XChange Seat Service and Maintenance Guide

Transcription

1 XChange Seat Service and Maintenance Guide

2 Table Of Contents Page General Information... 1 Registration Information... 1 Seat Cushion Latch... 2 Lap Shoulder Belt Replacement... 2 Sliding Buckles Replacement... 9 Testing of Seat belt Systems Seat Back Outer Cover Replacement Integrated Child Seat Restraint System Replacement Care and Maintenance Store this instruction manual behind the ICS removable seat pad (if equipped) or with the vehicle for future reference. General Information The SafeGuard team truly care about child passenger safety and are committed to providing innovative restraints that offer the utmost in safety and ease of use. While no restraint can prevent injury in every situation, proper installation, use, and maintenance of a restraint can substantially reduce a child s risk of serious injury or death. WARNING! DEATH or SERIOUS INJURY can occur: Follow all the instructions of this manual and the instructions of the vehicle manufacturer. Failure to properly install, use and maintain these seats and restraints may result in serious injury or death of the child being transported. If you have any questions after reviewing the instructions, please contact us at: SafeGuard Customer Service: or This restraint system conforms to all applicable Federal Motor Vehicle Safety Standards. Registration Information - For Aftermarket Seats If not previously done, please fill out the prepaid registration card attached to the bus seat and mail it today or register online at the website listed below. Restraints could be recalled for safety reasons. You must register this restraint to be reached in a recall. Send your name, address, and the restraint s model number, manufacturing date, and serial number to IMMI, U.S. 31 North, Westfield, IN or call or register online at For recall information, call the U.S. Government s Vehicle Safety Hotline at (TTY: ), or go to The seat model number and manufacture date are located on a label that is on the lower seat frame. Lift open seat cushion to view label (see illustration A ). The lap-shoulder belt restraint system part number is located on a label sewn to the end of the web at the belt anchorage (see illustration B ). Seat model number and manufacture date Lap-shoulder belt restraint system part number A 1 B

3 IMPORTANT NOTICE It is the responsibility of the installer to verify prior to actual installation that the installation of any XChange seat will permit seat to: 1) Retain minimum knee room and/or seat spacing requirements as specified by local, state, and/or federal requirements. 2) Not impact GVWR so that vehicle exceeds maximum rating for chassis. Seat Cushion Latch 1. Reach under the center of the seat cushion; release the latch by sliding the locking plate tab toward the seat front (Fig. 1) Lift up the rear of the seat cushion and pivot forward for access to the seat frame (Fig 2). 2 Lap Shoulder Belt Replacement REMOVAL: 1. Unlatch seat cushion and pivot up and forward (Fig 1). Belt Anchor Bolts (2 or 3) 1 Retractor Module Attach Bolts (4) 2

4 REMOVAL (Cont.): 2. Remove bolts (two or three - Fig 1) attaching shoulder belt anchors to seat frame (Fig 2). NOTE: Bolt quantities in Steps 2-4 will vary depending if it is a three-occupant or two-occupant seat. 2 NOTE: Bolts are secured with epoxy adhesive and may require additional effort to loosen. NOTE: Bolt attaching center shoulder belt anchor also attaches right side buckle. 3. Remove bolts (two or three - Fig 1) attaching shoulder belt retractor to seat frame (Fig 3) Remove bolts (one or two - Fig 1) attaching inner seat module to seat frame. An additional wrench is required to grip loose nut on backside of frame cross-member (Fig 4) Remove two Torx-45 screws, one on each lower corner of inner seat module, attaching module to seat frame (Fig 5). NOTE: To ease removal of seat back outer cover from lower pan in Step 6, slightly open tabs to allow cover attachment wire to clear tan amd allow cover to separate from pan (Fig 6)

5 REMOVAL (Cont.): 6. a) Remove inner seat module from seat. First push frame attachment bracket rearward on seat frame cross-member (Fig 7). b) Next, grasp web or upper edge of inner seat module, pull forward, and continue to rotate upper portion of inner seat module forward while slightly lifting module up (Fig 8). 7 c) Finally, as inner seat module lower frame structure rotates clear of seat frame, pull entire inner seat module from seat frame assembly (Fig 9) On shoulder belt system to be removed, raise shoulder belt to fully expose bezel, Remove #10 screw that attaches bezel with a 5/16 nut driver. (Fig. 10) 10 8 Remove bezel of lap-shoulder belt to be removed from inner seat module by lifting up off of module (Fig. 11). 11 4

