spring (9) at the linkage rod (6) and at the upper suspension part (1).

1 F

1 6

2

3

11 F 11 12

13 F

8 Detach the tension spring (8) at the stop lever (7) and at the upper suspension part (1).

Page 3 of 5

4 5

10

F

F

F

3

9 8

2 1

7 F

F

6

5

4

9 Detach the tension spring (13) at the stop lever (12) and at the upper suspension part (1).

10 Unscrew the rounded head screw (4) at the handle for the fore/aft isolator (2).

Installation note: Rounded head screw (4), 2.5 Nm.

2 2041

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.1 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 4 of 5

TABLE OF CONTENTS

11 Pull off the handle for the fore/aft isolator (2) at the L-bar (3) of the upper suspension part (1).

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the top and bottom side of the L-bar (3).

1 F

1 6

2

3

11 F 11

12 Detach the linkage rod (6) at the stop lever (7) and the linkage rod (10) at the stop lever (12).

13 Detach the linkage rod (6) at the linkage rod (10).

12

13 F

4 5

10

F

F

F

3

9 8

2 1

7 F

F

6

5

4

14 Mark the drill hole for the clamping sleeve (5) in the handle of the fore/aft isolator (2) and drive out the clamping sleeve (5) at the handle of the fore/aft isolator (2).

Installation note: Install the clamping sleeve (5) according to the marking.

2 2041

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.1 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 5 of 5

TABLE OF CONTENTS

15 Pull off the handle for the fore/aft isolator (2) at the linkage rod (6).

1

17 Remove two stop levers (7, 12).

Installation note: Apply acid-free multi-purpose lubricant to the front surface (F) and to the locking surfaces of the stop levers (7, 12).

18 Re-install the components in the reverse order of their removal.

F

1

16 Unscrew two flange head screws (11).

Installation note: Flange head screw (11), 2.25 Nm.

6

2

3

11 F 11 12

13 F

4 5

10

F

F

F

3

9 8

2 1

7 F

F

6

5

4

2 2041

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 1 of 7

TABLE OF CONTENTS

(1) Upper suspension part (2) Handle for fore/aft isolator (3) Rounded head screw (inner race).......................... 2.5 Nm (4) Clamping sleeve (5) L-bar (at the upper suspension part) ................................. to grease (6) Swivel lever (7) Lock washer (8) Stud (at the upper suspension part) ................................. to grease (9) Linkage rod (short) (10) Linkage rod (11) Stop lever......................... to grease (12) Tension spring (13) Tension spring

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 2 of 7

TABLE OF CONTENTS

(14) Linkage rod (15) Flange head screw............ 2.25 Nm (16) Stop lever......................... to grease (17) Tension spring

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

2 Remove the center and rear covers (Chap. 3.2).

3 Detach the bellows at the upper suspension part (see Chapter 3.4).

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 3 of 7

TABLE OF CONTENTS

Removal and installation

4

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

5 Tilt the seat suspension to the right.

6 Mark the screw positioning diagram for hanging in as well as the installation position of the tension springs (12, 13, 17).

Installation note: Install the tension springs (12, 13, 17) according to the marking.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 4 of 7

TABLE OF CONTENTS

7 Detach the tension spring (13) at the linkage rod (10) and at the upper suspension part (1).

8 Detach the tension spring (12) at the stop lever (11) and at the upper suspension part (1).

9 Detach the tension spring (17) at the stop lever (16) and at the upper suspension part (1).

10 Unscrew the rounded head screw (3) at the handle for the fore/aft isolator (2).

Installation note: Rounded head screw (3), 2.5 Nm.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 5 of 7

TABLE OF CONTENTS

11 Pull off the handle for the fore/aft isolator (2) at the L-bar (5) of the upper suspension part (1).

Note: To pull it off, turn the handle for the fore/aft isolator (2) to the left.

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the top and bottom side of the L-bar (5).

12 Detach the linkage rod (9) with the handle (2) at the swivel lever (6).

13 Mark the drill hole for the clamping sleeve (4) in the handle of the fore/aft isolator (2) and drive out the clamping sleeve (4) at the handle of the fore/aft isolator (2).

Installation note: Install the clamping sleeve (4) according to the marking.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 6 of 7

TABLE OF CONTENTS

14 Pull off the handle for the fore/aft isolator (2) at the linkage rod (9).

15 Loosen the lock washer (7) at the stud (8).

16 Pull off the swivel lever (6) at the stud (8).

Note: Apply acid-free multi-purpose lubricant to the entire surface (F) of the stud (8).

17 Detach the swivel lever (6) at the linkage rod (10).

18 Detach the linkage rod (10) at the stop lever (11) and the linkage rod (14) at the stop lever (16).

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.7.2 Locking mechanism for fore/aft isolator – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 7 of 7

TABLE OF CONTENTS

19 Detach the linkage rod (10) at the linkage rod (14).

20 Unscrew two flange head screws (15).

Installation note: Flange head screw (15), 2.25 Nm. 21 Remove two stop levers (11, 16).

Installation note: Apply acid-free multi-purpose lubricant to the front surface (F) and to the locking surfaces of the stop levers (11, 16).

22 Re-install the components in the reverse order of their removal.

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8

Handle for fore/aft isolator – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.8.1

Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

3.8.2

Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.1 Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

Page 1 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Handle for fore/aft isolator (2) Upper suspension part (3) Rounded head screw .......... 2.5 Nm (4) Clamping sleeve (5) Linkage rod (6) L-bar (at the upper suspension part) ................................. to grease (7) Stop lever

7 2 5

8

2

(8) Tension spring 6

2

1

F

5

4

3

1 2042

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.1 Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

Page 2 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 1 Turn the handle for the fore/aft isolator (1) forwards.

2 Unscrew the rounded head screw (3) at the handle for the fore/aft isolator (1).

Installation note: Rounded head screw (3), 2.2 Nm.

7 2 5

8

3 Drive out the clamping sleeve (4) at the handle of the fore/aft isolator (1).

2 6

2

1

F

5

4

3

1 2042

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.1 Handle for fore/aft isolator – removal and installation (seat suspension with handle on the left)

Page 3 of 3

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4 Carefully pull out the linkage rod (5) at the handle of the fore/aft isolator (1).

Note: Make sure that the linkage rod (5) remains hung into the stop lever (7) and that the tension spring (8) remains hung into the linkage rod (5).

7

5 Pull off the handle for the fore/aft isolator (1) at the L-bar (6) of the upper suspension part (2).

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the top and bottom side of the L-bar (6).

2 5

8

2 6

2

1

F

5

6 Re-install the components in the reverse order of their removal.

4

3

1 2042

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.2 Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Handle for fore/aft isolator

2

(2) Upper suspension part

F 5

10

(3) Rounded head screw .......... 2.5 Nm

8

2 F

7

1

(4) Clamping sleeve (5) L-bar (at the upper suspension part) ................................. to grease

F

(6) Swivel lever

3

4

(7) Lock washer

6

9

(8) Stud ................................. to grease (9) Linkage rod (short) 1

(10) Linkage rod (long)

1

(11) Stop lever

3 5

(12) Tension spring

2

4 6 11

7 8

10

2

9 10

12

F 2382

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.2 Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Detach the bellows at the front of the upper suspension part (see Chapter 3.4).

2

8

2 F 5

10

F 7

1

Removal and installation F

2 Unscrew the rounded head screw (3) at the handle for the fore/aft isolator (1).

Installation note: Rounded head screw (3), 2.5 Nm. 3 Pull off the handle for the fore/aft isolator (1) at the L-bar (5) of the upper suspension part (2).

Note: To pull it off, turn the handle for the fore/aft isolator (1) to the left.

Installation note: Apply acid-free multi-purpose lubricant to the sliding surfaces (F) on the top and bottom side of the L-bar (5).

3

4

6

9

1 1

3 5

2

4 6 11

7 8

10

2

9 10

12

F 2382

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.2 Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Page 3 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4 Detach the linkage rod (9) with the handle (1) at the swivel lever (6).

2 F 5

10

5 Mark the drill hole for the clamping sleeve (4) in the handle of the fore/aft isolator (1) and drive out the clamping sleeve (4) at the handle of the fore/aft isolator (1).

Installation note: Install the clamping sleeve (4) according to the marking.

8

2 F

7

1 F

3

4

6 Pull off the handle for the fore/aft isolator (1) at the linkage rod (9).

6

9

1 1

7 Loosen the lock washer (7) at the stud (8).

3 5

2

4 6 11

7 8

10

2

9 10

12

F 2382

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.8.2 Handle for fore/aft isolator – removal and installation (seat suspension with handle at the front)

Page 4 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

8 Pull off the swivel lever (6) at the stud (8).

Note: Apply acid-free multi-purpose lubricant to the entire surface (F) of the stud (8).

2

8

2 F 5

10

F 7

1 F

9 Detach the swivel lever (6) at the linkage rod (10).

Note: Make sure that the linkage rod (10) remains hung into the stop lever (11) and that the tension spring (12) remains hung into the linkage rod (10).

