WORKSHOP MANUALFootrest T2/ T4 4.17.0 Undisplaceable footrest 4.17.0 Footrest componentsT2/ T4 4.18.0 Leg support 4.19.0 Leg support cover 4.19.0 Cylinder for folding the leg support

ERGOS CLT, CLT- PLAXTON

WORKSHOP MANUAL

PASSENGER SEATS

ERGOS CLT

ERGOS CLT-PLAXTON

ERGOS CLH

ERGOS MODEL YEAR

, CLH, MODEL YEAR (EDI. JAN. 2000) REV.1

ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 0.- INDEX

ERGOS CLT, CLT- PLAXTON, CLH, MODEL YEAR (EDI. JAN. 2000) REV.1 0.1.0

INDEX 1.- INTRODUCTION Presentation 1.1.0 2.- GENERAL INFORMATION Main characteristics 2.1.0 Description of components 2.2.0 3.- TROUBLESHOOTING 3.1.0 4.- REPAIR MODULES Upholstered cushion 4.2.0 Housing for cushion cover 4.2.0 Padding 4.3.0

Upholstered backrest 4.3.0 Back cover 4.4.0 Backrest base housing 4.4.0 Backrest housing 4.5.0

Ashtray compact 4.6.0 Gas spring assembly 4.7.0 Gas spring 4.8.0 Reclining lever window side 4.8.0

Back frame 4.9.0 Side corridor 4.10.0 Side separator 4.10.0

Reclining lever aisle 4.10.0 Arm 4.11.0 Arm assembly 4.11.0

Press button/ trim 4.12.0 Central arm assembly/ window with support 4.13.0 Central arm assembly/ window 4.13.0 Frame/ cushion housing 4.14.0 Leg for aisle side 4.14.0 Side support 4.14.0 Displaceable assembly 4.15.0 Tubes of displaceable assembly 4.16.0 Securing of displacement system 4.16.0

Footrest T2/ T4 4.17.0 Undisplaceable footrest 4.17.0 Footrest componentsT2/ T4 4.18.0 Leg support 4.19.0 Leg support cover 4.19.0 Cylinder for folding the leg support 4.19.0

Independent small table 4.20.0 Table latch 4.20.0

Ashtray 4.21.0 Magazine rack 4.21.0

Fixed two-point safety belt 4.22.0 Two-point safety belt woundable on the sides 4.23.0 Two-point woundable belt: centre and lower assembly 4.24.0

ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 0.- INDEX

ERGOS CLT, CLT- PLAXTON, CLH, MODEL YEAR (EDI. JAN. 2000) REV.1 0.2.0

INDEX

Three-point safety belt 4.26.0

Ergos CLH Versions Headrest 4.28.0 Headrest cover 4.28.0 Back and headrest assembly 4.29.0

Handle 4.29.0 Glass holder 4.29.0 Ashtray 4.30.0 Tray 4.30.0

Ergos Model Year Versions Upholstered cushion 4.32.0

Displaceable assembly 4.33.0 Displaceable assembly tubes 4.34.0 Securing of the displacement system 4.34.0

5.- TIGHTENING TORQUE 5.1.0

6.- RECOMMENDED LUBRICATION 6.1.0

7.- INITIAL USE 7.1.0

8.- MAINTENANCE INTERVALS 8.1.0

9.- MAINTENANCE INSTRUCTIONS Maintenance and upkeep of fitted carpeting 9.1.0 Maintenance of leather 9.3.0 Cleaning of plastics 9.3.0 Paint protection 9.3.0 Cleaning of ashtrays 9.3.0

10.- TABLE OF REPAIR TIMES 10.1.0

ASIENTOS ESTEBAN

ERGOS CLT, CLT – PLAXTON, CLH, MODEL YEAR 0.-GENERAL DATA

ALPHABETIC INDEX

AAccessories, description of 3.2.0Accessories, maintenance of 8.2.0Aisle side panel, change of 4.10.0Arm assembly, change of 4.11.0Arm, breakdowns of 3.1.0 3.2.0Arm, change of 4.11.0Arms, maintenance of 8.2.0Ashtray, change of 4.21.0Audio, maintenance of 8.2.0

BBack and headrest assembly, CLH, change of 4.29.0Back cover, change of 4.4.0Back frame, changing of 4.9.0Backrest casing, change of 4.5.0Backrest, breakdowns of 3.1.0Backrest, description of 2.2.0Backrest, maintenance of 8.1.0Bottom headrest casing, change of 4.4.0

CCasing cushion cover, change of 4.2.0Central arm assembly with support, change of 4.13.0Central arm assembly, change of 4.13.0CLH Ashtray, change of 4.30.0CLH glass holder, change of 4.29.0CLH Handle, change of 4.29.0CLH tray, change of 4.30.0Compact ashtray, change of 4.6.0Control elements and components 2.1.0Cushion casing, change of 4.14.0Cushion frame, changing of 4.14.0Cushion, maintenance of 8.1.0

DDisplaceable assem bly, change of 4.15.0Displaceable assem bly, M odel Year, change of 4.33.0Displaceable, m aintenance of the 8.2.0Displaceable, noises in the 3.1.0

FFastening of the displacem ent system , M odel Year, changing of 4.34.0Fastening of the displacem ent system , M odel Year, changing of 4.16.0Fastenings, m aintenance of 8.2.0Fitted carpet, shade changing of 3.2.0Fitted carpets, m aintenance of 8.1.0 9.1.0Fitted carpets, periodic cleaning of 9.1.0Fitted carpets, regular cleaning of 9.1.0Foam , m aintenance of 8.1.0

Folding cylinder for leg support, change of 4.19.0Footrest support com ponents, T2/ T4, change of 4.18.0Footrest T2/ T4, change of 4.17.0Footrest, m aintenance of 8.2.0

GGas spring support, change of 4.7.0Gas spring, change of 4.8.0General Data 1.1.0 2.1.0

HHeadrest cover, change of 4.28.0Headrest, change of 4.28.0Headrest, description of 2.2.0Headrest, m aintenance of 8.1.0Housing, description of 2.2.0

IIndependent tray, change of 4.20.0Indisplaceable footrest, changing of 4.17.0

ERGOS CLT, CLT – PLAXTON, CLH, MODEL YEAR (EDI. JAN. 2000) REV.1 0.3.0

ASIENTOS ESTEBAN

ERGOS CLT, CLT – PLAXTON, CLH, MODEL YEAR 0.-GENERAL DATA

ALPHABETIC INDEX

LLeather, maintenance of 9.3.0Leg and supports, description of 2.2.0Leg support cover, change of 4.19.0Leg support, change of 4.19.0Leg support, maintenance of 8.2.0Leg, aisle side, change of 4.14.0Lubrication, points of 6.1.0

MMagazine holder, change of 4.21.0Main characteristics 2.1.0Maintenance, instructions for 1.1.1 9.1.0Maintenance, intervals 1.1.1 8.1.0Materials, problems posed by 3.2.0

PPadding, changing of 4.3.0Paint, protection of 9.3.0Plastic, cleaning of 9.3.0Press buttons, change of 4.12.0

RReclining lever aisle side, change of 4.10.0Reclining lever, window side, change of 4.8.0Reclining, maintenance of 8.2.0Recommended lubrication 1.1.0 6.1.0Repair, modules of 1.1.0 4.1.0Repair, table of times of 1.1.1 10.1.0

SSafety belt, breakdowns of 3.2.0Seat, description of 2.2.0Securing of side, change of 4.14.0Securing, breakdowns 3.1.0Service, start up of 1.1.1 7.1.0Side separator, change of 4.10.0Side, description of 2.2.0Sides, breakdown of 3.1.0Sides, maintenance of 8.2.0Stains, treatment of 9.1.0

TThree-point belt, change of 4.26.0Tightening torque 1.1.0 5.1.0Tightening torque, table 5.1.0Tray latch, changing of 4.20.0Trim, change of 4.12.0Troubleshooting 1.1.0 3.1.0Tubes of the displaceable Model Year, assembly, change of 4.34.0Tubes of the displaceable assembly, change of 4.16.0Two-point indisplaceable safety belt, change of 4.22.0Two-point safety belt, woundable at the sides, change of 4.23.0Two-point safety belt, woundable in the centre and below, change of 4.24.0

UUpholstered backrest, change of 4.3.0Upholstered cushion, change of 4.2.0Upholstered cushion, Model Year, change of 4.32.0

VWindow arm assembly with support, change of 4.13.0Window arm assembly, change of 4.13.0


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 1.-INTRODUCTION

1.- INTRODUCTION 1.1 - PRESENTATION This manual has been designed to render user-friendly data and maintenance and repair instructions for Esteban seats. In order to become acquainted with the different parts of the seat, with its assembly and disassembly, the service technician should carefully study the instructions contained in this manual, in order to use it as an element of reference when undertaking maintenance and repair work. This manual has been designed into modules, including the following sections:

• General data • Troubleshooting • Repair modules • Tightening torque • Recommended lubrication • Initial use • Maintenance intervals • Maintenance instructions • Table of repair times

General Data

The main components of the seat are described.

