USSC LLC 4 ONE LLC FIELD MODIFICATION INSTRUCTIONS

Transcription

1 and Retrofit of G2E Quick Release Cushion Upholstery 1 OF 32 A 1.0 PURPOSE: To replace both Back and Cushion Upholstery on the G2E seats. 2.0 Tools Required: 2.1 1/2 Socket and Wrench 2.2 5/8 Socket 2.3 Ratchet /64 Drill Bit 2.5 Drill 2.6 Utility Knife or Scissors 2.7 Rubber or Plastic Mallet 2.8 Flat Head Screwdriver 2.9 5mm Allen Wrench 2.10 Steamer 3.0 Materials Required: 3.1 Semi Permanent Thread locker, such as Blue Loctite 242 or equivalent 3.2 Permanent Thread locker, such as Red Loctite 271 or equivalent 3.3 Back Upholstery (See 2) 3.4 Cushion Upholstery (See 11 for changing out the old revision upholstery to the new quick release upholstery and 20 for quick release upholstery) Upholstery Clip P/N (Qty: 3), Rivet P/N (Qty: 12), and 16.5 of Hook Tape P/N: (Qty: 1) (The above is required if changing out old revision cushion upholstery)

2 and Retrofit of G2E Quick Release Cushion Upholstery 2 OF 32 A Figure Procedure: 4.1 Back Upholstery Replacement: Remove lumbar knob, if applicable, by pulling on the knob as shown in Figure 2. Figure 2 Lumbar Knob Remove armrest, if applicable, by using a 5mm Allen wrench or hex bit socket and ratchet as shown in Figure 3.

3 and Retrofit of G2E Quick Release Cushion Upholstery 3 OF 32 A Armrest Screws Figure Disconnect the ring clip from one of the two zippers on the back upholstery, as shown in Figure 4. Once completed, unzip the back cover. Ring Clip Figure Using a flat head screw driver or pry bar, release the headrest spring from the top of the back assembly, as shown in Figure 5. Once completed, pull the headrest up and out of the back assembly and then reposition the headrest spring back into place in the back frame.

4 and Retrofit of G2E Quick Release Cushion Upholstery 4 OF 32 A Headrest Spring Figure Using a flat head screw driver or pry bar, release the headrest plugs from the back assembly, as shown in Figure 6. Headrest Plug Figure Pull upholstery off of back assembly starting from the top, as shown in Figure 7.

5 and Retrofit of G2E Quick Release Cushion Upholstery 5 OF 32 A Figure Separate the center section, tombstone, of the back foam from the frame (a knife may be required if glued), as shown in Figure 8. Once removed, pull the tombstone foam out of the upholstery. Figure 8

6 and Retrofit of G2E Quick Release Cushion Upholstery 6 OF 32 A Installation of the new upholstery follows the same steps as upholstery removal but in opposite order. Begin by inserting the tombstone foam into the center of the new upholstery, as shown in Figure 9. Figure Position the top of the tombstone foam and plastic pull as shown in Figure 10. Push the tombstone foam and plastic pull up and behind the rest of the back foam.

7 and Retrofit of G2E Quick Release Cushion Upholstery 7 OF 32 A Figure Ensure that the plastic pull is seated behind both pieces of foam and lying flat (so that the front of the upholstery looks clean and does not trampoline) as shown in Figure 11.

8 and Retrofit of G2E Quick Release Cushion Upholstery 8 OF 32 A Figure Pull the bottom flap of the upholstery under the back frame as shown in Figure 12. Fit the upholstery up and around the sides of the back assembly.

9 and Retrofit of G2E Quick Release Cushion Upholstery 9 OF 32 A Figure Position the headrest plugs over the headrest tubes in the back frame as shown in Figure 13. Lock into place by tapping on the top of the plugs with a rubber or plastic mallet.

