MULTITRUCK Repair manual

Transcription

1 MULTITRUCK Repair manual

2 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 - Tachymeter - Fuel gauge - Odometer - Gearbox position - Service - Turning lights and hazard lights - Indicator lights - Pre-heating system - Engine stop Display features Group 9 Paint

3 Engine Oil GROUP 1

4 Cooling system

5 Gearbox GROUP 3

6 Continuous variable transmission

7 CVT Service

8 Maintenance Guide Variable Speed Power Transmission System VSP 2000 / LP2 CVTech-IBC Inc. 300 Labonté Street Drummondville, Quebec Canada J2C 6X9 Most recent update:

9 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 Reassembling the Drive Pulley Disassembling the Driven Pulley Reassembling the Driven Pulley Reinstalling the Pulleys on the Vehicle

10 Important Notice Only qualified personnel can perform maintenance and repair operations on the variable speed transmission system. Means there is a risk of serious injury if the instructions are not followed as described. Means that, when performing this step, there is a risk of damaging a part or of the components malfunctioning. 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. 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 Visual General condition at km Stationary sheaf Visual at km Sliding sheaf Visual at km Assembled centrifuge unit Visual at km Lower bearing Visual Replace at km Spring Visual at km Upper bearing Visual Replace at km Driven pulley Visual General condition at km Stationary sheaf Visual at km Sliding sheaf Visual at km Cam fittings Dimensional (see page 18) at km Spring Visual at km Drive belt Visual Dimensional (see page 8) at km 3

11 Handling Tools You ll Need Flathead screwdriver Pliers to remove the locking ring Torque wrench 17mm and 30mm bushings Driven pulley extractor Dismantling tool for the driven pulley Extractor Pillar press or drill press Drive pulley extractor, 20 mm or 0.75 inch thread *** Important: Using impact tools is not recommended.*** 4

12 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

13 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

14 Bolt the extractor to the end of the shaft. (Using pressure, turn one half turn). Sometimes, tapping the extractor gently 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). Driven pulley extractor Once you ve removed the drive pulley, make sure the drive belt can rotate in the same direction as before you removed it. 7

15 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 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 B mm 27mm D mm 31mm 8

16 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

17 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. 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 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

18 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

19 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

20 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

21 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

22 The Driven Pulley 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 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

23 Disassembling the cam 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

24 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

25 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. 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

26 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

27 Mounting the sliding sheaf on the stationary 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. Mounting the spring on the sliding sheaf 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). Keep the stationary sheaf and the cam (6) from moving. 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). 20

28 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 Grade Standard torque (newton meter) 8 mm to mm 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. 21

29 Drive line

30 Front Axle GROUPE 4

31 Rear Axle GROUPE 5

32 Wheel GROUPE 6

33 Handbrake

34 Brake

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36 Body shell and sub frame GROUP 7

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39 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

40 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 = Km Maximum value for the daily odometer = 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

41 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

42 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.