Troubleshooting A table-guide is included for troubleshooting, indicating the solution guidelines. The information contained in the table serves as a guideline to locate and diagnose the most common breakdowns. Some of the breakdowns described under this table may not apply to your specific seat, but may apply to the same models in previous versions.

Repair modules Disassembly operations are described for the various elements that make up the seat.

Tightening torque The tightening torque to be applied on the bolted joints of the various elements of the seat is described, as well as joining of the latter to the bus’ anchoring.

Recommended lubrication The lubrication points, together with the adequate type of lubrication, are indicated for correct lubrication. The minimum specification to be fulfilled by the lubrication is also indicated and the products manufactured by commercial brands that comply with the requirements posed by the standard are proposed, which, in principle, can be easily found in the market.

Placement in service

The guidelines to be followed after any important repair has been undertaken on the seats are indicated, as well as those applicable prior to delivery of the equipment, after first assembly of the same.

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR (EDI. JAN. 2000) REV.1 1.1.0

ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 1.-INTRODUCTION

Maintenance intervals The seat parts requiring regular maintenance or periodic inspections are indicated, with the time intervals to be applied. The information is presented as a table with two entries. All the components are listed vertically, indicating the operation to be undertaken, and regular maintenance operations are grouped horizontally, in such a way that a scheduled maintenance may be undertaken with minimum effort and with the guarantee of knowing that all points requiring regular attention will be revised.

Maintenance instructions Guidelines to be followed for the correct maintenance of upholstery and leather are indicated, as well as the instructions to follow to get rid of stains. Instructions for cleaning of plastics, ashtrays and paint protection are also given.

Table of repair times

Average unit times employed for change operations for the most common components are indicated. These are the times to be used in order to invoice guarantee repair services.


ASIENTOS ESTEBAN

ERGOS CLT, CLT – PLAXTON, CLH, MODEL YEAR 2.- GENERAL DATA

2.- GENERAL DATA

2.1- MAIN CHARACTERISTICS

TYPE: Passenger seat for buses MODEL Ergos CLT Ergos CLT Plaxton Ergos CLH Ergos Model Year MATERIALS:

• Structure: Made of steel. • Housing: Made of aluminium. • Paint: Electrostatic • Filling: Injected with polyurethane foam. • Sides: Made of aluminium • Upholstery: Made of wool pile and mixtures or synthetic pile.

CONTROL ELEMENTS AND COMPONENTS

Control elements Components

ERGOS C

REC

T

ARM

BACKREST

HANDLE

HEAD SUPPORT

LT, CLT – PLAXTON, CLH, MODEL YEAR

ARMRES

LEG

LINING LEVER MAGAZINE HOLDER

FOOTREST

AISLE SIDE

CUSHION

(EDI. JAN. 2000) REV.1 2.1.0

ASIENTOS ESTEBAN


2.2.- DESCRIPTION OF COMPONENTS

The seat comprises the following elements: trestle, leg, sides, seat, back support, head support and accessories. 2.2.1. TRESTLE • This structure is made up of two aluminium sections. The seat, leg(s) and the side

support are bolted into the section. • For displaceable seats, the mechanism tubes that enable displacement are located

within the sections. A displaceable seat enables a wider separation between the two seats that are supported by the trestle.

2.2.2. LEG AND SIDE SUPPORT • The leg is joined to the trestle by means of two screws. It is generally secured on the

aisle side. It is painted in coloured powdered paint. • The side support is secured onto the trestle by two bolts. It has various types of

mooring bridles to secure it to the wall section. 2.2.3. SIDE • It is both functional and aesthetic. It is screwed onto the cushion structure and the

press-buttons for reclining and displacing the seat are located in the external part. It is made of aluminium.

2.2.4. SEAT • This consists of a plastic housing, a steel cushion structure painted in epoxy powder

and a plastic back housing to which the foam for the cushion is adhered, and it is covered with the cushion cover. The upholstered cushion is joined to the trestle by means of screws, except for the “Model Year”, which is embedded by means of two catches. The cushion structure contains the reclining system and it is screwed to the trestle. The cushion is made of polyurethane foam and it is lined with the cushion cover. The cover encloses the cushion by means of sections that are housed within slots located in the base, which are stapled in order to prevent movement of the cover.

2.2.5. BACKREST • This consists of a steel structure painted in epoxy powder, a plastic housing, foam that

is adhered to the same by means of an adhesive, and a cover. This structure is used for anchoring the upholstered backrest, the compact assembly and the plastic housing. The cover is also incorporated by means of sections, inserted into slots at the bottom of the housing, which are located on the side and lower part of the backrest.

• Different optional accessories may be incorporated to the same: i.e. magazine holder, tray, ashtray, handle, clothes hanger and glass holder.

2.2.6. HEADREST • This is made of a structure formed by two rods that are secured onto a plastic structure

by means of two pins; the foam is adhered to the same. The cover of the headrest is closed by means of two plastic sections. The headrest could include comfort cushions secured by means of Velcro tape.


ASIENTOS ESTEBAN


2.2.7. ACCESSORIES • Accessories are located on the backrest except for the footrest and leg support, which

are secured onto the cushion. The accessories that are located on the back of the seat mainly include the ashtray compact, the magazine holder and the tray. The glass holder, audio and optional separate tray can also be incorporated.


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 3.- TROUBLESHOOTING

3.- TROUBLESHOOTING

TABLE FOR TROUBLESHOOTING

Description of the problem

Nº Inspection Cause Solution Note

Noises stemming from the backrest

1 The ashtray does not close correctly.

The steel strip in the ashtray is no longer effective

Change the steel strip from the ashtray-

2 The housing of the steel strip of the ashtray has broken.

Change the ashtray.

3 The ashtray compact has clearance.

Securing to the backrest has become loose.

Re-tighten the clamping screws

4 The plastic material has worn away by the support on the backrest.

Change compact

5 The separate tray does not close properly

Securing to the backrest has become loose.

Re-tighten clamping bolts.

Noise from the side panels

6 The side panels have clearance.

Securing to the frame of the cushion has become loose.

Re-tighten the securing screws

7 The side separator has become deformed.

Replace the side panel

8 The arm support makes a noise

The housing of the screw has become loose

Replace arm support

Noises from the fastenings

9 There are vibrations in the area that supports the side panel.

The securing screws are loose.

Re-tighten the screws.

Noises from the displaceable unit.

10 Vibrations can be felt in the displaceable unit when the seat is empty and the vehicle is in motion.

The washers and bushings of the tube in the displaceable unit are worn.

Replace the bushings and the washers from the tubes.

11

The pin from the lever located in the displaceable unit is worn.

Replace the lever located in the displaceable unit.

The pivoting mechanism of the arm is not working.

12 The pivoting mechanism of the armrest is blocked or is not maintained on a horizontal plane.

The star-shaped lug is either worn or broken.

Replace the star-shaped lug from the armrest.

The backrest does not recline.

13 The pushbutton does not activate the gas charged damper.

The pin located in the pushbutton has either broken or bent.

Replace the pushbutton and/or the pin.

14 The match-shaped rod located in the lever on the side panel is not properly positioned.

Place match-shaped rod in its adequate position.

15 The gas-charged damper does not respond when activating the reclining lever.

Faulty reclining gas-charged damper.

Replace gas-charged damper.

The backrest does not return to position .

16 The backrest returns to position only when aided, while the reclining lever is actuated.

The gas-charged damper has become empty.

Help the backrest back to its vertical position so that the damper may be recharged.


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 3.- TROUBLESHOOTING

Description of the problem

Nº Inspection Cause Solution Note

17 The backrest does not return to vertical position when aided, or else has problems when doing so.

Excessive tightening of the rotational axis of the backrest due to tolerances.

Ease the tightening by repeatedly moving and lubricate.

18 Dirt / oxide on the rotational axis and bushings of the backrest.

Remove the backrest. Clean and sand down the rotational axles and bushings and lubricate the same.

Fitted carpet loses its colour.

19 When pressing the pile with the finger and displacing it in the inverse direction to the pile, inner colour is deeper.

The fitted carpet is dirty. Clean the fitted carpet. Please go to specialised companies.