6 REMOVAL (Cont.): 9 On back side of inner seat module, slide stationary belt end loop off steel tab (Fig. 12). When removing the center lap-shoulder belt on the three-occupant seat, the stationary belt is removed by pushing the belt end loop through the bezel from the rear. Remove the white wedge and then pull the belt loop back through the bezel and remove from the module (Fig 13) Withdraw retractor and web with attachments from lower end of inner seat module (Fig 14 and Fig 15). INSTALLATION: Feed web and attachments through opening on lower side of seat inner module. 12 Install retractor in inner seat module lower channel pocket in proper position. 13 Pull web and attachments over the top of module checking to make sure there are no twists in web Reattach stationary belt loop to frame tab (or center bezel). 15 Reattach bezel to inner seat module Locate upper corners of SmartFrame module into seat back pocket corners (Fig. 16). 16 5

7 INSTALLATION (Cont.): 17 Continue down along the sides to locate the SmartFrame module in to the pocket opening. The SmartFrame module should snap into position (Fig. 17) as the module lower structure (A) rotates over the seat frame rear cross member (B) (Fig. 18). 17 A 18 B 18 Align both mounting holes on lower front of SmartFrame module with mounting weld-nut on seat frame (Fig. 19) Install both SmartFrame attaching screws and tighten to ft.-lbs. torque (Fig. 20) Pull SmartFrame module lower structure snug up against seat frame rear cross member (Fig. 21). 21 6

8 INSTALLATION (Cont.): 21 Properly locate wall side retractor, then align wall side mounting hole on seat frame rear cross member with retractor. Install 7/16 bolt and tighten to 25 ft-lb torque (Fig. 22) Properly locate aisle side retractor, then align aisle side mounting hole on seat frame rear cross member retractor. Install 7/16 bolt and tighten to 25 ft-lb torque (Fig. 23) Properly locate center retractor (if fitted), then align mounting hole to right of seat center on seat frame\rear cross member with retractor. If no retractor, install bolt and nut instead. Install 7/16 bolt and tighten to 25 ft-lb torque (Fig. 24 and 25)

9 INSTALLATION (Cont.): 24 Align mounting hole to left of seat center on seat frame rear cross member with matching hole on module lower structure. Install 7/16 bolt and flange nut and tighten to 25 ft-lb torque (Fig. 26 and 27) Align wall side shoulder belt lower anchor with seat wall side anchorage. Pull anchor plate slot down as far as possible to tighten stationary belt. Install 7/16 bolt and tighten to 25 ft-lb torque (Fig. 28 & 29) Repeat Step 25 for remaining belt anchors Ensure that seat back cover is tight on seat back by stretching cover down over lower side corners (Fig. 30). 30 Stretch cover in downward direction 8

10 INSTALLATION (Cont.): 28 Insert XChange seat wire under the seat frame metal tabs. Start in the center of seat and work toward the corners. Continue until the entire bottom wire is secured under the metal tabs (Fig. 31) After wire is inserted behind all metal tabs, using a screwdriver, press down all metal tabs to prevent wire from sliding out from under metal tabs. Sliding Buckles Replacement REMOVAL: 1 Unlatch seat cushion and pivot cushion up and forward. 2 Using two wrenches, loosen and remove nut at either end of buckle shaft (Fig. 1). 1 3 Pull shaft end with removed nut through support bracket hole. Continue to pull, angling in front of retractor, until enough shaft is withdrawn to allow removal of sliding buckles (Fig. 2). INSTALLATION: 2 1 Reverse steps 1 through 3. 2 While lifting on buckle, rotate seat cushion back into final position. Push down at center of seat cushion to ensure that seat cushion latches to frame (Fig. 3). 3 9

11 Testing of Seat Belt Systems 1 Test operation of each seat belt assembly as follows: a) Extract webbing from seat by pulling at the latch plate (Fig.1). b) Insert latch plate into buckle, listening for click to assure engagement (Fig. 2). c) Push buckle release button. (Fig. 3) Latch plate should eject from buckle and webbing should fully retract into seat. d) Repeat a-c for each belt system