43 C28 Essuie glace C C24 - Interconnection Moteur / tableau de bord A3 A5 C6 C7 C8 C5 C9 C4 B8 A2 A6 A1 A7 B1 A9 B2 B4 B7 B6 B5 A8 B3 C26- Commodo essuie glace B6 B5 B1 B2 B3 A6 vitesse2 vitesse1 intermittant Cde lave glace Niveau looked Cde lave glace E12M Clignotant gauche Clignotant droit feux de Position feux de Route feux de Croisement Avertisseur Plaquette de frein Charge alternateur Thermo contact Pression d'huile Températeure d'eau Capteur de vitesse masse Alim capteur de vitesse Capteur de vitesse signial Arrêt moteur Exitation Démarreur + APC Ventilateur vitesse 1 Ventilateur vitesse 2 Ventilateur vitesse 3 + APC Masse E1 E9 C1- Interconnection Moteur/ Tableau de bord M2 E6 E8 E5 E3 D2 D4 D3 Jauge carburant Masse carburant Point neutre Masse carburant Plaquette de frein Jauge carburant Arrêt moteur Code relai de préchauffage Charge alternateur Thermo contact Pression d'huile Températeure d'eau Capteur de vitesse masse Alim capteur de vitesse Capteur de vitesse signial COMBINE DE BORD C37 C38 M Frein à main Clignotant gauche Clignotant droit Frein à main+looked Capteur de porte Masse warning Anti brouillard Clignotant gauche Clignotant droit + PER M8 Feux de position Feux de Croisement Feux de route + APC Anti Buillard E2 Feux ar E13 E14 E8 E5 Feux de recul Masse E3 E4 Anti brouillard Clignotant gauche Clignotant droit Avertisseur Feux de position Feux de Croisement Feux de route B3 B5 b3 a3 A2 A4 B1 Commodo feux a1 b1 b2 B2 B4 A5 Masse C27 C36 +PER Masse Client Origine G Voir émail le 6 novembre 2006 Objet: EVO 8MD041 Ind Rév date Objet de la modification Plan électrique PDB C10 - warning C60-Anti Brouillard Date: Réf: 8MD041 Sidilec International ROUTE DE MAHDIA KM Sfax (Tunisie) Tél Fax Site web: Echelle: 1:1 Dess par:nouha Koubâa Vérifiée par: Abdellatif Jardak C25-Bougie de Préchauffage C9 - Inter ventilateur C16-Relai arrêt moteur C15-Relai de Préchauffage C14-Relai de demarrage Neiman C21 - GR C22- NO Bougie Ventilateur vitesse 3 Ventilateur vitesse 2 Ventilateur vitesse 1 + APC Code Relai + PER + PER Bougie Code Relai + ACC + APC Exitation Dém +Bat + APC + ACC E10 + APC + APC + APC + APC + PER + PER + PER C18- E3 C18- E2 C18- E1 4 C19- E4 C19- E3 C19- E2 C19- E1 F3 (15A) - Auto radio F2 (20A) - Plafonnier F1 (20A) F10 (20A) F9 (20A) - Allume cigare - Avertisseur sonore - Arrêt moteur F8 (15A) - Alternateur F7 (10A) Préchauffage - Combiné de bord - Feux code, position, route, clignotant, anti brouillard - Dégivrage - Essuie glace av et ar - Feux de recul - Relai de préchauffage -Combiné de bord ar - Ventilateur chauffage - Relai de Dégivrage ar - Feux stop C19- S1 C19- S2 C19- S3 C19- S4 C18- S1 C18- S2 C18- S3 E7 Eclairage +PER Masse 1 2 C12 - Allume cigare A B C6 - Contacteur point neutre A B C11 - Allume cigare C5 - Contacteur feux de recul Auto radio C7- Allimentation C8 - HP PER + ACC Masse C13A Eclairage Plafonnier C4 HP G C29 HP G Cde plafonnier + PER Masse M C13- Plafonnier C31 Connecteur de porte gauche EM2 C32 Connecteur de porte gauche M5 C3 + C2 - Batterie EM1 C6- Masse chassis

44 C3- Pression d'huile C4- Température d'eau C9- Thermo contact C11- Moteur ventilateur C12- Pompe lave 1 glace 2 Démarreur C2 C1 Alternateur C6 1 2 C5 Batterie C22 C23 A + B C7- Masse chassis M2 C31' Reprise masse C30A Option de recul H V C31- Contacteur frein à main 2 1 C32- Jauge à carburant 2 3 C21- Capteur de vitesse C18 - Contacteur stop C14 - Usure plaquette C15 - Usure plaquette C10 - Arrêt moteur Bougie de préchauffage C C16 - B Avertissement sonore A A B C8 - Bougie de préchauffage Allimentation Masse Signial E1 Arrêt moteur Usure plaquette E2 Allimentation capteur de vitesse (TDB) Masse capteur de vitesse (TDB) Signial capteur de vitesse (TDB) Avertisseur sonore +APC Pression d'huile (TDB) Température d'eau(tdb) Exitation démarreur Thermo contact (TDB) Charge Altemateur (TDB) Ventilateur vitesse 1 Ventilateur vitesse 3 Ventilateur vitesse 2 Pompe lave glace Niveau looked C 24 - Interconnexion Moteur / Tableau de bord EPM Clignotant av droit E4 E5 E6 E3 Clignotant av gauche Feux de position Feux de route Feux de croisement A2 A3 A5 A6 A7 A1 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 C4 C5 C6 C7 C8 C9 Feux de croisement Feux de position Clignotant av d E7 Feux de route Masse Masse Feux de croisement C17 Feux de route A B Feux de position Clignotant av G C13 Feux AV D C20 - Niveau looked Feux AV G 4 Stop 1 Feu arriere C30 6 Clignotant G Interconnexion 5 Anti brouillard Faisceau moteur Faisceau arrière 2 Masse 3 Clignotant D Feux arrières + éclairage plaques de police 7 Recul Anti Brouillard E8 Masse E9 + APC 5 Feu de recul + essuie glace ar D2 E3 D3 D4 E5 E6 E8 Frein à main (TDB) Niveau carburant Interconnexion Moteur / Tableau de bord Masse jauge Ind Rév date Date: Echelle: 1:1 Dess par:nouha Koubâa Vérifiée par: Abdellatif Jardak Objet de la modification Plan électrique Fx MoT MW6 Réf: 8MD043 ROUTE DE MAHDIA KM Sfax (Tunisie) Tél Fax Site web: Origine Sidilec International

45 Paint Group 9

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