20 The most protected parts of the fitted carpet have more vivid colours.

The fitted carpet is dirty. Clean the fitted carpet. Please go to specialised companies.

21 The colour of the fitted carpet changes depending on the angle from which it is observed.

The pile is flat due to incorrect maintenance.

Undertake correct maintenance.

See instructions for maintenance and conservation of fitted carpets.

Small balls appear on the back part of the upholstery of the backrest.

22 Resin has not been applied on the back.

Change upholstery on the back of the backrest.

Safety belt is loose.

23 Securing of the buckle / belt bobbin is loose.

The securing device is lacking a grooved washer.

Assemble grooved washer and tighten.


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 4.- REPAIR MODULES

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR (EDI.JAN.2000) REV.1 4.1.0

4.- REPAIR MODULES The instructions for the repair of seats as described under this section, are grouped under repair modules. The first part covers the whole seat and the rest describe the variations that apply to specific modules. Modules are structured into layers, in such a way that modules describing disassembly of external parts are incorporated as such under the modules describing disassembly of internal parts. Each module gives a detailed description of the disassembly operation for a specific element. Assembly operations are the exact steps, but in reverse, hence they are not described except for those cases where assembly requires special care, in which case, a detailed description of the assembly is included. The diagrams contained in this manual normally represent the double seat on the right side, in the direction of the movement of the bus. The diagrams corresponding to details on the side panels normally represent the right side by the window, or the right-hand side of the aisle. Repair of the other seats is undertaken in the same manner. Clamping devices (such as clamps and staples) are not mentioned in detail, nevertheless, these devices must be secured in their original position. As regards transport and storage, care must be taken to ensure that the seat is placed so that it rests on the metal structure, and never on the cushion or foam of the backrest, and it must be conveniently protected so that the painted parts do not scratch and that components do not bang against anything. When substituting parts, only original spares will be used, according to indications contained in the corresponding manual for spare parts. Utilisation of spares that are either not original, or else not approved by ESTEBAN, can result in incorrect performance of the equipment, or else a premature deterioration of the same. Utilisation of spares that are not original, may entail the loss of guarantee of the seat and ESTEBAN shall decline any responsibility for the damages that may arise due to such a use.

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4.01 Upholstered cushion Disassembly : 1.-Remove the two screws (1) placed in the lower part of the seat, together with the star shaped washer (3) and the flat washer (4). 2.-Press both lugs towards the inside (2) from the lower part of the cushion, and push the cushion upwards. 3.-Remove the cushion. Assembly : 1.-Introduce the back part of the cushion where it touches the backrest in the first place, ensuring that the sides of the cushion are inside the cushion housing. 2.-Hold the cushion with both hands and push it, keeping it on a horizontal plane, until it reaches the bottom. 3.-Press the lugs (2) towards the inside, to guide them into the slots of the cushion housing and press down until the lugs are totally inserted. 4.-Insert the screws (1), star-shaped washers (3) and flat washer (4). Important warning: The lugs can break if assembly operation is not performed correctly. 2,5±0,3 Nm 4.02 Housing of the back of the cushion Disassembly: 1.-Dismantle the cushion (see module 4.01). 2.-Remove the clamping device and the eleven staples that secure the cover. 3.-Remove the sections from the cover (with a screwdriver (1) if necessary). 4.-Remove the cover. Assembly: 1.-Rivet the two nuts with washers in the bottom of the cushion (2) (when placing a new cushion base). 2.-Adhere the cushion foam to the cushion base (3) 3.-Place clamping device and staple the cover with eleven staples to the cushion base (4). 4.-Upholster, ensuring the sections are properly fitted in (5). 5.-Shape the cover.

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4.03 Head cushion Disassembly : 1.-Remove the strip from the head cushion (1) pulling it towards the top and releasing the velcro fastenings. 2.-Repeat the operation with the comfort pillow (2). Assembly : Proceed as per previous steps in inverse order. 4.04 Upholstered backrest Disassembly : 1.-Disassembly cushion (See module 4.01). 2.-Release both clips (1) (sea detail D) which secure the lower part of the upholstered backrest, to the frame, using the screwdriver to lever the same (A). 3.-Remove the backrest assembly by vigorously pulling from the lower part towards the front, and towards the top, as per indications on the diagram. 4.-Remove the backrest assembly. Assembly : 1.-Secure the backrest from the top and vigorously push towards the bottom: after this, push it in. 2.-Introduce the clips (1) (see detail D) and secure them by gently hitting them with a hammer. 3.-Assemble cushion. Important warning: The lugs could break if assembly operation is not properly carried out. 4.05 Damping sections Disassembly : 1.-Remove cushion (see module 4.01) 2.-Remove upholstered backrest (see module 4.04) 3.-Remove the sections (B) from the backrest frame and (C) from the cushion frame. Assembly : Proceed in inverse manner. Observation: the section (C) covers the whole width of the cushion frame.

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4.06 Backrest cover High backrest Disassembly : 1.-Disassemble the upholstered backrest (see module 4.04). 2.-Turn the backrest over, cut the staples that secure the clamping device and remove the four staples that keep the cover of the backrest in place. 3.-Remove the sections of the cover with a screwdriver (A). 4.-Remove the top and bottom sections of the cover from the “U-shaped” slots which secure the same. Assembly : 1.-Insert the cover from the top part. 2.-Hold the cover and securing the side clamping devices with two staples each in the back housing of the plastic back. 3.-Shape the cover. 4.07 Bottom Housing of the Backrest Disassembly : 1.-Dismantle the upholstered backrest (see module 4.04). 2.-Remove backrest cover (see module 4.06). Assembly : 1.-Apply glue (2) on the back part of the new backrest foam. 2.-Apply glue (2) onto the side of the new backrest housing that is in contact with the foam. 3.-Glue both surfaces and leave to dry for a few minutes. 4.-Assemble cover (see module 4.06).

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4.08 Backrest housing Disassembly : 1.-Remove cushion, (see module 4.01). 2.-Remove upholstered backrest, (see module 4.04). 3.-Loosen both of the screw stoppers (1) which secure the bottom part of the housing on both sides of the backrest. 4.-Loosen the three screws (2) which secure the housing to the ashtray compact. 5.-Remove the housing. Assembly : Proceed in inverse manner. Important warning: Apply silicone onto the thread of the stopper (1) in order that it cannot accidentally become loose. To loosen / tighten the screw stopper, a special anti-theft key is required for screws / nuts.

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4.09 Ashtray compact Disassembly : 1.-Dismantle the cushion, (see module 4.01). 2.-Dismantle upholstered backrest (see module 4.04). 3.-Dismantle backrest housing. (See module 4.08). 4.-Loosen the two self-locking nuts (1) and remove the threaded screws (2) pulling them towards the top. 5.-Remove the compact assembly from the backrest by pulling from the handles towards the top. Assembly : Proceed with the same steps in inverse order. Important warning: The screws (2) have a square bar next to the head, which must be correctly inserted in the orifice (A) of the top securing tab belonging to the compact, on the backrest. Orifice (B) is cylinder-shaped and the threaded part of the screw goes through the same (2).

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4.10 Gas-charged damper Disassembly : 1.-Dismantle cushion. (See module 4.01) 2.-Remove the safety clamps (1) (C). 3.-Actuating the screwdriver as a lever (B), rotate the latch that drives the damper (4) overcoming the resistance of the spring (6) and maintain this position. 4.1 Aisle side. Gently push the lever (7) towards the aisle side until the head (5) of the reclining lever is outside the slot of the latch (4). 4.2 Window side. Loosen the nut (8) (D) and displace the guide (9) with the lever (7) towards the external part of the seat until the head (5) of the operating lever has come out of the slot on the latch (4). 5.-Remove the screwdriver that retains the latch that drives the spring. 6.-Move the gas damper assembly with a yoke towards the internal part of the seat, removing it with the anchoring pins (2) and (3). 7.-Remove the spring assembly with a pin. Assembly : 1.-Apply lubrication on the backrest anchoring pins (2) and on those on the cushion frame (3); detail (C). 2.-Place the gas damper inside the inlet aperture of the cushion frame, (A). 3.- Using a screwdriver, press the latch (4) – detail B – and insert one of the side holes of the yoke from the gas damper assembly, into the anchoring pin (3) until this retains the latch (4); remove the screwdriver. 4.-Move the backrest manually until the hole located in the casing of the gas damper, coincides with the anchoring pin (2) on the backrest. 5.-Press in the gas damper until it is totally inserted in the pins (2) and (3). 6.-Place the safety clamps (1). 7.-Using a screwdriver as a lever (B), rotate the latch (4), overcoming the resistance of the spring (6) and maintain in this position. 8.-Press reclining lever and place head (5) within the slot of the latch (4). Remove screwdriver. 9.-Continue with assembly steps in inverse direction to disassembly. Check performance. Important warning: Verify that the lever / reclining pushbutton do not have undue clearance. Verify that the backrest does not fold of its own accord. If it does, adjust the screw of the gas damper, see module 4.11. As from 11/99, the anchoring pins (2) and (3) are threaded and the Cir-clips (1), are substituted by nuts. (see detail E). 10±1,5 Nm

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4.11 Gas spring damper

Disassembly :

1.-Disassemble cushion, (see module 4.01) 2.-Disassemble gas damper assembly, (see module 4.10) 3.-Loosen the lock nut (4) and unscrew the gas spring (3) removing it from the yoke (2). Assembly :

Proceed in inverse steps, taking into account the following observations: • If the reclining lever / pushbutton has free play, loosen

the nut (4) and rotate the rod from the damper so that it penetrates further into the yoke (2).

