Mega MULTITRUCK 400 – 600 User Manual

MULTITRUCK 400 – 600

Repair manual

Contents

GROUP 1

Engine accessories
cooling fan

GROUP 3

Gearbox
Continuous variable transmission
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

GROUP 1

Engine Oil

Cooling system

GROUP 3

Gearbox

Continuous variable transmission

CVT Service

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

Table of Contents

Important Notice....................................................................................................3

Maintenance Frequency ........................................................................................3

Handling Tools You’ll Need.................................................................................4

Parts of the Transmission System .........................................................................5

Removing the 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

2

Important Notice

)

Only qualified personnel can perform maintenance and repair operations on the
variable speed transmission system.

L Means there is a risk of serious injury if the instructions are not followed as

¾

described.

¾

, Means that, when performing this step, there is a risk of damaging a part or of the

components malfunctioning.

¾ CVTech-IBC is held harmless of any and all liability as concerns damage or injury

resulting from the incorrect understanding of the text, improper use of the transmission
system, or improper use of the recommended tools.

¾ It is very important that you use the tightening torque indicated.

Maintenance Frequency

The transmission system does not require any 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
Stationary sheaf Visual at 10 000 km

Sliding sheaf Visual at 10 000 km
Assembled centrifuge

unit
Lower bearing Visual Replace at 10 000 km
Spring Visual at 10 000 km
Upper bearing Visual Replace at 10 000 km

Driven pulley
Stationary sheaf Visual at 10 000 km

Visual
General condition

Visual at 10 000 km

Visual
General condition

at 10 000 km

at 10 000 km

Sliding sheaf Visual at 10 000 km
Cam fittings Dimensional (see page 18) at 10 000 km
Spring Visual at 10 000 km

Drive belt

Visual
Dimensional (see page 8

3

at10 000 km

Flathead screwdriver

b

p

Handling Tools You’ll Need

Torque wrench

Pliers to remove

the locking ring

17mm and 30mm

ushings

Extractor

Driven pulley extractor

Pillar press or drill

ress

Dismantling tool
for the driven pulley

Drive pulley extractor,
20 mm or 0.75 inch thread

*** Important: Using impact tools is not recommended.***

4

Parts of the Transmission System

The transmission 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

5

Removing the Pulleys from the Vehicle

Remove the bolt (5) from the drive pulley and
the bolt (9) from the driven pulley.

Removing the Drive Pulley

Remove the 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 ¾ inch).

Insert the extractor rod into the shaft of the
drive pulley.

6

Sometimes, tapping the extractor gently with a
hammer can help free the shaft of the drive
pulley from the flywheel.

Bolt the extractor to the end of the shaft.
(Using pressure, turn one half turn).

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

7

Removing the Driven Pulley

The driven pulley can be removed manually but, in some cases, using the driven pulley
extractor can help.

Inspecting the Drive Belt

L ,The drive belt has to be inspected to avoid 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 31mm

8

Disassembling and Reassembling the Pulleys

, When disassembling the pulleys, jot down the direction in which the drive belt rotates

to make sure 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

9

Disassembling the Drive Pulley

Disassembling the cap and the centrifuge
blocks

Remove the nut (15) and the washer (14).
This frees the cap and the centrifuge blocks.

L To make sure you don’t disturb the

balance of the pulley, mark the original
position of each centrifuge block so it can be
replaced in the same position when the
centrifuge 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 press so you can lower the upper bearing (11).

Lower the upper bearing (11) so you can remove
the retaining ring (12) with a flathead
screwdriver.

10

Slowly raise it again being careful not to let any of the parts
fall.
There may be several spacing washers inside the sliding
sheaf.

, 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)

11

Disassembling the stationary sheaf (as needed)

Inspection

• Wear damage to the shaft (inside and out)

• Wear at the stationary 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)

12

Reassembling the Drive Pulley

Reassembling the sliding sheaf

To reassemble the sliding sheaf, see the procedure “Disassembling the sliding sheaf” and
reverse the directions.

, Make sure you put the spacing washers back in their original positions.

