CORVUS TERRAIN DX4 CAB Workshop Manual
  1. Manuals
  2. Brands
  3. CORVUS Manuals
  4. Offroad Vehicle
  5. TERRAIN DX4 CAB
  6. Workshop manual

CORVUS TERRAIN DX4 CAB Workshop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

WORKSHOP MANUAL
DX4 / PRO / CAB
Read this guide carefully. It contains important safety information.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TERRAIN DX4 CAB and is the answer not in the manual?

Questions and answers

Related Manuals for CORVUS TERRAIN DX4 CAB

Summary of Contents for CORVUS TERRAIN DX4 CAB

  • Page 1 WORKSHOP MANUAL DX4 / PRO / CAB Read this guide carefully. It contains important safety information.
  • Page 3 As CORVUS is constantly seeking new ways to improve the specifications, design and quality of its utility vehicles, ongoing modifications may take place. That is why the information in this catalogue may have changed since the time of printing. CORVUS reserves the right to modify models, colours, and/or technical specifications without notice and without incurring any obligation.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Notes Transmission oil - check Transmission oil - change General information Front differential oil - check/change Introduction 4WD locking oil - check/change Legal notices Pre-filter - Water separator - cleaning/replacement Cautions and warnings Filter - Water separator - cleaning/replacement Safety regulations CVT assembly Preliminary warnings...
  • Page 5 TABLE OF CONTENTS Rollbar cross member cover Front brake callipers Side drawers * Rear brake callipers Inner drawers * Brake discs Threshold plates Steering - disassembly Front hood Steering column Front hood base Steering cardan Front luggage compartment Steering arms and box Front lip EPS engine * Wheel arch...

  • Page 6: Notes

    NOTES WORKSHOP MANUAL Page We reserve the right to modify the product and the design.
  • Page 7 NOTES WORKSHOP MANUAL Page We reserve the right to modify the product and the design.
  • Page 8 NOTES WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 9: General Information

    GENERAL INFORMATION WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 10: Introduction

    We are delighted to be able to congratulate you on the purchase In the interest of technical development, CORVUS INNOVA of your CORVUS vehicle and we would like to thank you for the S.L. reserves the right to modify the construction, equipment confidence you have placed in us.

  • Page 11: Cautions And Warnings

    CAUTIONS AND WARNINGS SAFETY REGULATIONS YOU SHOULD READ THIS MANUAL CAREFULLY AND COMPLETELY DANGER BEFORE YOU ENJOY USING IT FOR THE FIRST TIME. IT CONTAINS INFORMATION AND SUGGESTIONS THAT WILL FACILITATE THE USE AND HANDLING OF THE VEHICLE. - If in order to perform certain operations on the engine, it is necessary that it should be left in gear, make sure that the premises are adequately ventilated;...

  • Page 12: Preliminary Warnings

    - During normal operation, the exhaust system and the engine are at - Use original CORVUS spare parts and lubricants recommended a high temperature. If you have to perform any operations on them, by CORVUS. Non-original or non-compliant spare parts can wait until they have cooled down or use gloves to avoid burns.
  • Page 13 “WORK METHODOLOGY” RECOMMENDATIONS - After you have removed them, replace all sealing/adjusting shim washers (1) and counter dowels. Bend the locking edges, adjusting them to the flat surfaces of the screw or nut after tightening it to the specified torque. - Install bearings and seals in such a way that the manufacturer’s brands are visible.

  • Page 14: Vehicle Identification

    VEHICLE IDENTIFICATION (CHASSIS - ENGINE) Your CORVUS TERRAIN DX4 has an identification plate which details: manufacturer, type approval, VIN, mass of the vehicle, maximum mass per axle (A1-A2) and towable mass (depending on type of braking and towing). The vehicle identification number is also stamped on the rear right-hand side of the chassis.

  • Page 15: Tooling Table

    TOOLING TABLE GROUP DESCRIPTION CODE IMAGE Steering and suspension Steering and suspension 80990000000 ball joint puller Spring hook 80990000001 Chassis and protections Sealing rubber cutting 80990000002 scissors Belt pulley installation / 03990000020 removal tool WORKSHOP MANUAL Page We reserve the right to modify the product and the design.
  • Page 16 TOOLING TABLE GROUP DESCRIPTION CODE IMAGE 03990000021 Belt pulley plates separator tool 03990000022 Drive belt pulley removal tool Ball-joint puller 80990000000 03990000023 Retaining key WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 17: Generic Table Of Tightening Torques

    GENERIC TABLE OF TIGHTENING TORQUES THREAD PITCH TIGHTENING TORQUE M 1.6 0.35 0.15 Nm 0.301 Nm M 2.5 0.45 0.63 Nm 1.1 Nm M 3.5 1.7 Nm 2.5 Nm 4.9 Nm 8.5 Nm 1.25 20 Nm M 10 41 Nm M 12 1.75 70 Nm...