• If the backrest folds of its own accord, loosen nut (4) and rotate the rod from the damper so that it is released from the yoke (2).

Tighten nut (4). Check performance. 1.-Verify that the lever does not have free play. 2.-Verify that the backrest does not fold of its own accord. Important warning: Use plastic clamps for rotating the rod from the damper. Hold from the threaded part. Do not hold the rod with pliers. Otherwise, marks may be produced which will give rise to subsequent oil leaks. 4.12 Reclining lever window side Disassembly : 1.-Dismantle cushion. (See module 4.01). 2.-Unloosen the nut (1) and put it away next to the spring washer (2). 3.-Remove the plate (3) together with the screw (6) which secures it to the bolster. 4.-Loosen, without removing the four nuts that secure the cushion frame to the bolsters, in such a way that it can slide over the same. 4.-Free the head (5) of the reclining lever (4), from its housing on the latch located on the gas damper in such a way that it can move freely. (See module 4.10). 5.- Slightly displace the cushion frame over the rails and rotate the reclining lever until the rod (5) coincides with the inlet slot located on the support that serves as a guide (7). 6.-Remove the reclining lever. Assembly : Proceed in inverse steps, taking the following into account: 1.-To adjust the reclining lever, tighten the nut (1) and verify that the reclining lever goes back to the bottom of the guide slot on the plate (3). Checks 2.-Check that the lever does not have free play. 3.-Check that the backrest does not fold of its own accord. If this is not the case, proceed to adjust the gas damper, (see module 4.11)

ASIENTOS ESTEBAN



4.13 Backrest frame Disassembly: 1.-Disassemble the cushion, (see module 4.01). 2.-Disassemble the upholstered backrest, (see module 4.04). 3.-Disassemble the gas damper assembly, (see module 4.10). 4.-Disassemble the backrest housing, (see module 4.08). 3.-Disassemble ashtray compact, (see module 4.09). 4.-Unscrew and remove the two screws on the backrest (1) and the two spring washers (2) that join the frame of the backrest to the cushion frame. 5.-Pull the frame upwards and remove it. Assembly: Proceed as per previous steps in inverse order. Important warning: Lubricate the cylindrical part of the rotational pin that rotates the backrest. Do not lubricate the threaded part.

5±0,7 Nm

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4.14 Aisle side panel Disassembly :

18±2 Nm 1.-Fold the backrest backwards. 2.-Remove cushion, (see module 4.01) 3.-Remove backrest, (see module 4.04). 4.-Unscrew and withdraw both bolt (1), and bolt (2), both flat star-shaped washers (3) and the inlaid star-shaped washer (4) that secure the arm (5) to the cushion frame. 5.-Remove arm (5). Assembly : Proceed as per previous steps but in inverse order. Important warning: place inlaid star-shaped washer (4) with the tapered part towards the thread of the screw.

4.15 Side panel Disassembly : 1.-Remove side panel, (see module 4.14). 2.-Remove bushings (1). 3.-Remove side panel (2). Assembly : 1.-Place side panel in arm assembly. 2.-Place the two top bushings (1) in the external part of the side panel over the axles where it meets the cushion frame. Assemble the lower bushing (1) (A) onto the screw that clamps the frame as the bushing is tightly adjusted to the cushion housing. 3.-Place the side panel with the screws. 4.-Tighten the screws. N.B.: The side panel is only placed on the window side when the seat has a safety belt. 4.16 Reclining lever aisle side Disassembly : 1.-Disassemble the cushion, (see module 4.01). 2.-Disassemble side aisle assembly, (see module 4.14) 4.-Free the rod (1) located on the reclining lever (2), from its housing in the latch located on the backrest reclining spring, in such a way that it can move freely, (see module 4.10). 5.-Rotate the reclining lever (2) until the rod (1), coincides with the inlet slot on the support that serves as guide (3). 6.-Remove the reclining lever. Assembly : Proceed in inverse order. Checks to be carried out Verify that the lever does not have free play. Verify that the backrest does not fold of its own accord. If this is not the case, proceed to adjust the gas damper (see module 4.11).

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4.17 Arm Disassembly : 1.-Disassemble the side panel. (See module 4.14). 2.-Using a screwdriver, remove the plastic covers of the arm supports, both internal (10) and external (4). 3.-Unscrew and remove screw (5), the washer (6) and the hexagonal nut (9). 4.-Remove the armrest (1) pulling it upward. 5.-Remove the two friction discs (8) and the bushing (7). Assembly: 1.-Place the bushing (7) on the axis of the armrest (2) and the two friction discs (8), one at each side. The flat part of the friction disc must be placed forming an angle of around 90º with the base of the side panel.

18±2 Nm

2.-Introduce the arm in such a way that the axis that supports the start-shaped part (3), goes into the slot of the friction discs and the widest part of the star-shaped part faces the axis of rotation of the armrest. Detail A. 3.-Place washer (6). 4.-Introduce the screw (5) into the axis of rotation, from the external part, place the screw in the inner housing and tighten. 5.-Press in covers (10) and (4).Verify performance. To change the position of the arm and to lower it until it locks into horizontal position, or lower it until it is folded *** (?) 4.18 Arm assembly Disassembly : 1.-Disassemble arm (See module 4.17) 2.-Place arm in horizontal position and remove the pin (2) by tapping it with a pointer in its axial direction. 3.-Remove the star-shaped part (3). Assembly : 1.-Place the star (3) inside the yoke of the armrest (1) and secure the same with a pin (2). For the assembly process, we recommend that you use another axis, of a lower diameter, as a guide. 2.-Assemble arm. Check performance: The star must be able to freely rotate on its axis.

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4.19 Pushbuttons and trims Disassembly : 1.-Remove the aisle side panel. See module 4.14. 2.-Remove the pins (5) that secure the trims and buttons to the housing. 3.-Remove trims (1), (3), (4), pushbutton (2), washer (7) and spacer bushing (6). Assembly : 1.-Place trim (1) securing it by applying pressure on the bottom part and on top by means of an elastic pin (5). 2.-Place trim (4) securing it with two elastic pins (5). 3.- Assemble the trim axis (3) on the spacer bushing (6) and the washer (7) and secure it by means of an elastic pin (5); check that it does not shift. 4.-Assemble the reclining pushbutton (2) and ensure it with an elastic pin (5). Verify that it moves freely. 5.-The pushbutton that activates the displaceable is assembled in the same manner as the reclining pushbutton. Note: It may be necessary to break the trim and pins in order to assemble new ones.

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4.20 Central arm assembly / window with support Assembly : 1.-Remove the cushion. See module 4.01). 2.-Remove the upholstered backrest. See module 4.04. 3.-Unscrew and remove the Allen screw (1) and the star-shaped washer (2). To this avail, fold the backrest until it is possible to access the head of the screw through an orifice made to this avail on the frame of the backrest. 4.-Unscrew and remove the Allen screw (3) with the tapered washer (4) 5.-Remove the arm (8). 6.-Remove the top spacer bushing (5), both central spacers (6) and the lower spacer bushing (7). Assembly : Proceed in inverse manner, taking care to assemble the spacers (5), (6), (7) in the position indicated on detail A. 15±1,5 Nm The star-shaped tapered washer (4) is assembled with the taper on the opposite side to the head of the screw. Note: In the event that a new housing is mounted, place special care that the holes are bored where the Allen screws go. The assembly depicted corresponds to a left-hand seat. Assembly of a right-hand seat is symmetrical. 4.21 Central arm assembly / window Disassembly : 1.-Remove the central / window arm assembly, (see module 4.20). 2.-If the arm is fixed, drill the elastic securing pin (6). 3.-Loosen and remove the screw (1) and the nut (5). 4.-Remove the arm (7). 5.-Remove the friction discs (3). 6.- Remove the bushing (2) and the washer (8) from the body of the armrest (4). Assembly : Proceed in inverse manner. N.B.: Place friction discs during assembly within the yoke located on the arm (7), one at each side with its black sides facing, and lubricate the sides of the body of the armrest (4) in the area that is in contact with the friction discs. The arm that is on the side of the window is generally fixed.