3

4

6

9

1

10 Re-install the components in the reverse order of their removal.

1

3 5

2

4 6 11

7 8

10

2

9 10

12

F 2382

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.9

Longitudinal horizontal shock absorber – removal and installation

REMOVAL / INSTALLATION (1) Longitudinal horizontal shock absorber........................... to grease

TABLE OF CONTENTS

5

3

2

F

7

(2) Upper suspension part (3) Swinging structure

Page 1 of 3

4

4 5

F

1

F

1

(4) Clearance spacer

3

F

(5) Lock washer (6) Axle (left)

6

(7) Axle (right)

2 2 1

3

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

2 Remove the center and rear covers (Chap. 3.2).

3 Remove the bellows at the front and left of the upper suspension part (see Chapter 3.4).

1

2043

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.9

Longitudinal horizontal shock absorber – removal and installation

REMOVAL / INSTALLATION

Page 2 of 3

TABLE OF CONTENTS

Removal and installation F

7

4

WARNING Risk of crushing!

6 Lift off the longitudinal horizontal shock absorbers (1) at the tube of the swinging structure (3).

Installation note: Press the longitudinal horizontal shock absorbers (1) onto the tube of the swinging structure (3) without using driving or hammering tools.

4

4 5

F

1

F

1 3

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

5 Loosen a lock washer (5) each at the left (6) and right axle (7) of the upper suspension part (2) and remove the clearance spacers (4).

5

3

2

F

6 2 2 1

3

1

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.9

Longitudinal horizontal shock absorber – removal and installation

REMOVAL / INSTALLATION 7 Pull the longitudinal horizontal shock absorbers (1) down at the left (6) and right axle (7) of the upper suspension part (2).

Installation note: Apply acid-free multi-purpose lubricant to the mounting surfaces (F) of the longitudinal horizontal shock absorbers (1).

Page 3 of 3

TABLE OF CONTENTS

5

3

2

F

7

4

4 5

F

1

F

1 3

F

6 2

8 Re-install the components in the reverse order of their removal.

2 1

3

1

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.10

Fore/aft isolator unit – removal and installation

Page 1 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Upper suspension part

4

(2) Handle for fore/aft isolator

6

5

6

1 10

(3) Swinging structure

11

(4) Buffer (5) Tension spring

9

11 11

(6) Socket 7 1

(7) Clamp .............................. to grease (8) Collar screw (inner race) ............................. to grease, 25 Nm

3

11

(9) Blind rivet (10) Buffer (11) Longitudinal horizontal shock absorber

Note: Replace the longitudinal horizontal shock absorbers (11) only if they are defective.

6

3

4

2

5

7

3

6

F F

F

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.10

Fore/aft isolator unit – removal and installation

Page 2 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

4

6

5

6

1 10

2 Remove the center and rear covers (Chap. 3.2).

3 Take off the bellows from the upper suspension part (see Chapter 3.4).

9

11 11 11 7 1

Removal and installation

3

11

4

WARNING Risk of crushing!

6

3

4

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

2

5

5 Turn (tilt) the seat suspension by 180°.

7

3

6

F F

F

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.10

Fore/aft isolator unit – removal and installation

Page 3 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Turn the handle of the fore/aft isolator (2) backwards to unlock the fore/aft isolator unit.

4

6

5

6

1 10

9

11

7 If the longitudinal horizontal shock absorber is defective: Remove the longitudinal horizontal shock absorber (Chapter 3.9).

11 11 7 1

8 If the longitudinal horizontal shock absorber is not defective: Lift off the longitudinal horizontal shock absorber at the tube of the swinging structure (see Chapter 3.9).

3

11

6

3

4

2

5

7

3

6

F F

F

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.10

Fore/aft isolator unit – removal and installation

Page 4 of 5

REMOVAL / INSTALLATION 9 Unscrew two collar screws (8).

Installation notes: • Collar screw (8), 25 Nm. • Apply acid-free multi-purpose lubricant to the entire surface (F) of the collar screws (8).

• During installation, the tension spring (5) is screwed on under tension.

10 Push the upper suspension part (1) forwards until the clamp (7) with all connected parts can be pushed off in upward direction at the tube of the swinging structure (3).

TABLE OF CONTENTS

4

6

5

6

1 10

9

11 11 11 7 1

3

11

6

3

4

2

5

11 Press off the clamp (7) at the swinging structure (3).

Installation note: Apply acid-free multi-purpose lubricant to the running surface (F) of the clamp (7).

7

3

6

F F

F

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.10

Fore/aft isolator unit – removal and installation

Page 5 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

12 Remove the buffer (4) at the socket (6).

4

6

5

6

1 10

13 Remove two sockets (6) from the legs of the tension spring (5).

14 Remove the tension spring (5) from the clamp (7).

11 11 11 7 1

15 If the buffer (10) is defective: Bore out the rivet head and drive out the blind rivet (9). Then, remove the buffer (10).

16 Re-install the components in the reverse order of their removal.

9

3

11

6

3

4

2

5

7

3

6

F F

F

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 1 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Compressor

10 9

(2) Cable tie................................ 360 N

1 6

1

7

(3) Lower suspension part

2

4

(4) Compressor cable (in the cable harness for seat suspension)

8

(5) Swinging structure 2

(6) Compressed-air hose *)

2

3

(7) Nozzle (8) Pad (9) Right-angle plug (blue cable) (10) Right-angle plug (black cable)

6

3

*) Use a sharp knife for cutting into lengths.

7

5

10 4 4

9

2 8 21 5

3

2

2

1

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 2 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

10 9

ATTENTION Leak test!

1 6

1

7

2

4

The leak test of the seat suspension should be performed upon installation of the compressor (1). To do this, apply 60 kg load to the suspension for 24 hours.

The lowering within this time must not exceed 15 mm.

8

2

2

3

1 Remove the bellows from the upper suspension part (see Chapter 3.4).

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 3 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation

10 9

1 6

1

7

2

2

4

WARNING Risk of crushing!

8

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

3

2

2

3

WARNING The pressure in the pneumatic system might cause injury!

The pneumatic system is to be vented before removing the compressor (1).

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 4 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4 Mark two right-angle plugs (9, 10) and disconnect the electrical connection between the right-angle plugs (9, 10) and the compressor (1).

Installation notes: • Reconnect the electrical connection between the right-angle plugs (9, 10) and the compressor (1) according to the marking.

• The cable outlet at the respective right-angle plug (9, 10) must point downwards.

10 9

1 6

1

7

2

4 8

2

2

3

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 5 of 8

REMOVAL / INSTALLATION 5 Mark the places where the compressor (1) is attached to the lower suspension part (3) by means of two cable ties (2) and remove the cable ties (2).

Installation note: Guide the cable tie (2) through the intended cut-outs at the lower suspension part (3) so that the locking head of the cable tie (2) points forwards.

Loosely close the cable tie (2) so that the compressor (1) still can be moved.

Align the compressor (1) so that a collision with the swinging structure (5) is prevented and then tighten the locking head of the cable tie (2) to 360 N by means of pliers in the direction shown (arrow).

TABLE OF CONTENTS

10 9

1 6

1

7

2

4 8

2

2

3

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 6 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Pull off the nozzle (7) at the connection (mandrel profile) of the compressor (1) and push it backwards at the compressed-air hose (6).

10 9

1 6

1

7

2

4 8

7

ATTENTION Damage!

Take care not to damage the connection (arrow) of the compressor (1) and the compressed-air hose (6).

Do not lift off the compressed-air hose (6) at the connection (arrow) of the compressor (1) e.g. by means of a screwdriver.

Cut off the compressed-air hose (6) in a clean and straight way directly behind the connection (arrow) of the compressor (1) by means of a sharp knife.

2

2

3

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 7 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Installation note: Push the compressed-air hose (6) completely onto the connection (arrow) of the compressor (1) by exerting pressure.

Notes: • The compressed-air hose (6) can be cut off only once.

• After cutting off, mark the compressed-air hose (6) in order not to cut it several times.

10 9

1 6

1

7

2

4 8

2

2

3

8 Pull off the nozzle (7) at the compressed-air hose (6).

9 Remove the compressor (1) in forward direction.

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.11

Compressor – removal and installation

Page 8 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

10 Remove the pad (8) from the lower suspension part (3).

Installation note: Place the pad (8) between the lower suspension part (3) and the compressor (1) so that the compressor (1) cannot come into contact with the lower suspension part (3).

10 9

1 6

1

7

2

4 8

2

2

3

11 Re-install the components in the reverse order of their removal.

6

3

7

5

10 4 4

9

2 8 21 5

3

2

2

1

2045

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 1 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Level control

3

(2) Bowden pull wire for height adjustment (downwards) 20

21

3 10

8

(4) Lower suspension part (6) Bowden pull wire for height adjustment (upwards)

13

7

(3) Upper suspension part (5) Handle for height adjustment

13

8

11 9

7

12 1

6

1

2

14 15 17

22 20

(7) Air hose (black) (8) Air hose (blue)

7 16

15

1

(9) Plug (blue cable) (10) Plug (red cable)

2 6

18

3

18

(11) Support (at the level control) (12) Baffle for Bowden pull wire (13) Micro-encapsulated hexagon nut....................... to replace, 25 Nm (14) Webbing

14 5

4

19

4 2046

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 2 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(15) Plastic clip

3

(16) Cable harness for seat suspension

20

21

3 10

8

(18) Micro-encapsulated hexagon nut....................... to replace, 25 Nm

11 9

7

12 1

6

1

2

14

(20) Additional air supply (21) Air intake hose

13

7

(17) Air hose (black)

(19) Plate

13

8

15 17

22 20

7 16

15

(22) Cable tie 1 2 6

18

3

18

14 5

4

19

4 2046

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 3 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

3

ATTENTION Leak test!