12 REMOVAL: Seat Back Outer Cover Replacement 1 Remove seat inner module. Refer to Section: Lap-Shoulder Belt Replacement steps Using a flat blade screw driver pry open tabs holding cover attachment wires in position. There are five tabs along the upper edge and four tabs along each side edge. The lower end of each side has a leg which is rotated behind a flange on the seat frame side (Fig. 1). 1 INSTALLATION: NOTE: By warming the cover prior to installation, proper fit will be more easily achieved. A warm cover will be more pliable and easier to contour to seat back foam and frame features. Leaving cover in a warm room for several hours or exposed to direct sunlight on a warm day will be adequate. 2 1 Replace scrim material to top of seat foam. Scrim will aid in sliding the new vinyl cover over the foam seat back (Fig. 2). 3 2 Place XChange seat back cover over foam. (Fig. 3) Beginning on top, wrap front surface of cover over front of foam Snug down both corners equally to fit tightly over foam. (Fig. 4) Tuck any exposed scrim under the adjacent vinyl cover. 4 3 Pull sides of XChange cover around seat sides (Fig. 19). 5 11

13 INSTALLATION (Cont.): 4 Center cover over foam by tucking cover inside corners around foam (Fig. 6). 5 Fit entire top of cover snugly around foam. Ensure seat cover seams match to foam shape. Seams should lay directly on the foam edges. (Fig. 7) Continue fitting sides of cover properly along seat back foam sides Locate seat back metal tabs. There are 13 total tabs- five along the top and four on each side. With screwdriver, slightly open metal tabs (Fig. 8). Lift tabs 8 7 Insert XChange seat wire under the seat frame upper metal tabs. Start in the center of seat and work toward the corners (Fig. 9). Continue until the entire top wire is secured under the top metal tabs. Tab 9 Wire 8 On wall side, tuck two (2) bottom vinyl tabs on lower edge of cover under lower edge of seat foam (Fig. 10) TABS 10 12

14 INSTALLATION (Cont.): 9 Attach XChange cover wall side wire to side of seat frame. Starting at the bottom of seat, rotate wire so that bent leg locates behind seat frame flange. Next insert cover wire under the seat frame wall side metal tabs. Start at the top of seat and work down the seat side. (Fig. 11) Continue until the entire side wire is secured. 11 Wire 10 Repeat Steps 8 and 9 on aisle side of seat. Close tabs 11 After wire is inserted behind all metal tabs, using a screwdriver, press down all metal tabs to prevent wire from sliding out from under metal tabs (Fig. 12)

15 Integrated Child Seat Restraint System Replacement REMOVAL: 1 Remove Integrated child seat inner seat module from XChange seat. Refer to Section: Lap- Shoulder Belt Replacement steps Remove two Allen head screws attaching belt adjuster block to inner module frame. (Fig.1). A locknut secures each screw and requires a wrench for holding (Fig. 2). Remove screws (Fig. 3) Remove belt adjuster block from seat module. (Fig. 4). 4 14

16 REMOVAL (Cont.): 4 On back side of module, pull back on upper webbing 3 bar web plate (Fig. 5) and then insert through slot on module panel to front side (Fig. 6). Repeat for other side 3 bar web plate On back side of module, pull back on lower webbing 3 bar web plate (Fig. 7) and then insert through slot on module panel to front side. (Fig. 8) Repeat for other side 3 bar web plate Remove seat back cushion pad (Fig. 9). 9 15

17 REMOVAL (Cont.): 7 Open Velcro attached flap on rear seat cushion cover to expose hinge nuts (2) in each corner of the child seat cushion pocket (Fig. 10) Remove both lower seat cushion hinge nuts. (Fig. 11 and Fig. 12). If necessary, open Velcro attached cover flap for better access to nuts Remove restraint and cushion assembly from inner module at corner hinge studs. Seat cushion will flex to clear stud (Fig. 13) If not open previously, open lower cushion cover velcro attached flap (Fig. 14). Fold out corner flaps

18 REMOVAL (Cont.): 11 Push buckle and web through cover opening to inside of cover (Fig. 15) Slide belt attachment plate out of seat cushion cover leaving cushion foam in place (Fig. 16) and (Fig. 17) Unthread lab belt portion of restraint web from anchor guides on each side corner (Fig. 18) and (Fig. 19)