18±2 Nm

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4.22 Frame / cushion housing Disassembly : 1.-Disassemble cushion, (see module 4.01). 2.-Disassemble upholstered backrest, (see module 4.04). 3.-Disassemble backrest housing, (see module 4.08). 4.-Disassemble gas-charged damper, (see module 4.10) 5.-Disassemble backrest frame, (see module 4.13). It is not necessary to disassemble the ashtray compact. 6.-Disassemble reclining lever, (see modules 4.12 and 4.16) 7.-Disassemble side panel, (see modules 4.14 and 4.20). 8.-Unscrew and remove the four hexagonal nuts (1), together with the star-shaped washers (2) and the flat washer (3) that secure the frame and the cushion housing to the bolsters on the frame. The front screws have flat and star-shaped washers. 9.-Remove the cushion frame by pulling upwards. 10.-Remove the cushion housing. 11.-Unscrew and remove screw (4), the star-shaped washer (5) and the flat washer (6), that secure the guide support (7) to the cushion housing. 12.- Remove the guide support (7). 13.-Remove the screws (8) that secure the housing to the cushion, sliding them towards the outside of the rails (9). Assembly : Proceed in inverse manner. N.B.: When a three-point belt is mounted, the back screws (8) that secure the frame of the cushion, have double studs (D). 4.23 Leg aisle side Disassembly :

25±3,8 Nm Observe the position of the leg for correct subsequent assembly. 1.-Unscrew the bolts that secure the leg to the floor. 2.-Unscrew both screw (10) and take out the leg (F) displacing it on the rails towards the outside. 3.-Remove both screws (11), the star-shaped washer (6) and the nut (10). Assembly : Proceed in inverse manner. 4.24 Securing side panel Disassembly : 1.- Unloosen the tie-downs that secure this to the wall, observing the position of the connecting elements in order to be able to undertake the correct assembly afterwards. 2.-Unscrew and remove the nut (14) and the star-shaped washer (13). 3.-Remove the connection (G) to the wall. Assembly : Proceed in inverse manner.

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4.25 Displaceable assembly. Disassembly: N.B.: In order to disassemble the displaceable unit in the aisle seat, it is advisable to fold the double seat of the bus. 1.-Disassemble cushion (see module 4.01). 2.-Remove aisle side panel (see module 4.14) and separate side panel (see module 4.15). 3.-Remove the lever (B) from the rail of the limiting plate (see module 4.27). 4.-Unscrew and remove the nut (1) star-shaped washer and nut (3), which join the limiting plate (A) to the bolsters of the seat and remove part (A). 5.-Unscrew both bolts (5) and remove the star-shaped washer (2) that joins the front tube (C) with the guide support (G) to the cushion housing. 6.-Slide the seat assembly (H) towards the aisle side until both tubes (C) and (D) come out from inside the rails on the bolsters (see module 4.26). Assembly: Proceed in inverse manner. N.B.: Push in the three sliding bushings (F) in the front tube (C) and back tube (D), into the corresponding orifices, with its respective washers (4), in order to avoid noises.

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4.26 Tubes in displaceable assembly. A)- Front tube: Disassembly: 1.-Disassemble cushion (see module 4.01). 2.-Remove aisle side panel (see module 4.14) and separate side panel (see module 4.15). 3.-Unscrew the two Allen screws (5) and corresponding star-shaped washers (2), that secure the front tube (E) to the seat frame. 4.-Remove the tube (E) towards the external part of the rails. Assembly: Proceed in inverse manner. B)- Back tube: Back Disassembly: 1.-Disassemble cushion (see module 4.01). 2.-Remove aisle side panel (see module 4.14) and separate side panel (see module 4.15). 3.-From the inside, unscrew the four bolts (1) and their corresponding star-shaped washers (2), that join the back tube assembly (D) to the seat frame. 4.-Rotate the tube (D) and remove it from the housing of the seat, applying downward pressure.

Front

25±3,8 Nm Assembly: Proceed in inverse manner. 4.27 Anchoring of displacement system Disassembly: 1.-Disassemble cushion (see module 4.01). 2.-Remove aisle side panel (see module 4.14) and separate side panel (see module 4.15). 3.-Remove Cir-Clip (4) and after this, the plastic washer (6). 4.-Separate assembly (B-C) from inside the rail pertaining to the assembly (A) and remove plastic washer (6). 5.-Remove the screws (7) and immediately after the spring (8) and the screw (9) and remove the washer (10). 6.-Separate part (B) from part (C) and remove the same. 7.-Unscrew the self-tapping screw (5) which secures the lever to the seat frame. 8.-Remove part (B) and separate handle (11). Assembly: Proceed in inverse manner

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4.28 Footrest T2/T4 Disassembly : 1.- Observe the position of the four screws that secure the footrest (1) to the bolsters in order that they can be correctly placed afterwards. 2.-Unscrew and remove the securing nuts and washers. It is not necessary to remove the screws of the rails to replace the footrest. 3.-Remove the footrest. Assembly : Proceed in inverse manner. 25±3,8 Nm 4.29 Fixed footrest Disassembly : 1.-Unscrew both screws (1) that secure the washer (2). 2.-Remove the clamp (2). 3.-Unscrew the three nuts (6) and the star-shaped washers (5). 4.-Remove the footrest (3). Assembly : Proceed in inverse manner.

25±3,8 Nm

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4.30 Footrest components T2/T4

T2 Disassembly : 1.-Disassemble (see module 4.28). 2.-Remove the spring (7) that joins the footrest to the footrest support (1). 3.-Unscrew cam stop bolt (10) and remove rubber protector (9), removing the washer (11) and the nut (12). 4.-Disassemble the arm on the footrest (6) from the footrest support (2), removing two screws (8), two washers (3), two bushings (4) and two internal washers (5). 5.-In the T4, release the spring (13) that joins the footrest support to the cover (19) and unscrew cover screw (14), removing the rubber protector (15), the spring washer (16), the star-shaped washer (17) and the nut (18). Assembly : Proceed in inverse manner.

T4

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4.31 Leg support Disassembly : 1.-Observe the position of the screws (1), the nuts (2) and washers (3), in order to be able to correctly assemble the leg support afterwards. 2.-Unscrew and remove the nuts (2) and the washers (3) and (4). It is not necessary to remove the screws that are located inside the rails in order to disassemble the part. 3.-Remove the leg support. Assembly : Proceed in inverse manner.

4.32 Leg support cover Disassembly : 1.-Position the extended leg support. 2.-Open the top Velcro fastenings (1). 3.-Open the side Velcro fastenings (2). 4.-Remove the upholstery through the top corners (3). 5.-Remove the cover. Assembly : Proceed in inverse manner. 4.33 Cylinder for folding leg support Disassembly : 1.-Once the leg support is folded, remove the clamp (4) from the spring axis, in order to take it out of the yoke (9) from the leg support. 2.-Remove the spring axis (6), the two bushings (5) and the two washers (7). 3.-Unscrew the spring from the anchoring of the stem (8). Assembly : Proceed in inverse manner.

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4.34 Independent tray Disassembly : 1.-Remove cushion, (see module 4.01). 2.-Remove upholstered backrest, (see module 4.04). 3.-Unscrew both bolts (1) which secure the tray legs to the backrest frame. 4.-Remove independent tray. Assembly : Proceed in inverse manner. Adjust the horizontal position of the tray by means of the two screws (2). Secure them with the two nuts (3). N.B.: When mounting the independent tray, the backrest housing counts on two slots on the lower part, to enable the arms of the tray to go through. 4.35 Tray latch Disassembly : 1.-Remove cushion, (see module 4.01). 2.-Remove upholstered backrest, (see module 4.04). 3.-Rotate latch (1) and fold tray (7) 4.-Unscrew the bolt that holds the plate (5). 5.-Remove flat washer (3), the spring (2), the flat washer (4), the extra bushing (6) and finally, the latch (1) from the tray. Assembly : Proceed in inverse manner. Check performance.

