Mega MULTITRUCK 400 - 600, Manual

Page 1: ...MULTITRUCK 400 600 Repair manual ...

Page 2: ...nsmission IBC repair manual GROUP 4 Front Axle GROUP 5 Rear Axle GROUP 6 Wheel Handbrake Brake GROUP 7 Body shell GROUP 8 Display features Tachymeter Fuel gauge Odometer Gearbox position Service Turning lights and hazard lights Indicator lights Pre heating system Engine stop Group 9 Paint ...

Page 3: ...GROUP 1 Engine Oil ...

Page 4: ...Cooling system ...

Page 5: ...GROUP 3 Gearbox ...

Page 6: ...Continuous variable transmission ...

Page 7: ...CVT Service ...

Page 8: ...Maintenance Guide Variable Speed Power Transmission System VSP 2000 LP2 CVTech IBC Inc 300 Labonté Street Drummondville Quebec Canada J2C 6X9 www cvtech ibc com Most recent update 2004 01 13 ...

Page 9: ...he Pulleys from the Vehicle 6 Removing the Drive Pulley 6 Removing the Driven Pulley 8 Inspecting the Drive Belt 8 Disassembling and Reassembling the Pulleys 9 Disassembling the Drive Pulley 10 Reassembling the Drive Pulley 13 Disassembling the Driven Pulley 15 Reassembling the Driven Pulley 19 Reinstalling the Pulleys on the Vehicle 21 ...

Page 10: ...lubrication It is designed to work without lubricants Given this you have to apply certain rules of cleanliness when handling the system to avoid having any products come into contact with its components To increase the life of the transmission system it is strongly recommended that you inspect the following Description Inspection Maintenance Interval Drive pulley Visual General condition at 10 00...

Page 11: ...is not recommended Driven pulley extractor Flathead screwdriver Pliers to remove the locking ring Torque wrench 17mm and 30mm bushings Dismantling tool for the driven pulley Extractor Pillar press or drill press Drive pulley extractor 20 mm or 0 75 inch thread ...

Page 12: ...on system is made up of three main parts the Drive Pulley 3 the Driven Pulley 7 and the Drive Belt 10 1 Flywheel 2 Gearbox 3 Drive pulley 4 Lock washer 5 Hexagon bolt retaining 6 Pin 7 Driven pulley 8 Lock washer 9 Hexagon bolt retaining 10 Drive belt ...

Page 13: ...he nut that holds the drive pulley in a closed position use a 30mm bushing Make sure you don t drop the cap and the units It s safer to remove the free parts that is the parts that are no longer attached Use an extractor that is appropriate for the threads at the end of the shaft 20 mm or inch Insert the extractor rod into the shaft of the drive pulley ...

Page 14: ...tly with a hammer can help free the shaft of the drive pulley from the flywheel Turn the bolt of the extractor until the pulley pulls away from the shaft of the flywheel 1 Once you ve removed the drive pulley make sure the drive belt can rotate in the same direction as before you removed it Driven pulley extractor ...

Page 15: ...id damage that might cause bodily harm and or material damage The drive belt must be replaced if you can see cracks in it when it s turned inside out The drive belt has an original width that allows the transmission system to work properly It must be replaced according to the specifications in the table below Number starting with Original width Width at which to replace B32 29 mm 27mm D32 33 mm 31...

Page 16: ... it rotates in the same direction when it is reassembled The Drive Pulley 1 Stationary sheaf 2 Spacing washer 3 Sliding sheaf 4 Assembled centrifuge unit 5 Lower bearing 6 Spacing washer 1 2mm 7 Spacing washer 0 68mm 8 Spacing washer 0 5mm 9 Spacing washer 1 0mm 10 Spring 11 Upper bearing 12 Retaining ring washer 13 Cap 14 Plate washer 15 Nut ...

Page 17: ... is reassembled Inspection Damage to the units 4A Condition of the anti noise springs 4C on some models Disassembling the sliding sheaf L Use a bench press see illustration or a drill press to make sure the sliding sheaf doesn t disassemble too abruptly it might jump apart like a spring Once you ve removed the sliding sheaf from the shaft of the stationary sheaf position the stationary sheaf on a ...

Page 18: ...Make sure you jot down the number of spacing washers 6 7 and 8 9 and their position so that the original performance of the pulley is not altered For peak performance make sure you clean the sliding parts with a degreaser Inspection Wear damage to bearings 5 and 11 Wear at the sliding sheaf s working angle Wear damage to the spring 10 ...

Page 19: ...nary sheaf s working angle Replacing the bearing 1B if necessary 1A Stationary sheaf 1B Bearing 1C Locking ring Before each part removal step make very sure you clean the shaft well Use an extractor so you won t damage any of the parts that don t have to be replaced Removing the locking ring 1C Removing the bearing 1B ...

Page 20: ...d a tube 105mm long with an inner diameter of 32mm insert the bearing 1B Using the same tools insert the locking ring 1C Make sure the shoulder of the shaft the bearing and the locking ring make perfect contact with each other Don t use too much pressure with the press or you ll damage the components Mounting the sliding sheaf on the shaft of the stationary sheaf Before you mount the sliding sheaf...