The leak test of the seat suspension should be performed upon installation of the level control (1). To do this, apply 60 kg load to the suspension for 24 hours.

The lowering within this time must not exceed 15 mm.

13

7 8 20

21

3 10

11 9

7

12 1

6

1

2

14 15 17

22 20

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

2 Remove the center and rear covers (Chap. 3.2).

13

8

7 16

15

1 2 6

18

3

18

3 Remove the bellows (Chap. 3.4).

14 5

4

19

4 2046

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 4 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation

3

13

8

13

7

4

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

5

WARNING The pressure in the pneumatic system might cause injury!

8 20

21

3 10

11 9

7

12 1

6

1

2

14 15 17

22 20

7 16

15

1 2 6

18

3

18

The pneumatic system is to be vented before removing the level control (1).

14 5

4

19

4 2046

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 5 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

3

6

WARNING Damage!

Take care not to damage the connections (mandrel profiles) of the additional air supply (20).

Mark the connections (arrows) of the two air hoses (7, 8) and pull off the air hoses (7, 8) at the connections (arrows) of the additional air supply (20).

Notes: • For easier removal, carefully slit the air hoses (7, 8) with a sharp knife.

• Do not use a screwdriver or similar tools to lift off the air hoses (7, 8) at the connections (arrows) of the additional air supply (20).

13

8

13

7 8 20

21

3 10

11 9

7

12 1

6

1

2

14 15 17

22 20

7 16

15

1 2 6

18

3

18

14 5

4

19

4 2046

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 6 of 10

REMOVAL / INSTALLATION Installation notes: • Re-install the air hoses (7, 8) according to the marking.

• Push the air hoses (7, 8) completely onto the respective connection (arrows) of the additional air supply (20) by exerting pressure.

7 Pull two air hoses (7, 8) inwards to the level control (1).

Note: The cable tie (22) by means of which the air hoses (7, 8) are attached to the level control (1) does not have to be removed.

Installation notes: • The air hoses (7, 8) have to be guided out (arrow) between the upper suspension part (3) and the air intake hose (21) to the additional air supply (20).

• Do not bend the air hoses (7, 8).

TABLE OF CONTENTS

3

13

8

13

7 8 20

21

3 10

11 9

7

12 1

6

1

2

14 15 17

22 20

7 16

15

1 2 6

18

3

18

14 5

4

19

4 2046

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 7 of 10

REMOVAL / INSTALLATION 8 Unscrew two micro-encapsulated hexagon nuts (18).

Installation notes: • Replace the micro-encapsulated hexagon nut (18); 25 Nm. • Make sure not to squeeze the webbing (14) when tightening the hexagon nuts (18).

9 Pull out the plate (19) at the lower suspension part (4) while holding the webbing (14) in position and slowly guiding it upwards to the level control (1).

TABLE OF CONTENTS

13

7 7 8

10

12

2

3 10

11 9

9 15 16

16

1

11 6

1 2

14

15

15 17

17 7

8

12

6

7 16

15

1 2

10 Pull the plate (19) out of the webbing (14).

Installation note: The bend of the plate (19) must point to the front.

13

8

6

18

3

18

14 5

4

19

4 2047

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 8 of 10

REMOVAL / INSTALLATION 11 Press the handle for height adjustment (5) down to release the Bowden pull wire (6) and detach the Bowden pull wire (6) at the level control (1).

Note: Detach the Bowden pull wire (6) at the support (11) first.

12 Mark two plugs (9, 10) and disconnect the electrical connection between the plugs (9, 10) and the level control (1).

Installation note: Reconnect the electrical connection according to the marking.

TABLE OF CONTENTS

13

8

13

7 7 8

10

12

2

3 10

11 9

9 15 16

16

1

11 6

1

6

2

14

15

15 17

17 7

8

12

7 16

15

1 2 6

18

3

18

14 5

4

19

4 2047

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 9 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

13 Pull two plastic clips (15) out of the level control (1).

13

8

13

7

14 Thread the cable harness for seat suspension (16) in downward direction between the air hoses (7, 17) and the level control (1).

7 8

10

12

3 10

11 9

9 15 16

15 Pull up the handle for height adjustment (5) to release the Bowden pull wire (2) and detach the Bowden pull wire (2) at the level control (1).

Note: Detach the Bowden pull wire (2) at the baffle (12) first.

2

16

1

11 6

1

6

2

14

15

15 17

17 7

8

12

7 16

15

1 2 6

18

3

18

16 Pull the Bowden pull wire (2) out of the level control (1).

14 5

4

19

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.12

Level control – removal and installation

Page 10 of 10

REMOVAL / INSTALLATION

TABLE OF CONTENTS

17 Unscrew two micro-encapsulated hexagon nuts (13).

Installation note: Replace the micro-encapsulated hexagon nut (13), 25 Nm.

19 Re-install the components in the reverse order of their removal.

13

7 7 8

10

12

2

3 10

11 9

9

18 Pull out the level control (1) at the upper suspension part (3) and remove it in downward direction.

13

8

15 16

16

1

11 6

1

6

2

14

15

15 17

17 7

8

12

7 16

15

1 2 6

18

3

18

14 5

4

19

4 2047

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.13

Level control (micro-switch, outlet valve) – adjustment

Page 1 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Level control

3

5

(2) Outlet valve (3) Micro-switch (5) Cam switch

3

7

4 6

2

5

A

B

(4) Valve tappets

1

7

(6) Valve lever (7) Cam disk (8) Round head screw (for micro-switch)

9

1

8

(9) Round head screw (for outlet valve) (10) Compressor

1

10 2064

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.13

Level control (micro-switch, outlet valve) – adjustment

Page 2 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

3

5

2 Remove the center and rear covers (Chap. 3.2).

Condition for adjustment:

4

3

7

4 6

3 Take off the bellows from the upper suspension part (see Chapter 3.4).

5

A

B 2

9

1

1

7

8

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

1

10 2064

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.13

Level control (micro-switch, outlet valve) – adjustment

Page 3 of 5

REMOVAL / INSTALLATION 5 Adjusting the micro-switch (3): Adjust the clearance between cam switch (5) and cam disk (7) by turning the round head screw (8).

Notes: • Specified value: Clearance (A) = 0.8 – 1.2 mm.

• Turn the round head screw (8) to the left, the cam switch (5) is moving towards the cam disk (7). Thus, the pressure on the cam switch (5) increases and the compressor (10) will react earlier.

• Turn the round head screw (8) to the right; the cam switch (5) is moving away from the cam disk (7). Thus, the pressure on the cam switch (5) decreases and the compressor (10) will react later.

TABLE OF CONTENTS 3

5

5

A

B

3

7

4 6

2

9

1

1

7

8

1

10 2064

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.13

Level control (micro-switch, outlet valve) – adjustment

Page 4 of 5

REMOVAL / INSTALLATION • When the cam switch (5) is placed on the cam disk (7) under pressure, the compressor (10) will react too early and start already during the compression and expansion of the seat suspension.

6 Adjusting the outlet valve (2): Adjust the clearance between valve lever (6) and cam disk (7) by turning the round head screw (9).

Notes: • Specified value: Clearance (B) = 1.0 – 1.5 mm.

Lay a feeler gauge with 1.0 – 1.5 mm between the valve lever (6) and the cam disk (7) (valve must let off air).

• Turn the round head screw (9) to the left; the valve lever (6) is moving towards the cam disk (7). Thus, the pressure on the valve tappet (4) at the outlet valve (2) increases and the outlet valve (2) will let off air earlier.

TABLE OF CONTENTS 3

5

5

A

B

3

7

4 6

2

9

1

1

7

8

1

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.13

Level control (micro-switch, outlet valve) – adjustment

Page 5 of 5

REMOVAL / INSTALLATION • Turn the round head screw (9) to the right; the valve lever (6) is moving away from the cam disk (7). Thus, the pressure on the valve tappet (4) at the outlet valve (2) decreases and the outlet valve (2) will let off air later.

TABLE OF CONTENTS 3

5

5

A

B

3

7

4 6

2

7 Fit the bellows into the upper part of the suspension (see Chapter 3.4).

9

1

1

7

8

8 Install the center and rear covers (Chap. 3.2).

9 Install the upper seat part at the seat suspension (see Chapter 3.1).

1

10 2064

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 1 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Air intake hose (2) Compressed-air hose (3) Lower suspension part

1

3

2

12

5

(4) Compressor (5) Nozzle

11

1

(6) Catch spring (7) Coupling (compressed-air hose)

10

10

(8) Coupling (air intake hose)

1

4

(9) Air spring (10) Additional air supply (11) Clamp

9

1

(12) Clip

4 2

6

10 4 2 4

3

5

2

7 8

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 2 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

ATTENTION Leak test!