10 and Retrofit of G2E Quick Release Cushion Upholstery 10 OF 32 A Figure 13 Headrest Plug Trim a small hole in the upholstery for the lumbar rod to fit through, if applicable, as shown in Figure 14. Re-zip the bottom upholstery flap to the back flap. Lumbar Rod Figure Re-zip the upper zipper as shown in Figure 15. Reattach ring clip to both zippers.

11 and Retrofit of G2E Quick Release Cushion Upholstery 11 OF 32 A Upper Zipper Ring Clip Figure If applicable, locate and cut three holes in the upholstery for armrest attachment, as shown in Figure 16.

12 and Retrofit of G2E Quick Release Cushion Upholstery 12 OF 32 A Cut Here Figure If applicable, attach armrest to back assembly using the three armrest screws that were removed earlier, as shown in Figure 17. Apply semi permanent thread locker to the screws prior to assembly and then tighten using a 5mm hex bit socket or Allen key. Figure Align slot on lumbar knob with lumbar shaft, as shown in Figure 18, and press into place.

13 and Retrofit of G2E Quick Release Cushion Upholstery 13 OF 32 A Figure Reinstall headrest with the notches in the headrest rods facing rearwards as shown in Figure 19. Figure Cushion Upholstery Replacement (old version to quick release retrofit):

14 and Retrofit of G2E Quick Release Cushion Upholstery 14 OF 32 A Although not necessary, removing the seat from the vehicle could aid in this one time upholstery change Remove the back assembly by removing the four 7/16-20 bolts, two per side, using a 5/8 socket and ratchet as shown in Figure 20. Figure 20 7/16 Mounting Hardware Remove the mounting brackets from the cushion assembly by removing the six 5/16-18 bolts, three per side, using a 1/2 socket and ratchet or a 1/2 open end wrench as shown in Figure 21. NOTE: Remember the positioning of the mounting brackets and the hardware used as these will vary from application to application. 5/16 Mounting Hardware Figure 21

15 and Retrofit of G2E Quick Release Cushion Upholstery 15 OF 32 A Release the cushion upholstery J-retainers from the bottom of the seat pan as shown in Figure 22. Upholstery J-retainers Figure Pull the cover off the frame starting from the front corners and working your way back, as shown in Figure 23. Figure 23

16 and Retrofit of G2E Quick Release Cushion Upholstery 16 OF 32 A Rotate the plastic upholstery pull upwards and pull through the cutout in the foam cushion and out the other side, as shown in Figure 24. Figure 24 NOTE: Proceed to step if installing a new foam cushion Use a steamer to release the upholstery flaps from the foam cushion, as shown in Figure 25. NOTE: Use Caution when operation the steamer, serious burns can result!

17 and Retrofit of G2E Quick Release Cushion Upholstery 17 OF 32 A Upholstery Flaps Figure Use a steamer, from the topside of the upholstery, to release the upholstery from the foam cushion, as shown in Figure 26. This works best when starting from one corner and finishing at the opposite. NOTE: Use Caution when operation the steamer, serious burns can result! Figure 26

18 and Retrofit of G2E Quick Release Cushion Upholstery 18 OF 32 A Use a template to locate and drill, using a 13/64 drill bit, the ten (10) holes for mounting the hook tape and upholstery brackets, as shown in Figure 27. Mounting Holes Figure Position the three upholstery clips, P/N: , as shown in Figure 28. The notches in the sides of the brackets should line up with the edge of the pan. The hem on the brackets should be facing the dymetrol. Notch Hem Dymetrol Figure 28

19 and Retrofit of G2E Quick Release Cushion Upholstery 19 OF 32 A Insert nine rivets, P/N: into the upholstery clips (3 per clip) and securely fasten to the cushion frame, as shown in Figure 29. Figure Apply a 16.5 piece of Hook Tape, P/N: , to the back of the pan as shown in Figure 30. Insert three rivets, P/N: into the hook tape and securely fasten to the cushion frame as shown in Figure 30.