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4.36 Ashtray Disassembly : 1.-Open the ashtray (1). 2.-Pulling the ashtray gently towards the outside, press the strip (2) until the retention stop is released. 3.-Remove the ashtray. Assembly : 1.-Align the lower part of the ashtray with the hollow of the ashtray compact. 2.-Push in the lid of the ashtray, pressing on the strip (2) until the stop is released. Check performance. 4.37 Magazine holder Disassembly : 1.-Remove cushion (see module 4.01). 2.-Remove upholstered backrest (see module 4.04). 3.-Remove the four securing screws (1) with their corresponding washers (2) that secure the magazine holder to the plastic housing. 4.-Break the two flanges (3) to extract the magazine holder. Assembly : 1.-Place the new magazine holder (A) on the back part in order to position the same. 2.-Introduce the two flanges (3) and open them to secure the same: screw the four screws on the inside (1) with their corresponding washers (2). 3.-Continue as per assembly but in reverse direction. Important warning: In the event that a magazine holder is to be mounted on a seat that did not have one before, a template must be used to mark the position of the new magazine holder. Check performance.

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4.38 Fixed two-point safety belt Aisle side Disassembly : Belt 1.-Loosen the nuts that secure the frame and cushion housing and displace the assembly until you have access to the belt. 2.-Unscrew and remove screw (10) and the flat washer (9). 3.-Remove belt (8). Buckle 1.-Remove the aisle side panel (1), (see module 4.14). 2.-Remove the side separator (2) and the three separating bushings (6). 35±5,3 Nm 3.-Remove the buckle assembly (5) and the securing plate (7). 4.-Unscrew and remove screw (3) and the flat washer (4). 5.- Remove the buckle (5). Assembly : Proceed in inverse manner. Verify performance. Window side

35±5,3 Nm Disassembly : Belt 1.-Loosen the nuts that secure the frame and the cushion housing of the aisle side and displace the assembly until you have access to the belt. 2.-Unscrew and remove the screw (1) and the washer (2) 3.-Remove the safety belt (3). Buckle 3.-Loosen the nuts that secure the frame and cushion housing on the side panel and displace the assembly until there is access to the buckle. 4.-Unscrew and remove the screw (6) and the washer (5). 5.-Remove the buckle (4). Assembly : Proceed in inverse manner. Verify performance. Observations: In order to replace the extra strip of the buckle / belt, the central arm must be disassembled. (See module 4.20). The strip is secured to the lower arm screw. 35±5,3 Nm

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4.39 Two-point safety belt that coils on the sides Aisle side Disassembly : Bobbin 1.-Remove the aisle side panel (1), (see module 4.14). 2.-Remove the side separator (2) and the three separator bushings (6). 3.-Remove the safety belt assembly (5) and securing plate (7). 4.-Remove the screw (3) and the flat washer (4) 5.-Remove the safety belt (5). Buckle 6.-Loosen the securing nuts from the frame and cushion housing and displace the unit until you have access to the buckle. 7.-Unscrew and remove screw (10) and the flat washer (9). 8.-Remove buckle (8). 35±5,3 Nm Assembly : Proceed in inverse manner. Check performance. Very important: remove plastic housing on the bobbin that is mounted on the side panel. 35±5,3 Nm Window side Disassembly : Bobbin 1.-Loosen the nuts that secure the frame and cushion housing on the aisle side and on the side in order to displace the assembly until you have access to the bobbin (see module 4.22). 2.-Unscrew and remove screw (11) and washer (12). 3.-Remove safety belt (13). Buckle 4.-Unscrew and remove bolt (16) and washer (15). 5.-Remove buckle (14). Assembly : Proceed in inverse manner. Check performance. Observations: In order to change the extra strips on the buckle / bobbin, the central arm must be disassembled. (See module 4.20). The strip is secured to the lower screw on the arm.

35±5,3 Nm

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4.40 Woundable two-point safety belt: Centre and lower assembly. Bobbin Disassembly : 1.-Unscrew the four nuts (3), star-shaped washers (2) and flat washers (1) that secure the assembly to the frame. 2.-Remove, extracting from the lower part, the assembly made up of the two bobbins (4) and (5), mounted on the support (10). 3.- For each of the bobbins, unscrew the bolt (11) and washer (12) which secures the return to the belt support assembly. 4.-Remove the return (13) together with the hook located at the end of the belt. 5.-Remove the return hook. 6.-Unscrew the bolt (6) and the two pins (13) and remove the bobbins (4) / (5), the nut (9), the star-shaped washers (7) and the flat washers (8). Assembly : 1.-Disassemble cushion (see module 4.01). 2.-Follow inverse process to disassembly Important: before screwing the return hook, this must be positioned by means of a tool that avoids subsequent performance problems.

35±5,3 Nm

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ERGOS CLT, CLT-PLAXTON, CLH, MODEL Y

Buckle (window side without side panel and without arm)

Assemb Disassembly : 35±5,3 Nm 1.-Disassemble cushion (see module 4.01). 2.-Unscrew safety nut (8) and Remove rotation bushing (6) and washer (7) from buckle (5). 2.-Remove screw (9) and embedded washer (10). 3.-Remove buckle taking out the dowel from its housing between the frame and cushion housing. Buckle (window side without side panel and with arm)

35±5,3 Nm

35±5,3 Nm

Assembly detail
Disassembly : 1.-Disassemble cushion (see module 4.01). 2.-Release side arm support (see module 4.20) 3.-Remove buckle (11) taking out the dowel from its housing between the frame and cushion housing and picking up the buckle bushing (12) and the spacer bushing (13). Buckle ( on Aisle side window / panel) Assembly detail
EAR

ly detail

(EDI.JAN.2000) REV.1 4.25.0

Disassembly : 1.-Disassemble aisle side panel /window, (see module 4.14). 2.-Remove buckle (1) and pick up buckle bushing (2), spacer bushing (3) and embedded washer (4). Assembly Proceed in inverse manner in all three cases.

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4.41 Three-point belt Bobbin Disassembly : 1.-Disassemble cushion, (see module 4.01). 2.-Release securing triangle (13) from the strap of the belt to the support (C), unscrewing the bolt (10), nut (12) and washer (11). 3.-Disassemble the upholstered backrest, (see module 4.04). 4.-Unscrew the two bolts (8) and remove guide (9). 5.-Remove the hook (14) and the securing triangle through the hollow practiced on the upholstered backrest. 6.-Unscrew pin (6) removing the nut (7). 7.-Unscrew bolt (5) and remove bobbin (4). Assembly : 1.-Proceed in inverse steps. Very important: when placing the guide (9) of the belt on the backrest, the following steps must be taken: 1.-Introduce two securing clamps (12) into the hole in the upholstery of the backrest in such a way that they will be positioned in notches in the holes. 2.-Introduce belt tape in external guide (9) through the slot located in the lower side. 3.-Place external guide (9) of tape into upholstery orifice, introducing the two top flanges and pushing downwards and upwards. 4.-Secure position by means of two screws (8) guided by the clamps (12). 5.-Verify that the belt tape slides without grazing against anything. Buckle Disassembly : 1.-Disassemble cushion, (see module 4.01).

35±5,3 Nm 2.-Unscrew and remove bolt (1) and star-shaped washer (2) 3.-Remove buckle (3). Assembly : Proceed in inverse manner. Check performance. Observations: The bobbins (4) are placed in the centre of the double housing. The screw (1) also secures the side panel, or the central armrest, or window, depending on the case. (See module 4.14, screw (2)). (See module 4.20, screw (3)). 35±5,3 Nm

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ERGOS CLH VARIATIONS

Housing of the backrest

Handle

Tray

Ashtray

Glass holder

Head support

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4.42 Headrest Disassembly: 1.-Remove the head support (1) from the backrest, pulling upwards. Assembly: 1.-Press over the upholstered backrest, so that the headrest rods coincide with the anchoring structure. N.B.: Make sure that you hear when inserting the headrest and check that it is firmly secured in place. 4.43 Headrest cover Disassembly: 1.-Remove the headrest (see module 4.43). 2.-Remove the sections from the cover (1) using a screwdriver to this avail. 3.-Unstick the plastic structure (2) from the foam inside the headrest (3). 4.-Remove the plastic structure from inside the headrest. 5.-Remove the foam (3) from inside the cover. Assembly: 1.-Place rods (A) inside the housing, securing them with the pins (B). 2.-Apply silicone inside (3). 3.-Place the structure assembly (2) inside the foam (3) and leave to dry for a few minutes. 4.-Place new cover (1) and secure with sections.