Reassembling the stationary sheaf

Using a press and 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 (3) on the shaft of the
stationary sheaf (1), make sure you place the spacing washer
(2) on the shaft.

13

, When you mount the sliding sheaf (3), make sure you center the spacing washers (8-9)

properly on the shaft.

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.

Narrow side

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.

14

1.... Stationary sheaf

2.... Spacing washer (1.2mm)

3.... Spacing washer (0.68mm)

4.... Sliding sheaf

5.... Spring

6.... Cam

7.... Pin

8.... Retaining ring

The Driven Pulley

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 cam

Position of the
sliding sheaf

15

Disassembling the cam

L Be careful! A great deal of compression is used to mount the driven pulley. When you

disassemble it, it might jump up like a spring (spring effect).

To make sure 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.

16

Carefully lift the cam to free it from 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

17

Disassembling the sliding sheaf

You can remove the cam fittings with a flathead screwdriver.

4A....Sliding sheaf

4B....Cam fitting

_______________________________________

You can also remove the cam fittings without disassembling the pulley.

• Making sure the stationary sheaf doesn’t move, twist the sliding sheaf.

• Use a 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 sheaf has wear damage)

For peak performance, make sure you clean the inside bearings with a degreaser.

Stationary sheaf

18

The stationary sheaf (1) cannot be disassembled without damaging the parts. All you can
do is inspect 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.

19

Mounting the sliding sheaf on the stationary sheaf

Mounting the spring on the sliding sheaf

, To make sure the pulley works properly,

remember to put back between the two
pulleys as many spacing washers as you
removed when you disassembled it.

, Place the spring in the sliding sheaf (4) in the same

position as 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).

Turn the sliding sheaf (4) counter clockwise one third (1/3) of a turn.

• Lower the cam to lock the cam fittings in place (4B).

• Install the retaining ring (8).

• Keep the stationary sheaf and the cam (6) from moving.

20

Reinstalling the Pulleys on the Vehicle

Once the pulleys and the drive belt are properly installed, use a torque wrench
(standard torque) to tighten the two bolts.

Minimum
diameter of
the bolt
8 mm 8.8 21 to 28
10 mm 8.8 42 to 54

Grade Standard torque

(newton meter)

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.

21

Drive line

GROUPE 4

Front Axle

GROUPE 5

Rear Axle

GROUPE 6

Wheel

Handbrake

Brake

GROUP 7

Body shell and sub frame

GROUP 8

This display is only fitted on the Mega Multitruck (except Electric Vehicle).

You can read the reference 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

1-Speedometer

The speed signal is delivered by a Hall Effect sensor fitted on the gearbox case.
The sensor sends 8 pulse per revolution.
The sensor is driven by the intermediary shaft of the gear box and the display convert the
electric signal to the needle control.

It’s a linear progression from 0 km/h to maximum speed.

Maximum speed shown for a L6e (QLeM) = 80 Km/h
Maximum speed shown for a L7e (QLoM) = 120 Km/h

When the ignition is off, the needle goes to 0 Km/h

2-Fuel gauge

Analogical signal from the tank sensor (potentiometric sensor)
The fuel level is displayed by a bar graph (6 bar) and a minimum indicator light.

Low level = Blinking of the last bar and lighting of the minimum indicator light.

3-ODOMETER (Daily and general)

The speed sensor gives the speed 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 odometer by a long push on the left button when the daily odometer is displayed.

The speed unit is located at the right of the odometer.
To switch from Miles to Kilometre =

- Push on the left button

- Put the ignition ON

The Unit will automatically change. (Repeat this process to change again)

4-Gear box position indicator

It is managed by the two sensors on the gearshift lever.
Lever on the N position = N is displayed by the LCD and N indicator light is lighting
Lever on the D position = D is displayed by the LCD
Lever on the R position = R is displayed by the LCD

5-Service management

How much distance has been covered since the last service. Calculated with the
odometer.

First service = 1000Km or 1 year
Normal service 5000Km or 1 year
When the ignition is on, you can see the distance to the next service during 5 second, it is

displayed instead of the odometer with a little symbol (key) .Afterward the odometer came back
and the key symbol disappear.