1

3

The leak test of the seat suspension should be performed upon installation of the air hoses (1, 2). To do this, apply 60 kg load to the suspension for 24 hours.

The lowering within this time must not exceed 15 mm.

2

12

5 11

1

1

10

10 4

1 Remove the bellows from the upper suspension part (see Chapter 3.4).

9

1 4 2

6

10 4 2 4

3

5

2

7 8

1 3 2048

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 3 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation

2

1

3

WARNING Risk of crushing!

2

12

5

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

3

11

1

1

10

10 4

WARNING The pressure in the pneumatic system might cause injury!

9

1 4

The pneumatic system is to be vented before removing the air intake hose (1) and the compressed-air hose (2).

2

6

10 4 2 4

3

5

2

7 8

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 4 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4

If the compressed-air hose (2) is defective: 4.1 Pull off the nozzle (5) at the connection (arrow) of the compressor (4) and push it backwards at the compressed-air hose (2).

4.2

1

3

2

12

5

ATTENTION Damage!

Take care not to damage the connection (mandrel profile) of the compressor (4).

Pull off the compressed-air hose (2) at the connection (arrow) of the compressor (4).

Notes: • For easier removal, carefully slit the compressed-air hose (2) with a sharp knife.

• Do not use a screwdriver or similar tools to lift off the compressed-air hose (2) at the connection (arrow) of the compressor (4).

4 1 9 4 2

6

10 4

4

3

1

2

5

2

7 8

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Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 5 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Installation note: Push the compressed-air hose (2) completely onto the connection (arrow) of the compressor (4) by exerting pressure.

1

3

2

12

5

4.3 Pull off the nozzle (5) at the compressed-air hose (2).

4.4 Pull the catch spring (6) out of the air spring (9).

4.5 Pull the coupling (7) of the compressed-air hose (2) out of the air spring (9).

Installation note: First, push the catch spring (6) into the air spring (9) and then plug the coupling (7) into the air spring (9) with a click.

4 1 9 4 2

6

10 4

4.6 Remove the compressed-air hose (2).

4

3

1

2

5

2

7 8

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 6 of 8

REMOVAL / INSTALLATION 5

TABLE OF CONTENTS

If the air intake hose (1) is defective:

5.1 Take off the air intake hose (1) at the clamp (11).

1

3

2

12

5 11

1

5.2

ATTENTION Damage!

Take care not to damage the connection (mandrel profile) of the additional air supply (10).

Pull off the air intake hose (1) at the connection (arrow) of the additional air supply.

Notes: • For easier removal, carefully slit the air intake hose (1) with a sharp knife.

• Do not use a screwdriver or similar tools to lift off the air intake hose (1) at the connection (arrow) of the additional air supply (10).

1

10

10 4

9

1 4 2

6

10 4 2 4

3

5

2

7 8

1 3 2048

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 7 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Installation note: Push the air intake hose (1) completely onto the connection (arrow) of the additional air supply (10) by exerting pressure.

1

3

2

12

5

5.3 Pull out the clip (12) at the lower suspension part (3) and hang it out at the air intake hose (1).

5.4 Pull the catch spring (6) out of the air spring (9).

5.5 Pull the coupling (8) of the air intake hose (1) out of the air spring (9).

Installation note: First, push the catch spring (6) into the air spring (9) and then plug the coupling (8) into the air spring (9) with a click.

4 1 9 4 2

6

10 4

4

3

1

2

5

2

7 8

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.14

Air hoses – removal and installation

Page 8 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

5.6 Mark the installation position of the air intake hose (1) and remove the air intake hose (1) from the seat suspension.

Installation note: Install the air intake hose (1) according to the marking.

1

3

2

12

5

6 Re-install the components in the reverse order of their removal.

4 1 9 4 2

6

10 4

4

3

1

2

5

2

7 8

1 3 2049

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.15

Handle for height adjustment – removal and installation

Page 1 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Handle for height adjustment ................... to replace, if necessary

4

(2) Support

4 3

(3) Latching nose (at the support) (4) Hook (at the handle for height adjustment)

1 3

2

1 Detach the bellows at the front and left of the upper suspension part (see Chapter 3.4).

4

3

1

3 4

3 2

3 2

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.15

Handle for height adjustment – removal and installation

Page 2 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 4

2

4 3

ATTENTION Risk of breakage!

The handle for height adjustment (1) is wedged in the support (2) at the bottom of the support (2) by means of two latching noses (3). Carefully separate the parts. When the handle for height adjustment (1) is deformed, replace it.

1 3

Use a screwdriver to bend open (arrow) the handle (1) between the handle (1) and the support (2) until the two latching noses (3) are released from the hooks (4). Pull off the handle (1) at the support (2).

2

4

3 Re-install the components in the reverse order of their removal.

3

1

3 4

3 2

3 2

1 2050

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16

Holder for height adjustment – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left) 3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left)

Page 1 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Upper suspension part

8

(2) Bowden pull wire for height adjustment (downwards) (3) Bowden pull wire for height adjustment (upwards)

1

7

2

8

10 6

8

9

10

5

(4) Handle for height adjustment ................... to replace, if necessary

3

3

(5) Bowden pull wire for vertical shock absorber adjustment

2

7

4

7 11

(6) Support (7) Clamp (at the support)

2

8

7 3

1

6 5

F 11

(8) Round head screw (inner race).......................... 2.5 Nm

1

F F

(9) Lever................................ to grease (10) Blind rivet

12

9 2

(11) Compression spring

4

(12) Socket.............................. to grease 4

3

2051

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left)

Page 2 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

8 1

2 Remove the center and rear covers (Chap. 3.2).

7

2

8

2

8

7

10 6

8

3

1

3 Remove the left cover (see Chapter 3.3).

9

10

5 3

3 2

4 Detach the bellows at the upper suspension part (see Chapter 3.4).

7

4

7 11

6 5

F

Removal and installation

11 1

5

F F

WARNING Risk of crushing!

12

9

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

2 4 4

3

2051

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left)

Page 3 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Detach the Bowden pull wire for height adjustment at the level control in downward direction (see Chapter 3.12).

7 Detach the Bowden pull wire for height adjustment at the level control in upward direction (see Chapter 3.12).

8 1

7

2

8

2

8

7

10 6

8

3

1

9

10

5 3

3 2

8 Detach the Bowden pull wires (2, 3) at the respective clamp (7) of the support (6).

7

4

7 11

6 5

F

9 Press off the Bowden pull wire for vertical shock absorber adjustment (5) at the bottom of the support (6).

11 1

F F

10 Drill open the rivet head and drive the blind rivet (10) out of the socket (12).

12

9 2 4 4

3

2051

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left)

Page 4 of 5

REMOVAL / INSTALLATION

TABLE OF CONTENTS

11 Unscrew two round head screws (8).

Installation note: Round head screw (8), 2.5 Nm. 12 For easier removal of the Bowden pull wires (2, 3), pull the lever (9) together with the support (6) out of the upper suspension part (1) as far as possible.

13 Detach the Bowden pull wires (2, 3) each at the lever (9) and at the support (6).

8 1

7

2

8

2

8

7

10 6

8

3

1

9

10

5 3

3 2

7

4

7 11

6 5

F 11

14 Drive out the socket (12) at the lever (9) and at the support (6).

Installation note: Apply acid-free multi-purpose lubricant to the entire external surface (F) of the socket (12).

1

F F

12

9 2 4 4

3

2051

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.1 Holder for height adjustment – removal and installation (seat suspension with handle on the left)

Page 5 of 5

REMOVAL / INSTALLATION 15 Pull out the support (6) at the lever (9) and remove two compression springs (11).

Installation notes: • The compression springs (11) must lie on the respective hook (arrows).

• Apply acid-free multi-purpose lubricant to the inner surfaces (F) of the lever (9).

16 If the handle for height adjustment (4) is defective: Remove the handle for height adjustment (4) (Chapter 3.15).

TABLE OF CONTENTS

8 1

7

2

8

2

8

7

10 6

8

3

1

9

10

5 3

3 2

7

4

7 11

6 5

F 11 1

17 Re-install the components in the reverse order of their removal.

F F

12

9 2 4 4

3

2051

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front)

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Upper suspension part

1

(2) Bowden pull wire for height adjustment (upwards)

4

2

(3) Bowden pull wire for height adjustment (downwards)

4

6

2

(4) Round head screw (inner race).......................... 2.5 Nm (5) Support

6

3

5

(6) Clamp (at the support)

7

3

(7) Handle for height adjustment ................... to replace, if necessary 3

3

2

2

2 6

5

6

3

5 7

7 2383

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front)

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

1 4

2 Remove the center and rear covers (Chap. 3.2).

2 4

3 Remove the bellows at the front of the upper suspension part (see Chapter 3.4).

6

2

6

3

5

4 Remove the front cover (Chap. 3.27).

7

3

Removal and installation 3

5

3

2

2

2 6

5

6

3

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

5 7

7 2383

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front)

Page 3 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Detach the Bowden pull wire for height adjustment (3) at the level control in downward direction (see Chapter 3.12).

1 4

4

7 Detach the Bowden pull wire for height adjustment (2) at the level control in upward direction (see Chapter 3.12).

6

2

6

3

5

8 Unscrew three round head screws (4).

Installation note: Round head screw (4), 2.5 Nm.