19 REMOVAL (Cont.): 14 Unthread web from rear H slot (Fig. 20) Thread buckle web from narrow web slot to adjacent larger buckle slot (Fig. 21) Pass buckle through adjacent larger buckle slot (Fig. 22) on belt attachment plate and remove restraint assembly. INSTALLATION: 22 Installation is the reverse of removal. Refer to Steps 17, 18 and 19 for additional information. 17 Make sure restraint web is properly oriented on seat belt attachment plate before inserted into seat cushion cover (Fig. 23)

20 INSTALLATION (Cont.): 18 Pull web tight on seat attachment plate before closing cover flap (Fig. 24) Pull cover tight over seat attachment plate before closing Velcro flap (Fig. 25)

21 Care and Maintenance Care and maintenance of the SafeGuard Bus Seat is the responsibility of the owner of the SafeGuard Bus Seat. Clean seat cushions, webbing and buckle with a damp sponge using mild soap solution and lukewarm water. Never use bleach or cleansers. Never lubricate the seat belt buckle. Seat Inspection Seats should be inspected regularly and after a crash: Inspect frame members and welds for damage, signs of failure or corrosion. Inspect that all attachment fasteners are present and secure. Inspect vinyl covering for cuts, tears or punctures that expose seat cushion or seat back foam. Inspect foam for cuts or missing sections. Verify that no portion of seat frame can be felt through foam. Inspect for tight fit of seat cover over all foam. Replace foam if covering is loose or bagging. Replace foam if any localized collapse of foam exists. If any of these conditions develop or exist on the SafeGuard XChange Bus Seat, it will require repair or replacement of the affected parts immediately, regardless the age of the seat. See your OEM School Bus dealer or authorized SafeGuard Bus Seat dealer for replacement parts. 20

22 Care and Maintenance Seat Belt Inspection Lap-shoulder seat belt restraints and integrated child seat restraints on the SafeGuard XChange Bus Seat should be inspected regularly and after a crash as follows: Inspect belt on entire system for cuts, fraying, abrasion, and extreme or unusual wear. Inspect buckle for proper operation by inserting latch plate and listening for an audible click. Verify the buckle is not damaged cracked or broken. Inspect latch plate for proper operation by inserting into buckle. Latch plate must insert smoothly and produce an audible click Verify proper latching by tugging on the belt Latch plate must not be worn, deformed, or corroded. Inspect seat belt height adjuster for damage. Move adjuster up and down. It must move freely. Inspect retractor operation. When pulled and released slowly, webbing must spool out and retract without locking. Inspect mounting hardware at each restraint attachment point. Hardware should be tight. Hardware must not be missing, rusted, corroded, or damaged. If any of these conditions develop or exist on the SafeGuard XChange Bus Seat belt system, it will require replacement of the seat belt(s) immediately, regardless the age of the seat. See your OEM School Bus dealer or authorized SafeGuard Bus Seat Seat Belt Reverse Lock-Up Correction If during the seat installation process the lap-shoulder seat belt restraint becomes locked-up and cannot be pulled out, perform the following steps. 1. Move the shoulder height adjuster down. 2. Grasp the top of the shoulder belt webbing close to where it exits the top of the seat and above the shoulder height adjuster. 3. Pull the web with a constant even force, tight enough to pull some additional (1/2 inch) web from the belt exit. 4. Slowly release the web. This should unlock the retractor. 21

23 Care and Maintenance User Assistance For assistance using the SafeGuard Bus Seat, contact the OEM Bus dealer or IMMI/ SafeGuard Customer Service at SafeGuard Bus lap-shoulder seat belt restraints and child restraints are certified to applicable U.S. Federal Motor Vehicle Safety Standards FMVSS 209, 213, and 302. The SafeGuard Bus Seat, when properly installed per the instructions and with applicable hardware, allows the bus to meet U.S. Federal Motor Vehicle Safety Standards FMVSS 210, 222, and

24 safeguardseat.com School Bus Seating Westfield, IN Made in U.S.A. SafeGuard Customer Service IMMI All rights reserved. 4294P 06/12 PN Rev 02