Page 21: ... Mounting the cap and the centrifuge blocks Make sure you are mounting the centrifuge blocks correctly The narrow part of the block fits into the sliding sheaf Tightening the pulley Use a torque wrench with a 30mm bushing to tighten the pulley Use a tightening torque of 95 to 108 newton meters Narrow side ...

Page 22: ... ring Disassembling the Driven Pulley Make sure you jot down the position of the spring on the sliding sheaf and the cam When you reassemble the pulley the position of the spring must be the same as when you disassembled it This ensures that the performance of the pulley is not affected Position of the sliding sheaf Position of the cam ...

Page 23: ...you disassemble the driven pulley safely use a press or a driven pulley dismantling tool The pulley has to be blocked so it won t turn Also it is recommended that the pulley be stabilized on the press to keep it from moving during the different disassembling steps Push on the cam to free the retaining ring maximum 2 or 3mm Remove the retaining ring with an appropriate pair of pliers ...

Page 24: ...om the shaft Jot down the number of spacing washers between the two sheaves to ensure that the original performance of the pulley is not altered Inspection Wear damage to the cam Wear damage to the spring Visual inspection of the components ...

Page 25: ... flathead screwdriver to remove the shoes L Be careful not to get a finger jammed when handling the shoes You should use a pair of long nose pliers _______________________________________ Inspection If the cam fittings 4B are worn by half the original thickness X see illustration replace them Wear in the sheaf s working angle 4A Wear to the inside bearings of the sheaf do not replace unless the sh...

Page 26: ...nspect it Inspection Wear damage to the shaft inside and out Wear to the sheaf s working angle Visual inspection Reassembling the Driven Pulley Mounting the cam fittings on the sliding sheaf Use a hammer to mount the cam fittings 4A Don t be too rough with the hammer You might damage the fittings ...

Page 27: ...s when you disassembled it Place the pin 7 on the shaft of the stationary sheaf 1 Mounting the cam To mount the cam 6 use the disassembling procedure in reverse Place the spring in the cam in the same position as when you disassembled it Lock the cam into position on the stationary sheaf 1 and on the pin 7 Keep the stationary sheaf and the cam 6 from moving Turn the sliding sheaf 4 counter clockwi...

Page 28: ...led use a torque wrench standard torque to tighten the two bolts Minimum diameter of the bolt Grade Standard torque newton meter 8 mm 8 8 21 to 28 10 mm 8 8 42 to 54 To tighten the drive pulley use a screwdriver or other tool to block the engine from turning Be careful not to damage any of the parts ...

Page 29: ...Drive line ...

Page 30: ...GROUPE 4 Front Axle ...

Page 31: ...GROUPE 5 Rear Axle ...

Page 32: ...GROUPE 6 Wheel ...

Page 33: ...Handbrake ...

Page 34: ...Brake ...

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Page 36: ...GROUP 7 Body shell and sub frame ...

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Page 39: ... AM8K06A under the needle Display functionality features 1 Analogical speedometer 2 LCD fuel gauge 3 LCD Odometer daily and general 4 Gearbox position LCD indicator 5 LCD Service indicator light 6 Turning light hazard light and buzzer 7 Indicator lights 8 Pre heating system and indicator light 9 Stop managing ...

Page 40: ... signal to the display the display calculates the mileage for the odometer according to the wheel diameter and gearbox ratio Odometer is a LCD display with 6 number and 1 decimal place et 1 point décimal Maximum value for the main odometer 999 999 Km Maximum value for the daily odometer 999 9 Km You can switch from the main odometer to the daily by a short push on the left button Reset the daily o...

Page 41: ... the message 1 year is displayed for 5 second and the key symbol will stay on To reset the service management Put the ignition on Push on the two buttons for 6 second until 10 second after the ignition is on 6 Turning lights and hazard lights Turning lights management and right and left display indicator management In good order 100 blinking per minute With a broken bulb 200 blinking per minute Tu...

Page 42: ...he pre heating system and the indicator light are switching off by the display The pre heating time depends of the engine temperature drive by a CTN sensor If the CTN sensor is unplugged 0 c is taken to estimate the pre heating time 9 Engine Stop When the ignition is switched off the engine stop solenoid is fed for 8 seconds by a timing relay ...

Page 43: ...auffage Essuieglace avetar Feuxderecul Combinéde bord Relaide Dégivragear Feuxstop Relaide préchauffage Alternateur F3 15A F2 20A F1 20A F10 20A F9 20A F8 15A F7 10A C19 S1 C19 S2 C19 S3 C19 S4 C18 S1 C18 S2 C18 S3 APC APC APC APC PER PER PER C18 E3 C18 E2 C18 E1 4C19 E4 C19 E3 C19 E2 C19 E1 AntiBuillard Feuxar Feuxderecul Masse Freinàm ain M assecarburant Jaugecarburant Masse 1 9 3 8 C10 warning ...

Page 44: ... lave glace Ventilateur vitesse 1 Charge Altemateur TDB Exitation démarreur Thermo contact TDB Température d eau TDB Pression d huile TDB APC Allimentation capteur de vitesse TDB Masse capteur de vitesse TDB Signial capteur de vitesse TDB Avertisseur sonore Usure plaquette Arrêt moteur Feux arrières éclairage plaques de police Anti Brouillard Masse APC 5 Feu de recul essuie glace ar Frein à main T...

Page 45: ...Group 9 Paint ...

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