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4.44 Backrest assembly with head support Disassembly: 1.-Disassemble cushion (see module 4.01) 2.- Disassemble upholstered backrest (see module 4.04) 3.-Extract the head support (see module 4.42). 4.-Extract the buttons that join the top housing of the backrest (2) with the lower housing (3). 5.-Remove the top housing assembly (2). 6.-Disassemble the lower housing (identical to module 4.08). Assembly: Proceed in inverse manner N.B.: apply silicone on the securing buttons. 4.45 Horizontal backrest handle Disassembly: 1.-Saw the handle. Assembly: 1.-Insert the new handle applying pressure from top to bottom, introducing the long square bar in the first place. 4.46 Glass holder Disassembly: 1.-Open the cover (2). 2.-Lift the ring of the glass holder (3). 3.-Extract these from the lugs with a screwdriver. Assembly: 1.-Proceed in inverse manner.

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4.47 Ashtray Disassembly : 1.-Open the ashtray (1). 2.-Gently pulling the ashtray towards you, press the strip (2) until the retention stop springs. 3.-Extract the ashtray. Assembly : 1.-Align the lower part of the ashtray on the hollow of the ashtray compact. 2.-Push the cover of the ashtray, pressing the strip (2) until the retention stop springs. Push in the ashtray cover pressing the strip (2) until the retention stop springs. Check performance. 4.48 Tray Disassembly: 1.-Disassemble cushion (see module 4.01) 2.- Disassemble upholstered backrest (see module 4.04) 3.-Unscrew the four bolts (1) that secure the tray (A) to the backrest housing (6). 4.-Remove the guides that secure the table. 5.-Remove the securing plates (3), the washers (4) and the nuts (5) which are inside the backrest housing (6). Assembly: Proceed in inverse manner

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ERGOS MODEL YEAR VARIATIONS

Head cushion

Ashtray compact Arm

Cushion Independent tray

Magazine holderAisle side

Footrest

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ERGOS CLT, CLT-PLAXTON, CLH, MO

4.49 Upholstered cushion Disassembly : 1.-Press on the lugs (2) in the direction indicated by the arrow (see section detail) and remove the cushion (see detail A-1). 2.-Pull the cushion upwards, removing it completely (see detail A-2). Assembly : 1.-Introduce the back part of the cushion that bears against the backrest in the first place, making sure that the sides of the cushion have been placed inside the cushion housing. 2.-Hold the cushion with both hands and push it horizontally until it touches the bottom. 3.-Press the cushion on the front until the lugs (2) are totally inserted in the cushion housing (1) (see detail A-1).

D l

l

Detai

etai

DEL YEAR (EDI.JAN.2000) REV.1 4.32.0

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4.50 Displaceable assembly Disassembly: 1.-Disassemble cushion (see module 4.48). 2.-Release the securing system of the displaceable assembly (E) (see module 4.51). 3.-Unscrew the two bolts (1) and remove the star-shaped washer (4) that joins the front tube (B) to the guide support (C) to the cushion housing. 4.-Slide the seat assembly (H) towards the aisle side until the two tubes (B) and (D) have come out of the bolster rails (see module 4.50). Assembly: Proceed in inverse manner. N.B.: Insert the three sliding bushings (F) by applying pressure into the front tube (C) and the back tube (D), into the corresponding orifices, with its respective washers (4), in order to avoid noises.

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4.51 Tubes from the displaceable assembly. A)- Front tube: Disassembly: 1.-Disassemble cushion (see module 4.49). 2.-Disassemble the anchoring system of the displaceable assembly (see module 4.51). 3.- Unscrew the two Allen bolts (3) and its corresponding star-shaped washers (4) which secure the front tube (B) with the seat frame. 4.-Remove the tube (B) taking it out of the rails. Assembly: Proceed in inverse manner. B)- Back tube: Back Disassembly: 1.-Disassemble cushion (see module 4.49). 2.-Remove Aisle side panel (see module 4.14) and separate side panel (see module 4.15). 3.-Unscrew the four bolts from the inside (1) and its corresponding star-shaped washers (2) that join the back tube assembly (D) to the seat frame. 4.-Rotate the tube (D) and remove it from the seat housing, pressing it down. Assembly: Proceed in inverse manner. 4.52 Anchoring of the displacement system Disassembly: 1.-Disassemble cushion (see module 4.49). 2.-Unscrew the three bolts (5) that secure the displacement assembly to the side. 3.-Release the towrope of the displacement assembly (8) and cut the flange (13) that secures the towrope to the cushion frame (14). 4.-Unscrew and remove the two nuts (1) and the two washers (2) that join the limiting plate (A) to the seat bolsters and take out part (A) with the anchoring cylinder (3), the spring (11), the spring screw (12) and the towrope (4). 5.-Remove the towrope from the anchoring cylinder. 6.-Release the Cir-Clip (6) from the bolt (7) that is in the displacement assembly, remove the screw (7) and remove the two driving rods (). Assembly: Proceed in inverse manner

Front

Back

Front

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ERGOS CLT, CLT – PLAXTON, CLH, MODEL YEAR 5.- TIGHTENING TORQUE

5.- TIGHTENING TORQUE

The bolted joints shall be tightened according to the tightening torque indicated in the following table, unless there is a special specification. This specification for tightening torque is applicable to joints with hexagonal or cylindrical bolts, and steel nuts where the friction coefficient between contact surfaces is 0.12 to 0.14.

Tightening torque based on diameter, pitch and quality of the screw Quality

Tightening torque (Nm)

Nominal Diameter

Pitch

5.6 8.8 M4 0,7 1,5 +/- 0,3 2,9 +/- 0,5 M5 0,8 3,0 +/- 0,5 6,0 +/- 0,9 M6 1 5,0 +/- 0,7 10 +/- 1,5 M8 1,25 12,5 +/- 2 25 +/- 3,8

M10 1,5 24,5 +/- 4 49 +/- 7,4 SAE 7/16” 20threads/inch 35 +/- 5,3

The quality of the bolt is indicated on the head of the same. If in doubt when using a new screw, use quality 8.8. For M4 bolts for securing backrest accessories, which do not indicate quality on the head, the tightening torque corresponding to 5.6 quality will be applied.

Joints bolted on the seat Nominal diameter

Quality Observations

Securing to the front bolster. M8 8.8 Securing to the back bolster. M8 8.8 Securing of the cushion to the backrest. M10 5.6 Securing of gas damper M6 8.8 Securing of the aluminium side panel to the structure

M8 8.8 Torque = 18±2 Nm.

Side armrest rotation bolt M8 8.8 Torque = 18+2 Nm. Central armrest rotation bolt M8 8.8 Torque = 18+2 Nm. Central arm securing to the structure M8 8.8 Torque = 15±1´5 Nm. Securing of the legs to the bolsters M8 8.8 Securing of the reclining stop plate M8 8.8 Securing of reclining tube support M8 8.8 Torque = 18±2 Nm. Rotational bolt M6 5.6 Securing of the displaceable to the front bolster M8 8.8 Back nut in rotational bolt with nut M6 5.6 Securing of footrest to the seat M8 8.8 Securing of the bobbin to the anchoring support SAE 7/16 8.8 Securing of the buckle to the anchoring support buckle

SAE 7/16 8.8

Securing of the bushing M8 8.8 Torque = 15±1´5 Nm. Securing of the cushion base to the cushion housing

4 5.6 Torque = 2´5±0´3 Nm.

N.B.: For bolt – plastic, bolt – aluminium, bolt – strip joints, lubricated joints and other situations that may be deemed different to those indicated under Tightening Torque, Esteban’s specifications will be applied.


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ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 6.- RECOMMENDED LUBRICATION

6.- RECOMMENDED LUBRICATION

For the correct performance of the seat, we recommend the use of the lubrication indicated, or equivalent products. Points of lubrication

Temperature

range

Type of

lubrication

Specification

KLÜBER

MOLYKOTE

KRAFFT - Friction discs in

arms. - Backrest rotation

screws

-40ºC to +90ºC

Base oil + lithium soap + solid lubricants

USDA-H2 Certification. Also complies with Volkswagen’s VWTL751 certification.

DOUTEMPY PMY 45

- Headrest bushings. - Securing pins gas

damper

-30ºC to +110ºC

Base mineral oil + lithium soap + solid lubricants

KPF2K Standard (-30ºC) In accordance with DIN 51502 Standard

MOLYKOTE LONGTERM W-2 (This is manufactured by Dow Corning)


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ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 7.- INITIAL USE

7.- INITIAL USE Before initial use of the seats is made, and after any important repairs have been undertaken, a series of checks must be effected in order to verify the correct condition of components, both as regards its aesthetic appearance and its performance ... These checks are visual for external components and manually driven for elements that incorporate mechanisms. The total list of checks to be undertaken is indicated under the “Maintenance Intervals” section, under the heading “Checks”.