7

9 For easier removal of the Bowden pull wires (2, 3), pull the support (5) together with the handle for height adjustment (7) out of the upper suspension part (1) in downward direction as far as possible.

10 Detach the Bowden pull wires (2, 3) at the respective clamp (6) of the support (5).

2

3

3

3

2

2

2 6

5

6

3

5 7

7 2383

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.16.2 Holder for height adjustment – removal and installation (seat suspension with handle at the front)

Page 4 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

11 Pull the handle for height adjustment (7) upwards and detach the Bowden pull wire for height adjustment in upward direction (2) at the support (5).

Note: After being detached, the Bowden pull wire for height adjustment in upward direction (2) is loose.

1 4

2 4

6

2

6

3

5

12 Detach the Bowden pull wire for height adjustment in downward direction (3) at the support (5) and remove the support (5) with the handle for height adjustment (7).

7

3

3

3

2

2

2 6

13 If the handle for height adjustment (7) is defective: Remove the handle for height adjustment (7) (Chapter 3.15).

14 Re-install the components in the reverse order of their removal.

5

6

3

5 7

7 2383

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17

Bowden pull wires for height adjustment – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) 3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front)

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 1 of 5

TABLE OF CONTENTS

(1) Bowden pull wire for height adjustment in downward direction (2) Bowden pull wire for height adjustment in upward direction

3 4

(3) Upper suspension part

2 1

(4) Bowden pull wire for vertical shock absorber adjustment

1

5 3

(5) Through anchor 4

3 1

3

5

2 2 2052

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 2 of 5

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

2 Remove the center and rear covers (Chap. 3.2).

3 4

3 Remove the left cover (see Chapter 3.3).

2 1

1

5 3

4 Detach the bellows at the upper suspension part (see Chapter 3.4).

4

Removal and installation

5

WARNING Risk of crushing!

3

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

1

3

5

2 2 2052

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 6

Page 3 of 5

TABLE OF CONTENTS

Removal of Bowden pull wire for height adjustment in downward direction (1): 3

6.1 Detach the Bowden pull wire at the level control (see Chapter 3.12).

4

2 1

6.2 Detach the Bowden pull wire at the holder for height adjustment (see Chapter 3.16).

6.3 Mark the installation position of the Bowden pull wire (1) and pull out the Bowden pull wire (1) at the upper suspension part (3) in upward direction.

Installation notes: • Install the Bowden pull wire (1) according to the marking.

• The Bowden pull wire (1) should be placed in front of the Bowden pull wire for vertical shock absorber adjustment (4) (arrow).

• Adjust the new Bowden pull wire (1) to the length of the old one (1) (excess length of the wire).

1

5 3

4

3 1

3

5

2 2 2052

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION 7

Page 4 of 5

TABLE OF CONTENTS

Removal of Bowden pull wire for height adjustment in upward direction (2): 3

7.1 Detach the Bowden pull wire at the level control (see Chapter 3.12).

4

2 1

1

5 3

7.2 Detach the Bowden pull wire at the holder for height adjustment (see Chapter 3.16).

7.3 Pull out two through anchors (5) at the upper suspension part (3) and detach them at the Bowden pull wire (2).

4

3 1

3

5

2 2 2052

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.1 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle on the left) REMOVAL / INSTALLATION

Page 5 of 5

TABLE OF CONTENTS

7.4 Mark the installation position of the Bowden pull wire (2) and pull out the Bowden pull wire (2) at the upper suspension part (3) in upward direction.

Installation notes: • Install the Bowden pull wire (2) according to the marking.

• Adjust the new Bowden pull wire (2) to the length of the old one (2) (excess length of the wire).

3 4

2 1

1

5 3

4

8 Re-install the components in the reverse order of their removal.

3 1

3

5

2 2 2052

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 1 of 4

TABLE OF CONTENTS

(1) Bowden pull wire for height adjustment in upward direction

3

(2) Bowden pull wire for height adjustment in downward direction

2

1

(3) Upper suspension part (4) Front plate (at upper suspension part)

4

(5) Clamp (6) U-shaped rail (at upper suspension part)

3 2

5

6

3

2

1

4 2384

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION

Page 2 of 4

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

3 2

1

2 Remove the center and rear covers (Chap. 3.2).

3 Detach the bellows at the upper suspension part (see Chapter 3.4).

4

4 Remove the front cover (Chap. 3.27).

Removal and installation

5

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

3 2

5

6

3

2

1

4 2384

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION 6

Page 3 of 4

TABLE OF CONTENTS

Removal of Bowden pull wire for height adjustment in downward direction (2):

3 2

1

6.1 Detach the Bowden pull wire at the level control (see Chapter 3.12).

4

6.2 Detach the Bowden pull wire at the holder for height adjustment (see Chapter 3.16).

6.3 Detach the Bowden pull wire (2) at the clamp (5).

6.4 Mark the installation position of the Bowden pull wire (2), pull out the Bowden pull wire (1) to the left through the aperture (arrow) of the U-shaped rail (6) and remove it.

Installation notes: • Install the Bowden pull wire (2) according to the marking.

• Adjust the new Bowden pull wire (2) to the length of the old one (2) (excess length of the wire).

3 2

5

6

3

2

1

4 2384

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.17.2 Bowden pull wires for height adjustment – removal and installation (seat suspension with handle at the front) REMOVAL / INSTALLATION 7

Page 4 of 4

TABLE OF CONTENTS

Removal of Bowden pull wire for height adjustment in upward direction (1):

3 2

1

7.1 Detach the Bowden pull wire at the level control (see Chapter 3.12).

4

7.2 Detach the Bowden pull wire at the holder for height adjustment (see Chapter 3.16).

7.3 Mark the installation position of the Bowden pull wire (1) and pull out the Bowden pull wire (1) in upward direction between the front plate (4) and the upper suspension part (3).

Installation notes: • Install the Bowden pull wire (1) according to the marking.

• Adjust the new Bowden pull wire (1) to the length of the old one (1) (excess length of the wire).

8 Re-install the components in the reverse order of their removal.

3 2

5

6

3

2

1

4 2384

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 1 of 10

TABLE OF CONTENTS

(1) Bowden pull wire for height adjustment in downward direction

14

A

13

16

18

(2) Bowden pull wire for height adjustment in upward direction

2

(3) Handle for height adjustment

14

19

15

(4) Level control

17

20

2

1

(5) Regulating screw 13

(6) Clamp

21

4

(7) Counternut (8) Lock nut (9) Lock nut (10) Counternut (11) Clamp (12) Regulating screw

2

5 6 7 8

1

9 10 11 12

4

(13) Holder for Bowden wire end cap

1

(14) Bowden pull wire lever 2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 2 of 10

TABLE OF CONTENTS

(15) Retracting spring

14

A

(16) Outlet valve

13

16

18

(17) Valve tappets

2

(18) Valve lever

14

(19) Cam disk

19

15

20

2

(20) Suspension device (21) Leveling valve

13

2

21

5 6 7 8

1

9 10 11 12

17

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 3 of 10

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

14

A

2 Remove the center and rear covers (Chap. 3.2).

13

16

17 18

2 14

19

15

3 Preparatory work for seat suspension with handle on the left: Remove the left cover (see Chapter 3.3).

20

2 13

21

1

4

4 Preparatory work for seat suspension with handle at the front: Remove the front cover (Chap. 3.27).

2

5 6 7 8

1

9 10 11 12

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

TABLE OF CONTENTS

Inspection of seat suspension with handle on the left

14

A

4 Pull up and press down the handle for height adjustment (3) several times and check the following: • easy running of the Bowden pull wires (1, 2) • smooth operation of the Bowden pull wire lever (14), valve lever (18) and valve tappets (17) at the outlet valve (16).

5 Check the neutral position of the handle for height adjustment (3) and the tensile force of the retracting spring (15) at the level control (4): • The retracting spring (15) must set the handle for height adjustment (3) in neutral position.

• The retracting spring (15) must tighten the Bowden pull wires (1, 2) and hold the Bowden pull wire lever (14) in neutral position.

Page 4 of 10

13

16

17 18

2 14

19

15

20

2 13

2

21

5 6 7 8

1

9 10 11 12

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 5 of 10

TABLE OF CONTENTS

6 Check the clearance between the Bowden pull wire lever (14) and the holder for the Bowden pull wire end cap (13).

Specified value: Clearance (A) = 2 mm with the handle for height adjustment (3) pulled up.

Note: When the specified value exceeds 2 mm, the suspension cannot be lifted above the middle position.

14

A

13

16

17 18

2 14

19

15

20

2 13

2

21

5 6 7 8

1

9 10 11 12

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

TABLE OF CONTENTS

Adjustment of seat suspension with handle on the left 1

14

A

Adjustment of Bowden pull wire for height adjustment in upward direction (2):

13

16

17 18

2 14

19

15

1.1 Detach the regulating screw (12) at the clamp (11).

1.2 Loosen the counternut (10) and adjust the clearance between the Bowden pull wire lever (14) and the holder for Bowden pull wire end cap (13) using the lock nut (9).

Notes: • Specified value: Clearance (A) = 2 mm.