If the distance to the next service is less than 200 Km, the distance displayed will blink for 5
second and after the key symbol will stay on.

If the time to the next service is less than 20 days, the message “1 year” displayed will blink for 5
second and after the key symbol will stay on.

When the time to the next service is completely past, 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.

Turning lights are only available when the ignition is on, hazard light are always available.

The buzzer works with the hazard and turning lights.

The buzzer will also advise you if the lamps are on when you want to leave the vehicle:

- The ignition must be off

- The lamp must be on

- The door must be open

7-Indicator lights and hazard lights

Indicator lights managed by the display:

Low beam lamp
Hi beam lamp
Charging system defect
Low oil pressure
High cooling system temperature
Brake pad wear
Handbrake and low brake fluid level

8-Pre-heating

When the ignition is on, the display managed the pre-heating system and the
pre-heating indicator light.

When the ignition is off, the 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.

Client

G

1

06-11-06

Voir émail le 6 novembre 2006 Objet: EVO 8MD041

M3

M2

Dess par:Nouha Koubâa

Rév

Echelle:

Vérifiée par: Abdellatif Jardak

Ind

Date:

Réf: 8MD041

date

1:1

26-07-2006

Site web:www.sidilec.com.tn

Tél. [phone] Fax. [phone]

ROUTE DE MAHDIA KM 10 3054 Sfax (Tunisie)