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR (EDI. JAN 2000) REV.1 7.1.0

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ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 8.- MAINTENANCE INTERVALS

8.- MAINTENANCE INTERVALS

Regular maintenance Checks Maintenance intervals Every

week Every 6 months

Once a year

Every 2 years

Every 3 years

Weekly Half- yearly

Fitted carpets

• Gentle vacuum cleaning to absorb the dust X • Humid cleaning by the “spray-extraction” procedure

(wool pile fitted carpets and other mixes). Alternatively, cleaning with dry foam. Please refer to instructions on Maintenance and Upkeep of fitted carpets.

X X

• Dry-cleaning with adequate solvents (synthetic pile fitted carpets: acrylic, polyester, etc.).

• Alternatively cleaning with dry foam. Please refer to instructions on Maintenance and Upkeep of fitted carpets.

X X

• Check that there are no problems such as eroding or bare patches due to lack of tissue or decolouring.

X

• Check that there are no stains and that the pile is not flattened.

X

• Check that seams are not frayed, or that there are no loose threads.

X

• Check that lining has no creases or bags. X • Check that the direction of the pile is uniform. X

Backrest

• Check that backrest is maintained at any intermediate position, both when occupied, or empty, while not acting on the reclining control.

X

• Check that backrest folds gently under the weight of the passenger when the reclining control is actuated.

X

• Check that the backrest recuperates its vertical position when freeing it of load, actuating the reclining control.

X

• Check that there is no clearance in the backrests. X • Check that backrests are aligned. X • Check that vibrations do not cause any noise. This

check can be made with the vehicle in motion, when it is running empty, or when it is at a standstill, by hitting the backrest with the hand with a dry blow from behind.

X

• Lubricate and clean pins and bushings pertaining to the rotation of the backrest.

X

Cushions

• Check that cushions are well secured. X • Re-tighten cushion anchoring to platform. X

Headrests

• Check that headrests are secured and that they can be taken out and inserted correctly.

X

• Check that headrest cushion is well secured and that it is placed correctly.

X

Foam

• Check that foam is not flattened, or deformed X


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 8.- MAINTENANCE INTERVALS

Regular maintenance Checks Maintenance intervals Every

week Every 6 months

Once a year

Every 2 years

Every 3 years

Weekly Half-yearly

Reclining mechanism

• Check that reclining actuating pushbuttons/levers work gently.

X

• Check that reclining pushbuttons/levers are properly assembled and that they do not have transverse or longitudinal play.

X

Arms / Sides

• Check that arm reclining mechanism works properly, that is, that it is blocked in horizontal position and can be folded downwards.

X

• Check that arms do not have clearance and change friction discs if necessary.

X X

• Check that aisle side panels are aligned and that they do not present aesthetic defects, or clearance.

X

• Re-tighten bolts that secure the side panel to the cushion frame.

X

• Retighten bolt-axis that joins the backrest arm to butt spring.

X

• Re-tighten bolt that secures the spring to cushion frame.

X

• Re-tighten armrest rotating nut. X • Re-tighten screws in central arm support. X • Re-tighten plastic arm support securing bolts. X

Accessories

• Check that mobile accessories (trays, glass holders, ashtrays) open and close correctly.

X

• Check that magazine holders are in good condition. X • Check that handles do not have clearance. X

Foot rest

• Check that footrest works properly. X • Re-tighten footrest anchoring to the frame. X

Leg support

• Check that the mechanism of the leg support works correctly.

X

Displaceable

• Check that displaceable works properly. X • Re-tighten securing of tubes to cushion frame. X

Audio

• Check that audio system works correctly. X • Re-tighten amplifier securing bolts. X

Anchoring

• Check that aisle leg and wall tie-downs are not loose. X • Retighten wall anchoring to wall rail. X • Re-tighten side anchoring to frame. X • Re-tighten screws that secure leg to frame. X • Re-tighten anchoring of leg to floor. X


ASIENTOS ESTEBAN

ERGOS CLT, CLT-PLAXTON, CLH, MODEL YEAR 9.-MAINTENANCE INSTRUCTIONS

9.- MAINTENANCE INSTRUCTIONS 9.1.- MAINTENANCE AND UPKEEP OF FITTED CARPETS 9.1.1 REGULAR CLEANING A gentle vacuum cleaning, on a weekly basis, will clean and lengthen the life of the fitted carpet. Take care not to apply too much friction with the vacuum cleaner nozzles and vacuum up and down (with and against the pile), in an even and gentle manner. 9.1.2 PERIODIC THOROUGH CLEANING A thorough cleaning is recommended every six months, depending on the dirt accumulated, and to this avail we recommend the following:

a) For pile and wool fitted carpets and mixtures, we recommend a humid cleaning operation,

according to “spray-extraction” procedures, to be preferably undertaken by a professional company, using the most appropriate method in each case (shampoo for wool or similar type of upholstery).

b) For synthetic pile fitted carpets (acrylic, polyester, etc.), dry cleaning can be used, using the

appropriate solvents to this avail. We also recommend that you consult a professional for this type of cleaning.

c) Dry foam can also be used as another alternative both for natural fibre and synthetic fitted carpets, taking care to ensure they are of good quality and following the pertinent instructions for use. Once again, we recommend that you consult a professional.

d) In the event that you use “vaporetta” (steam appliance) cleaning methods, or similar, take care that no drops of water, which form by the condensation of steam in the nozzle of the cleaning device, are deposited, as they would provoke stains on the fitted carpet. The best thing is to consult a professional company for this type of cleaning.

9.1.3 TREATMENT OF STAINS In the event that a stain is present, it is very important to act as quickly as possible and before it dries, since otherwise, it shall be very difficult to remove. If the stain is liquid or greasy, it must be quickly absorbed using a clean cloth, or a sponge. In the event of solid or semi-solid spots, eliminate the excess in the first place, with a spatula or similar appliance. If the stain has already dried, gently brush it in order to eliminate the waste matter, and afterwards absorb it with a humid cloth or sponge. In any case, always act starting from the periphery and then continuing with the internal part of the stain, in order to reduce the size.


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The following is a list of treatments to be undertaken on the most usual stains after having applied the above-mentioned cleaning operations:

Oil. Cover the fresh stain with talcum powder or special ointment for stains. Leave to stand for some hours. Brush. If the stain is dry, use stain remover. Tar. Use benzol, or stain removing solvent. Ballpoint pen. Apply alcohol on the stain. Shoe polish. Dissolve with ethyl alcohol, rub with clean cloth and wash with neutral soap. Coffee/Cocoa. Apply benzene or stain removing solvent. Cola. Wipe with acetone or nail varnish remover and wash immediately after. Grease. Use alcohol for burning, turpentine or similar product. If this persists, use stain remover. Glue. Compounds, once dried, are hard to eliminate, and therefore must be treated immediately with acetone, when possible. Lipstick. Clean locally with alcohol. Perfume / Makeup. Clean locally with hot glycerine and rinse with water and neutral detergent. Paint. Clean immediately with cotton cloth immersed in solvent; if the stain is due to oil paint, clean with trementine or similar; for synthetic paint: clean with appropriate solvent. Sprinkle with talcum and brush when dry. Chewing gum. Treat with ethyl alcohol and carefully remove traces of chewing gum. Chocolate. Use tepid water and soap or neutral shampoo and rinse afterwards. For difficult stains, use benzene or stain remover. Nail varnish. Clean with acetone or nail varnish remover. After this, wash and rinse. Fruit. Wash with neutral detergent solution. If stains persist, use dry foam. Milk. Use detergent or neutral shampoo for upholstery. Ice cream. Wash with tepid water and treat, if necessary, with stain remover. Rust. Remove with anti-rust stain remover or lemon juice alternatively. Grass. Dampen with alcohol and wash. Urine. Use neutral detergent for upholstery. If this persists, consult a professional. Resin. Eliminate the solid parts and after this treat with solvent (gum spirit) and wash.


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Blood. Clean immediately with tepid water and neutral detergent. If the blood has dried, repeat the operation various times. Sweat. Brush with vinegar or diluted alcohol. Tea. Act as per tea and coffee instructions. Ink. Dampen with alcohol and wash with neutral detergent solution. White wine. Rinse with cold water immediately and wash after this. Red wine. Wash immediately after treating the stain locally with lemon juice. Vomit. Wash with detergent or shampoo for upholstery and rinse.

9.2.- MAINTENANCE OF LEATHER Periodic cleaning with a white clean cloth, dampened in distilled water, is essential to prevent dirt. If any solution is spilled, immediately absorb it with the cloth, without applying

Documents

WORKSHOP MANUALFootrest T2/ T4 4.17.0 Undisplaceable footrest 4.17.0 Footrest componentsT2/ T4 4.18.0 Leg support 4.19.0 Leg support cover 4.19.0 Cylinder for folding the leg support