20 and Retrofit of G2E Quick Release Cushion Upholstery 20 OF 32 A Figure Apply spray foam adhesive to the underside of the cushion upholstery and to the top of the foam as shown in Figure 31. Spray Glue Figure Align upholstery and foam and insert the plastic upholstery pull through the slot in the foam as shown in Figure 32. Continue to wrap the upholstery around the foam cushion.

21 and Retrofit of G2E Quick Release Cushion Upholstery 21 OF 32 A Figure Reattach the mounting brackets to the seat frame using the hardware that was removed previously, as shown in Figure 33.

22 and Retrofit of G2E Quick Release Cushion Upholstery 22 OF 32 A Figure Attach the loop tape on the rear upholstery flap to the hook tape that was installed onto the back of the seat frame as shown in Figure 34. Figure 34

23 and Retrofit of G2E Quick Release Cushion Upholstery 23 OF 32 A Attach upholstery J-retainer to the seat frame as shown in Figure 35. There are two pieces per side and one in the front. The J-retainers should click when fully engaged to the upholstery clips. Figure Reinstall the back assembly using the original 7/16 hardware that was removed previously, as shown in Figure 36.

24 and Retrofit of G2E Quick Release Cushion Upholstery 24 OF 32 A Figure Figure 37 shows the completed seat with current upholstery. If seat was removed from vehicle, reinstall at this point. Figure Cushion Upholstery Replacement (quick release):

25 and Retrofit of G2E Quick Release Cushion Upholstery 25 OF 32 A Check to ensure that the seat cushion you are about to reupholster is the quick release version by inspecting the rear flap for loop tape. If there is no loop tape, please refer to step Release the back upholstery flap from the seat frame by separating the hook and loop tape as shown in Figure 38. Figure Using a standard screw driver push the plastic J-retainer strip off of the upholstery clips as shown in Figure 39. Continue to pull off the remaining J-retainer strips. Figure 39

26 and Retrofit of G2E Quick Release Cushion Upholstery 26 OF 32 A Pull the cushion assembly up and away from the seat assembly as shown in Figure 40. Figure 40 NOTE: Proceed to step if installing a new foam cushion Rotate the plastic upholstery pull and insert through the slot in the foam as shown in Figure 41. Use a steamer to release the upholstery from the foam and work from corner to corner. NOTE: Use Caution when operation the steamer, serious burns can result!

27 and Retrofit of G2E Quick Release Cushion Upholstery 27 OF 32 A Figure Apply spray foam adhesive to the underside of the cushion upholstery and to the top of the foam as shown in Figure 42. Spray Glue

28 and Retrofit of G2E Quick Release Cushion Upholstery 28 OF 32 A Figure Align upholstery and foam and insert the plastic upholstery pull through the slot in the foam as shown in Figure 43. Continue to wrap the upholstery around the foam cushion.

29 and Retrofit of G2E Quick Release Cushion Upholstery 29 OF 32 A Figure Attach the front J-retainer to the seat frame as shown in Figure 44. The J-retainer should click when fully engaged to the upholstery clip.

30 and Retrofit of G2E Quick Release Cushion Upholstery 30 OF 32 A Figure Pull the rear upholstery flap under the back assembly and attach the loop tape on the upholstery flap to the hook tape on the seat frame as shown in Figure 45.

31 and Retrofit of G2E Quick Release Cushion Upholstery 31 OF 32 A Figure Attach the side J-retainers to the seat frame as shown in Figure 46. The J-retainer should click when fully engaged to the upholstery clip.

32 and Retrofit of G2E Quick Release Cushion Upholstery 32 OF 32 A Figure Figure 47 shows the completed seat with current upholstery. If seat was removed from vehicle, reinstall at this point. Figure Inspection: 5.1 Check to insure that all mounting hardware is tight. 5.2 Check to insure that the seat cushion is securely attached.