Objet de la modification

International

Sidilec

Origine

Essuie
glace

Eclairage
Plafonnier

4

1 53

2

C19

C28

E1

+ PER

C13A

C60-Anti
Brouillard

A B
C6 - Contacteur
point neutre

A B

C5 - Contacteur
feux de recul

Plan électrique PDB

E3

E4

E14

E13

C27
C36

+PER

EM2

Masse

E2

Feux de route

Feux de Croisement

Feux de position

Avertisseur

Clignotant droit

Clignotant gauche

a1 b1 b2 B2 B4 A5

Commodo feux

B3 B5 b3 a3 A2 A4 B1

Anti brouillard

M8

E7

E8

E5

E10

Masse

Cde lave glace

M1

+ PER

+ APC

Feux de route

Feux de Croisement

Feux de position

Clignotant droit

Clignotant gauche

Anti brouillard

warning

Masse

Capteur de porte

Frein à main+looked

Clignotant droit

Clignotant gauche

Code relai de préchauffage

Arrêt moteur

Jauge carburant

Masse carburant

Point neutre

Thermo contact

Charge alternateur

Plaquette de frein

Pression d'huile

Températeure d'eau

Capteur de vitesse masse

Alim capteur de vitesse

Capteur de vitesse signial

3 4 7 14 13 6 20 9 12 5 1 2 28 15 7 8 5 6

21 23 10 3 17 14 25 12 13 4 29 27 18 2

COMBINE DE BORD C37 C38

- Combiné de
bord

- Allume
cigare

- Auto radio

- Feux code,
position, route,
clignotant, anti
brouillard

- Avertisseur
sonore

- Plafonnier

- Dégivrage
ar

- Arrêt moteur

Préchauffage

- Ventilateur
chauffage

- Essuie glace
av et ar

- Feux de recul

-Combiné de
bord

- Relai de
Dégivrage ar

- Feux stop

- Relai de
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- E3C18- E2

C18- E1

4 C19- E4

C19- E3

C19- E2C19- E1

Anti Buillard

Feux ar

Feux de recul

Masse

Frein à main

Masse carburant

Jauge carburant

Masse

1 9 3 8

C10 - warning

Eclairage

Masse

+PER

C11 - Allume
cigare

1 2

C12 - Allume
cigare

E6 E8 E5 E3 D2 D4 D3

C1- Interconnection Moteur/ Tableau de bord

+ APC

E12M

intermittant

vitesse1

vitesse2

B6 B5 B1 B2 B3 A6

C26- Commodo essuie glace

E9

EM1

Masse

Cde plafonnier

M5

C2 -

Exitation Dém

+ ACC

+ APC

Code Relai

Bougie

+ PER

+ PER

Code Relai

Bougie

Ventilateur vitesse 1

Ventilateur vitesse 2

Ventilateur vitesse 3

+ APC

Ventilateur vitesse 3

Ventilateur vitesse 2

Ventilateur vitesse 1

+ APC

Exitation Démarreur

Arrêt moteur

Capteur de vitesse signial

Alim capteur de vitesse

Capteur de vitesse masse

Températeure d'eau

Pression d'huile

Thermo contact

Clignotant droit

Charge alternateur

Plaquette de frein

Avertisseur

feux de Croisement

feux de Route

feux de Position

Clignotant gauche

Niveau looked

Cde lave glace

A3 A5 C6 C7 C8 C5 C9 C4 B8

A2 A6 A1 A7 B1 A9 B2 B4

B7 B6 B5 A8 B3

C24 - Interconnection Moteur / tableau de bord

C25-Bougie
de
Préchauffage

1 4 3 2

C9 - Inter ventilateur

C16-Relai arrêt
moteur

3 2 1 5 2 3 1 5

C15-Relai de
Préchauffage

3 2 1 5

C14-Relai de
demarrage

C21 - GR
1 2

Neiman

C22- NO

1 2

+Bat

+ APC

+ ACC

Masse

+ ACC

+PER

8 7 4

Batterie

C3 +

C6- Masse

chassis

C32

Connecteur

de porte

gauche

C31

Connecteur

de porte

gauche

C7- Allimentation

Auto radio

3 2 1

C8 - HP
6 5 4 3

C13-

Plafonnier

C29
HP G

C4
HP G

Plan électrique Fx MoT MW6

Origine

Sidilec

International

Objet de la modification

ROUTE DE MAHDIA KM 10 3054 Sfax (Tunisie)

Tél. [phone] Fax. [phone]

Site web:www.sidilec.com.tn

26-07-2006

1:1

date

Réf: 8MD043

Date:

Ind

Vérifiée par: Abdellatif Jardak

Echelle:

Rév

Dess par:Nouha Koubâa

V

H

E9

E8

C31'
Reprise masse

7 Recul

3 Clignotant D

2 Masse

5 Anti brouillard

6 Clignotant G

1 Feu arriere

4 Stop

C30
Interconnexion
Faisceau moteur
Faisceau arrière

C30A
Option de recul

E3

E7

E4

E5

E6

Feux de route

Feux de croisement

C17
Feux AV
G

1 4 5 6 3

Masse

Feux de position

Clignotant av G

Masse

Clignotant av d

Feux de position

Feux de route

Feux de croisement

4 5 6 3 1

C13
Feux AV
D

C20 ­ Niveau
looked

A

B

EPM

E2

Bougie de préchauffage

Ventilateur vitesse 3

Ventilateur vitesse 2

Clignotant av gauche

Feux de position

Feux de route

Feux de croisement

Clignotant av droit

Niveau looked

Pompe 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 (TDB)

Niveau carburant

Masse jauge

D2 E3 D3 D4 E5 E6 E8

Interconnexion Moteur / Tableau de bord

C 24 - Interconnexion Moteur / Tableau de bord

A2 A3 A5 A6 A7 A1 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 C4 C5 C6 C7 C8 C9

C10 - Arrêt
moteur

E1

Signial

Masse

Allimentation

C25

C8 - Bougie de
préchauffage

C15 - Usure

plaquette

C14 - Usure

plaquette

A

B

C18 ­ Contacteur
stop

C16 ­ Avertissement
sonore

B

A

1

3

2

C21­ Capteur de
vitesse

C32- Jauge à carburant
2 32 1

C31- Contacteur frein à main

M2

C7- Masse
chassis

C23

C6

C22
A + B

Batterie

C5

1 2

Alternateur

Démarreur

C2 C1 1 2

C12- Pompe lave
glace

2 4 3 1

C11- Moteur
ventilateur

C9- Thermo
contact

C4- Température
d'eau

C3- Pression
d'huile

Group 9

Paint