• Turn the lock nut (9) towards the regulating screw (12) to lengthen the Bowden pull wire (2) (clearance (A) increases).

• Turn the lock nut (9) away from the regulating screw (12) to shorten the Bowden pull wire (2) (clearance (A) decreases).

Page 6 of 10

20

2 13

2

21

5 6 7 8

1

9 10 11 12

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 7 of 10

TABLE OF CONTENTS

1.3 Secure the lock nut (9) with the counternut (10) and make sure not to distort the Bowden pull wire (2).

14

A

13

16

17 18

2

1.4 Hang in the regulating screw (12) at the clamp (11).

14

19

15

20

2

1.5 Operate the handle for height adjustment (3) several times and check the specified value; repeat the adjustment, if necessary.

13

2

21

5 6 7 8

1

9 10 11 12

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT 2

Page 8 of 10

TABLE OF CONTENTS

Adjustment of Bowden pull wire for height adjustment in downward direction (1):

14

A

13

16

17 18

2

2.1 Detach the regulating screw (5) at the clamp (6).

14

19

15

2.2 Loosen the counternut (7) and adjust the tension of the Bowden pull wire (1) at the level control (4) using the lock nut (8).

Notes: • Turn the lock nut (8) towards the regulating screw (5) to lengthen the Bowden pull wire (1).

• Turn the lock nut (8) away from the regulating screw (5) to shorten the Bowden pull wire (1).

• Specified value: The Bowden pull wire (1) must be tightened at the suspension device (20) of the level control (4), but not prestressed.

20

2 13

2

21

5 6 7 8

1

9 10 11 12

1

4

4 1

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 9 of 10

TABLE OF CONTENTS

2.3 Secure the lock nut (8) with the counternut (7) and make sure not to distort the Bowden pull wire (1).

14

A

13

16

17 18

2

2.4 Hang in the regulating screw (5) at the clamp (6).

14

19

15

20

2

2.5 Operate the handle for height adjustment (3) several times and check the tension; repeat the adjustment, if necessary.

13

21

1

4

3 Seat suspension with handle at the front: Install the front cover (Chapter 3.27).

4 Seat suspension with handle on the left: Install the left cover (see Chapter 3.3).

2

5 6 7 8

1

9 10 11 12

4 1

5 Install the center and rear covers (Chap. 3.2).

6 Install the upper seat part at the seat suspension (see Chapter 3.1).

2 3 3 2053

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.18

Bowden pull wires for height adjustment – inspection and adjustment

INSPECTION/ADJUSTMENT

Page 10 of 10

TABLE OF CONTENTS

Inspection and adjustment of seat suspension with handle at the front 1 To inspect and adjust the seat suspension with handle at the front, carry out the same steps which have to be carried out for the seat suspension with handle on the left.

13

14

A

16

17 18

2 14

19

15

20

2 13

21

9 10

12

5

7

4

8 2

2

1 11

1

1

6

3

3 2386

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.19

Air spring – removal and installation

Page 1 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Lower suspension part

90°

(2) Air spring

3

(3) Swinging structure (4) Countersunk screw (inner race)............................. 6 Nm (5) Step (at the air spring)

3

1 2 2 1

4

2

5 4

1 2054

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.19

Air spring – removal and installation

Page 2 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the bellows from the upper suspension part (see Chapter 3.4).

90°

3

Removal and installation

2

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it at the rear between the swinging structure and the lower suspension part by means of suitable spacers.

3

1 2 2 1

3

WARNING The pressure in the pneumatic system might cause injury!

The pneumatic system is to be vented before removing the air spring (2).

4

2

5 4

1 2054

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.19

Air spring – removal and installation

Page 3 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4 Remove the compressed-air hose from the air spring (see Chapter 3.14).

90°

3

5 Remove the air intake hose from the air spring (see Chapter 3.14).

6 Unscrew the countersunk screw (4) from the air spring (2).

Installation notes: • Countersunk screw (4), 6 Nm. • The internal thread collar (arrow) at the bottom of the air spring (2) must lie flush in the drill hole (arrow) of the lower suspension part (1).

3

1 2 2

7 Turn the air spring (2) by 90° until the bayonet catch fits through the longitudinal hole in the swinging structure (3).

1

4

2

5 4

1 2054

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.19

Air spring – removal and installation

Page 4 of 4

REMOVAL / INSTALLATION

TABLE OF CONTENTS

8 Press the air spring (2) down and pull the bayonet catch out of the swinging structure (3).

9 Remove the air spring (2) from the seat suspension.

Installation note: The step (5) at the bottom of the air spring (2) must click into place in the cut-out (arrow) of the lower suspension part (1).

90°

3

3

1

10 Re-install the components in the reverse order of their removal.

2 2 1

4

2

5 4

1 2054

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 1 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Additional air supply (2) Upper suspension part

2

(3) Sealing ring

5

(4) Rounded head screw (inner race)......................... 2.5 Nm (5) Blind rivet

7 7

(6) Support

4

1

(7) Air hose (level control) (8) Air hose (level control)

9

6

1

8

2

8 9

4 6

5 1

3

(9) Air intake hose 2

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 2 of 6

REMOVAL / INSTALLATION

ATTENTION Leak test!

TABLE OF CONTENTS

2 5

The leak test of the seat suspension should be performed upon installation of the additional air supply (1). To do this, apply 60 kg load to the suspension for 24 hours. The lowering within this time must not exceed 15 mm.

7 7 9

6 4

1

1

8

2

8 9

4 6

5 1

3

1 Remove the right cover (see Chapter 3.3).

2

2 Remove the bellows from the upper suspension part (see Chapter 3.4).

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 3 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation 2

3

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

4

5

WARNING Risk of crushing!

7 7

4

1

1

2

8 9

4 6

5 1

3

WARNING The pressure in the pneumatic system might cause injury!

The pneumatic system is to be vented before removing the additional air supply (1).

9

6

8

2

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 4 of 6

REMOVAL / INSTALLATION

5

ATTENTION Damage!

Take care not to damage the connections (mandrel profiles) of the additional air supply (1) and of the air hoses (7, 8, 9). Do not lift off the air hoses (7, 8, 9) at the connections (arrows) of the additional air supply (1) by means of a screwdriver.

Mark the air hoses (7, 8, 9) and cut them off in a clean and straight way directly behind the connections (arrows) of the additional air supply (1).

Installation notes: • Install the air hoses (7, 8, 9) according to the marking.

• Slightly heat the air hoses (7, 8, 9) and then push them completely onto the corresponding connections (arrows) of the additional air supply (1) by exerting pressure.

TABLE OF CONTENTS

2 5 7 7 9

6 4

1

1

8

2

8 9

4 6

5 1

3

2

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 5 of 6

REMOVAL / INSTALLATION Notes: • The air hoses (7, 8, 9) can be cut off only once.

• After cutting, mark the air hoses (7, 8, 9) in order not to cut them several times.

TABLE OF CONTENTS

2 5 7 7 9

6

6 Bore out the rivet head and drive out the blind rivet (5).

4

1

1

8

2

8 9

4 6

5

7 Hang out the additional air supply (1) at the upper suspension part (2) and remove it.

Installation note: The nose (arrow) at the top part of the support (6) must click into place in the longitudinal hole (arrow) of the upper suspension part (2).

1

3

2

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.20

Additional air supply – removal and installation

Page 6 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

8 Pull off the sealing ring (3) at the additional air supply (1).

2

9 Unscrew the rounded head screw (4) and remove the support (6) at the additional air supply (1).

Installation note: Rounded head screw (4), 2.5 Nm.

5 7 7

4

1

10 Re-install the components in the reverse order of their removal.

9

6

1

8

2

8 9

4 6

5 1

3

2

1

2055

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.21

Cable harness of vehicle connection – removal and installation

REMOVAL / INSTALLATION

Page 1 of 2 TABLE OF CONTENTS

(1) Cable harness for vehicle connection (2) Upper suspension part (3) Bellows (4) Plug (cable harness of seat suspension) (5) Socket (cable harness for vehicle connection) (6) Clamp

1 Remove the rear cover (see Chapter 3.2).

2 Detach the bellows at the rear of the upper suspension part (see Chapter 3.4).

Press the bellows down where it is detached.

2056

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.21

Cable harness of vehicle connection – removal and installation

REMOVAL / INSTALLATION

Page 2 of 2 TABLE OF CONTENTS

Removal and installation 3 Detach the cable harness for vehicle connection (1) at the clamp (6).

4 Disconnect the electrical connection between the plug (4) and the socket (5).

5 Remove the cable harness for vehicle connection (1).

Installation note: The cable harness for vehicle connection (1) is guided out on the rear right (arrow) between the bellows (3) and the upper suspension part (2).

6 Re-install the components in the reverse order of their removal.

2056

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22

Cable harness of seat suspension – removal and installation

Page 1 of 1

TABLE OF CONTENTS 3.22.1 Cable harness for seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation 3.22.2 Cable harness for seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION

Page 1 of 6

TABLE OF CONTENTS

(1) Entire cable harness (2) U-profile

(5) Swinging structure

17

18

(3) Level control (4) Upper suspension part

4

4 13

7

17

16

15

(9) Right-angle plug

14

13

9

3

1

8

11 12

(7) Plastic clip (8) Plastic clip

16

13

2

(6) Compressor

2

9

7

1

14 19 19

1

12

14

14 10

(10) Blind rivet

2

(11) Holding plate

1 4

(12) Plastic clip (13) Plug

3

9

(14) Plastic clip

1

(15) Blind rivet

7

8 1

8

9

5

6

6

5

2057

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION

Page 2 of 6

TABLE OF CONTENTS

(16) Clamp (17) Plug (cable harness of seat suspension) (18) Socket (cable harness for vehicle connection)

17

18

17

(20) Linkage rod (see page 6)

16

13

9

3

1

8

11 12 14

16

13

2

15

2

13

7

(19) Air hose

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

4

4

9

7

1

14 19 19

1

12

14

14 10 2 1

2 Remove the center and rear covers (Chap. 3.2).

4

3 Take off the bellows from the upper suspension part (see Chapter 3.4).

3

9 1

7

8 1

8

9

5

6

6

5

2057

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION

Page 3 of 6

TABLE OF CONTENTS

Removal and installation

4

17

17

15

4

1

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

2

13

4

16

13 3

2

1

14 19 19

18

1

12

14

5 Mark the installation position of the cable harness of the seat suspension (1).

2 1 4

6 Disconnect the electrical connection between the plug (17) and the socket (18).

3

9 1

7 Bore out the rivet head and drive out the blind rivet (15) at the U-profile (2) and at the upper suspension part (4).

7

8 1

8

9

5

6

6

5

2058

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION

Page 4 of 6

TABLE OF CONTENTS

8 Detach the U-profile (2) at the upper suspension part (4) and lay it down with the cable harness (1).

4

17

17

15 1

9 Mark two plugs (13) and disconnect the electrical connection between the plugs (13) and the level control (3).

Installation note: Reconnect the electrical connection according to the marking.

2

13

4

16

13 3

2

1

14 19 19

18

1

12

14

10 Pull out two plastic clips (14) at the level control (3).

2 1

11 Thread the cable harness for seat suspension (1) in downward direction between the air hoses (19) and the level control (3).

4 3

9 1

7

8 1

8

9

5

6

6

5

2058

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION

TABLE OF CONTENTS

12 Detach the cable harness of the seat suspension (1) at the clamp (16).

4

4

17

18

13 Pull out the plastic clip (12) at the upper suspension part (4).

15 Pull out two plastic clips (7) at the upper suspension part (4).

16

13

9

3

1

8

11 12 14

16

13 17

15

2

13

7 2

14 Bore out two rivet heads and drive out the blind rivets (10) at the holding plate (11) and at the upper suspension part (4).

Page 5 of 6

9

7

1

14 19 19

1

12

14

14 10 2 1

16 Pull out the plastic clip (8) at the swinging structure (5).

4 3

9 1

7

8 1

8

9

5

6

6

5

2057

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.1 Cable harness of seat suspension with vehicle plug integrated at the rear of the upper suspension part – removal and installation REMOVAL / INSTALLATION 17 Mark two right-angle plugs (9) and disconnect the electrical connection between the right-angle plug (9) and the compressor (6).

Installation notes: • Reconnect the electrical connection according to the marking.

• When establishing the electrical connection, the cable output at the right-angle plug (9) must point downwards.

Page 6 of 6

TABLE OF CONTENTS

4

4 18 7 2 17

16 11 12

15 14

13

1

8 9

9

20

7

1

14 10

4

18 Pull out and remove the cable harness of the seat suspension (1) between the linkage rod (20) and the upper suspension part (4).

Installation note: Install the cable harness of the seat suspension (1) according to the marking.

2 1

3 1

7

9

19 Re-install the components in the reverse order of their removal.

8 1

8

9

5

6

6

5

2059

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.2 Cable harness of seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation REMOVAL / INSTALLATION

TABLE OF CONTENTS D

(1) Plug (cable harness for seat suspension) (4-pin) (2) Cable tie

Page 1 of 5

14

14

A

1

2

(3) Cable harness for seat suspension

7 3

(4) Cable tie with bracket 4

(5) Cable clamp (6) Corrugated pipe support

C

(7) Upper suspension part

6 12

(8) Rivet head

6

5

(9) Holding plate (10) Air hose between compressor and additional air supply

11

3

13

11

3 6 8

(11) Cable to compressor

7 8

9

(12) Cable connector (13) Plug (cable harness for seat suspension) (8-pin) B

(14) Cable tie with bracket

10 6

9

2876

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.2 Cable harness of seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

2 Remove the centre cover (see Chapter 3.2).

Page 2 of 5

D

14

14

A

1

2

7 3

3 Detach the bellows at the upper suspension part (see Chapter 3.4).

4

11

3 C

Removal and installation

6 12

4

6

5 13

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

11

3 6 8

7 8

9

B

5 Disconnect two electrical connections (B) at the compressor (see Chapter 3.11).

10 6

9

2876

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.2 Cable harness of seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation REMOVAL / INSTALLATION 6 Disconnect the electrical connection (A) at the cable harness for vehicle connection.

Page 3 of 5

TABLE OF CONTENTS D

14

14

A

1

2

7 Disconnect the electrical connection (C), blue and red lines (see Chapter 3.12).

7 3 4

11

3

8 Mark the points where the cable harness (3) is attached to the seat suspension.

For seat suspensions with cable exit on the right side: • 4 corrugated pipe supports (6) • 1 cable connector (12) • 1 cable tie with bracket (4)

C 6 12

6

5 13

11

3 6 8

7 8

9

For seat suspensions with cable exit on the left side (D): • 3 corrugated pipe supports (6) • 1 cable connector (12) • 2 cable ties with brackets (14).

B 10 6

9

2876

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.2 Cable harness of seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation REMOVAL / INSTALLATION 9 Remove the corrugated pipe supports (6) and the cable connector (12) at the air hose (10).

Page 4 of 5

TABLE OF CONTENTS D

14

14

A

1

2

10 Press the cable tie with bracket (4 or 14) out of the upper part of the suspension (7).

7 3 4

11

3

11 Bore out two rivet heads (8) and drive out the remaining blind rivets at the holding plate (9) and at the upper suspension part (7).

C 6 12

6

5 13

12 Lay down the plug (13) with the angle plate (9).

11

3 6 8

7 8

9

B 10 6

9

2876

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.22.2 Cable harness of seat suspension with vehicle plug integrated at the outside of the cable harness – removal and installation REMOVAL / INSTALLATION 13 Note: Depending on the design of the seat, the mounting position of the cable harness (3) may be different.

Accordingly, the method of attachment can also different to be terms of the representation.

Therefore, it is important to mark the method of attachment of the cable harness (3) and then pull out the cable harness (3) from the seatsuspension.

Installation notes: ● Install the cable harness (3) according to the marking. ● For seat suspensions with cable exit on the left side: fasten the cable to the compressor (11) and cable harness (3) at the indicated locations (D) to the upper suspension part (7) with two cable ties with brackets (14).

14 Re-install the components in the reverse order of their removal.

Page 5 of 5

TABLE OF CONTENTS D

14

14

A

1

2

7 3 4

11

3 C 6 12

6

5 13

11

3 6 8

7 8

9

B 10 6

9

2876

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 1 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Upper suspension part

C

A

(2) Guiding rail (at the upper suspension part) .............. to grease

1

45°

B 2 1

(3) Swinging structure 5

(4) Roller (rear) (5) Roller (front)

3

4 F

2

2

Notes: • The locking mechanism for the fore/aft isolator is preassembled at the upper suspension part (1) (see Chapter 3.7).

• Moreover, a buffer and three clamps are preassembled at the upper suspension part (see Chapters 3.10, 3.14, 3.21 and 3.22).

• Reuse or convert assemblies which are not included in the scope of delivery of the new upper suspension part (1).

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 2 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Remove the upper seat part from the seat suspension (see Chapter 3.1).

C

A 1

B 2

2 Remove the center and rear covers (Chap. 3.2).

1 5

3 Remove the left and right covers (Chap. 3.3).

3

4 F

4 Take off the bellows from the upper suspension part (see Chapter 3.4).

5 Remove the Bowden pull wire and the handle for vertical shock absorber adjustment at the upper suspension part (see Chapter 3.5).

Note: The Bowden pull wire does not have to be removed at the vertical shock absorber.

45°

2

2

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 3 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

6 Remove the longitudinal horizontal shock absorber (Chapter 3.9).

1

7 Remove the fore/aft isolator unit at the upper suspension part (see Chapter 3.10).

Note: The clamp remains attached to the swinging structure.

45°

B 2 1

5 3

4 F

2

2

8 Remove the holder for height adjustment (Chap. 3.16).

4

9 Remove the Bowden pull wires for height adjustment (Chap. 3.17).

10 Remove the cable harness for vehicle connection (Chap. 3.21).

C

A

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 4 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

11 If the locking mechanism for the fore/aft isolator is preassembled: Remove the handle for the fore/aft isolator at the L-bar of the upper suspension part (see Chapter 3.8).

Note: The handle does not have to be removed from the linkage rod.

1

45°

B 2 1

5 3

4 F

12 If the locking mechanism for the fore/aft isolator is not preassembled: Remove the locking mechanism for the fore/aft isolator (Chap. 3.7).

13 Remove the cable harness of the seat suspension with the U-profile at the upper suspension part (see Chapter 3.22) and lay the cable harness of the seat suspension down.

C

A

2

2

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 5 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

14 Detach the air intake hose on the rear right at the clamp of the upper suspension part (see Chapter 3.14).

C

A 1

45°

B 2 1

15 Remove the level control at the upper suspension part (see Chapter 3.12) and lay it down.

Notes: • The cable harness of the seat suspension does not have to be removed from the level control.

• The belt retractor of the level control is tensioned; hold the level control and carefully guide it down.

5 3

4 F

2

2

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 6 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

16 Remove the additional air supply at the upper suspension part (see Chapter 3.20) and lay it down.

Note: The air hoses do not have to be removed from the additional air supply.

C

A 1

45°

B 2 1

5 3

4 F

Removal and installation

2

2

17

WARNING Risk of crushing!

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 7 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

18 Push the upper suspension part (1) forwards (arrow A) until the cut-outs (arrow) on the left and right sides at the guiding rails (2) are located at the same height with the front rollers (5).

C

A 1

B 2 1

5 3

4 F

19 Lift out the upper suspension part (1) over the front rollers (5).

20 Laterally turn the upper suspension part (1) by approx. 45° (arrow B) and then lift it off the rear rollers (4) in upward direction (arrow C).

Installation note: Apply acid-free multi-purpose lubricant to the two guiding rails (2) at the side surfaces (F) of the rollers (4, 5).

45°

2

2

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.23

Upper suspension part – removal and installation

Page 8 of 8

REMOVAL / INSTALLATION

TABLE OF CONTENTS

21 Pull the two front rollers (5) and the two rear rollers (4) off the axles of the swinging structure (3).

C

A 1

45°

B 2 1

22 Re-install the components in the reverse order of their removal.

5 3

4 F

2

2

4

3

5 4

5

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 1 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Lower suspension part

8

(2) Guiding rail (at the lower suspension part) .............. to grease

45°

B C

(3) End stop *) (4) Buffer (5) Fixed bearing

5

(6) Swinging structure

A

(7) Roller

7

(8) Upper suspension part

3

(9) Collar screw (inner race)....................................... 6 Nm 9

3

1

4

10 F

*) preassembled

5

2

(10) Micro-encapsulated hexagon nut....................... to replace, 25 Nm (11) Countersunk screw

6

4

1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 2 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

1 Take off the bellows at the lower suspension part (see Chapter 3.4), push it upwards and fix it at the lower suspension part (8).

8 45°

B C

2 Remove the compressor (Chap. 3.11).

Note: Alternatively, the compressed-air hose may remain installed at the compressor. To be protected against shocks and impacts, the compressor must be fixed (e.g. by means of adhesive tape at the swinging structure (6)).

3 Remove the webbing of the level control at the lower suspension part (see Chapter 3.12).

5

A

7 3

6

4

5

2 9 3

1

4

10 F 1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 3 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

4 Pull out the clip intended for fastening the air intake hose at the lower suspension part (see Chapter 3.14).

8 45°

B C

5 Unscrew the countersunk screw at the lower suspension part intended for fastening the air spring (see Chapter 3.19).

5

A

7

Removal and installation 3

6

4

6

5

2

WARNING Risk of crushing!

9

Move the seat suspension to the highest position and secure it between the swinging structure and the lower suspension part by means of suitable spacers.

3

1

4

10 F 1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 4 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

7 Unscrew two micro-encapsulated hexagon nuts (10) and pull out the countersunk screws (11) at the lower suspension part (1).

Installation notes: • Replace the micro-encapsulated hexagon nut (10); 25 Nm. • The cam (arrow) at the head of the countersunk screw (11) acts as antirotation device and must engage in the groove (arrow) of the lower suspension part (1).

8 Unscrew two collar screws (9) and remove the end stops (3) with the buffer (4) from the guiding rails (2).

Installation note: Collar screw (9), 6 Nm.

8 45°

B C

5

A

7 3

6

4

5

2 9 3

1

4

10 F 1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 5 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

9 Push the swinging structure (6) backwards (arrow A) until the two fixed bearings (5) at the swinging structure (6) fit through the cut-out (arrows) of the left and right guiding rail (2) of the lower suspension part (1).

8 45°

B C

5

A

10 Lift the swinging structure (6) with the two fixed bearings (5) out of the guiding rails (2) of the lower suspension part (1) at the front.

7 3

6

4

5

2 9 3

1

4

10 F 1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.24

Lower suspension part – removal and installation

Page 6 of 6

REMOVAL / INSTALLATION

TABLE OF CONTENTS

11 Laterally turn the swinging structure (6) including the attached upper suspension part (8) by approx. 45° (arrow B) in order to pull the two rollers (7) out of the guiding rails (2) and then lift it off in upward direction (arrow C).

Installation note: Apply acid-free multi-purpose lubricant to the side surfaces (F) of the two guiding rails (2) where the rollers are moved.

8 45°

B C

5

7 3

6

4

12 Remove the lower suspension part (1).

13 Re-install the components in the reverse order of their removal.

A

5

2 9 3

1

4

10 F 1 11 11

10 2

F 11

9 7 11

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.25

Swinging structure – disassembly and assembly

Page 1 of 1

DISASSEMBLY / ASSEMBLY

TABLE OF CONTENTS

(1) Swinging structure 3

(2) Clearance spacer (if required) thickness ................... 0.2 or 0.5 mm

2 3

(3) Roller ......... max. clearance 0.3 mm

2

(4) Buffer 3

(5) Fixed bearing

2

(6) Tube section (7) Central bearing (of the swinging structure) Installation note: Apply acid-free multi-purpose lubricant (F) to the central bearing (7).

1

7

F 2

4 F 5 7

6

2 2

Note: If the swinging structure (1) is defective, the entire seat suspension will be replaced (see Chapter 3.1).

3

3

3

4 5 6

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Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.26

Worn parts – replacement

Page 1 of 3

REPLACEMENT

TABLE OF CONTENTS

(1) Micro-encapsulated hexagon nut ............................ to replace, 25 Nm (see Chapters 3.13 and 3.24)

2

1

3

4

5

(2) Buffer (see Chapter 3.10) (3) Fixed bearing (see Chapter 3.25)

6

8

7

9

10

(4) Roller (see Chapter 3.25) (5) Clearance spacer (see Chapter 3.9) (6) Blind rivet (5 x 10) (see Chapters 3.16, 3.20, and 3.22)

11

14

13

12

15

(7) Blind rivet (4.8 x 15.5) (see Chapter 3.10) (8) Buffer (see Chapter 3.10) 16

17

18

19

20 *)

21 *)

MeDok-2061

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.26

Worn parts – replacement

Page 2 of 3

REPLACEMENT

TABLE OF CONTENTS

(9) Socket (see Chapter 3.10)

2

1

3

4

5

(10) Countersunk screw (inner race)............................. 6 Nm (see Chapter 3.19) (11) Buffer (see Chapter 3.25)

6

8

7

9

10

(12) Collar screw (inner race)............................. 6 Nm (see Chapter 3.24) (13) End stop (see Chapter 3.24)

11

14

13

12

15

(14) Buffer (see Chapter 3.24) (15) Countersunk screw (see Chapter 3.24) (16) Cable tie (3.6 x 200) (see Chapter 3.1) (17) Cable tie (7.6 x 387) (see Chapter 3.11)

16

17

18

19

20 *)

21 *)

MeDok-2061

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.26

Worn parts – replacement

Page 3 of 3

REPLACEMENT

TABLE OF CONTENTS

(18) Bellows pin (see Chapters 3.2 and 3.4)

2

1

3

4

5

(19) Micro-encapsulated cap screw (M8 x 12)............. to replace, 25 Nm (see Chapter 3.1) (20) Micro-encapsulated cap screw (M8 x 16)............. to replace, 25 Nm *) not required for this seat model

6

8

7

9

10

(21) Expanding rivet *) not required for this seat model 11

16

14

13

12

17

18

19

15

20 *)

21 *)

MeDok-2061

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.27

Front cover – removal and installation (seat suspension with handle at the front)

Page 1 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

(1) Front cover

2 2

(2) Blind rivet (3) Upper suspension part (4) Bowden pull wire for height adjustment in upward direction

1

(5) Bowden pull wire for height adjustment in downward direction 3 4

1 Remove the upper seat part at the seat suspension (see Chapter 3.1).

5

2385

Material no. 1 160 241_e

Repair manual GRAMMER seat suspension MSG 97AL – June 2013

3.27

Front cover – removal and installation (seat suspension with handle at the front)

Page 2 of 2

REMOVAL / INSTALLATION

TABLE OF CONTENTS

Removal and installation

2 2

2 Bore out two rivet heads and drive out the blind rivets (2).

Installation note: During riveting of the front cover (1), make sure that the Bowden pull wires (4, 5) run beneath the front cover (1).

1

3 Remove the front cover (1) at the upper suspension part (3).

4 Re-install the components in the reverse order of their removal.

3 4

5

2385

Material no. 1 160 241_e