  • Page 18: Specific Table Of Tightening Torques

    SPECIFIC TABLE OF TIGHTENING TORQUES GROUP ELEMENT SCREW THREAD TIGHTENING TORQUE G3/4 20 Nm Filling plug Transmission Draining plug M14x150 20 Nm Filling plug M14x150 20 Nm Front Diff M14x150 20 Nm Draining plug 70 Nm Driven belt pulley clamping screw Driving belt pulley clamping screw 70 Nm Engine-DC plate screw...

  • Page 19: Specifications

    SPECIFICATIONS ENGINE DIMENSIONS CHASSIS Total height 1,973 mm Type Round tubular, spine- Cycle Four-stroke Total length 3,414 mm shaped steel chassis. No. cylinders 3 cylinders in line Total width Distance 1,656 mm Suspension Cooling Liquid between axles 2,238 mm Front Independent with Displacement 993 cc...
  • Page 20 SPECIFICATIONS CABIN APPROVAL Windshield Type EU T1B Front Fixed laminate Emission of gases EC STAGE V (<19 kW) Rear Fixed tempered EPA FINAL TIER 4 (<19 kW) Seats 2, separated Windshield wiper Control unit Seat belt 2-point LIQUIDS Fuel Diesel B7 / B10 Coolant 50% ESPC.

  • Page 21: Multifunction Panel

    MULTIFUNCTION PANEL Warning indicators (see details) Speedometer (km/h) Seat belt Clock Mode Tachometer (rpm) (See detail) 4WD indicator Total and partial Trip odometer. (See detail) Hour meter Gear Differential Fuel level Service Engine coolant indicator lock warning temperature indicator WARNING The multifunction device is water resistant but not waterproof.
  • Page 22 More information in the maintenance section of this manual. If the warning indicator illuminates when the engine has started or when you are driving, you must turn off the engine and contact your nearest CORVUS garage. Parking brake and brake fluid level malfunction Warning indicator to indicate that: - The parking brake is activated;...
  • Page 23 More information in the maintenance section of this manual. If the warning indicator illuminates when the engine has started or when you are driving, you must turn off the engine and contact your nearest CORVUS garage. Steering indicators The warning indicator will illuminate when a change of direction is indicated by the indicator switch or the emergency button.
  • Page 24 MULTIFUNCTION PANEL Fuel level Fuel tank displacement of 40 L of diesel fuel. The warning indicator will illuminate when there are 5 litres of fuel left. Operating Conditions Voltage supply: From 10 to 16 V DC Minimum operating voltage supply without reset: 6.5 V dc Operating temperature margin: -20 °C to 80 °C...
  • Page 25 MULTIFUNCTION PANEL SUMMARY OF FEATURES Definition of each feature and its dependence at the architecture and programming level. ANALOGUE DIGITAL INPUT VIA OUTPUT VIA THE INDICATION BY INDICATION BY INPUT VIA THE INDICATION BY LCD THE CONNECTOR CONNECTOR STEP ENGINE INDICATOR PILOT CONNECTOR Odometer...
  • Page 26 MULTIFUNCTION PANEL LEFT TURN SIGNAL Positive Gauge FUEL LEVEL 8 bars R max. 338 ohms FUEL RESERVE INDICATOR 224 ohms 1 bar LONG-RANGE LIGHTS Positive DIESEL HEATER Positive COMBINED BRAKE AND HAND BRAKE Icon FLUID LEVEL Positive ENGINE WATER TEMPERATURE 8 bars Variable resistor Icon...
  • Page 27 MULTIFUNCTION PANEL ANALOGUE DIGITAL INPUT VIA OUTPUT VIA THE INDICATION BY INDICATION BY INPUT VIA THE INDICATION BY LCD THE CONNECTOR CONNECTOR STEP ENGINE INDICATOR PILOT CONNECTOR REAR DIFFERENTIAL LOCK Positive Icon Common input for NEUTRAL Icon R-L-N-H Common input for REVERSE Icon R-L-N-H...
  • Page 28 MULTIFUNCTION PANEL FUNCTIONALITIES Speed sensor - Pulse inputs coming from a Hall effect sensor. - The sensor’s output has to be of the open manifold type. - The instrument has 3 connector pins dedicated to the speed sensor: • Pin-6 - “Speed_sensor_supply” to feed the Hall sensor. •...
  • Page 29 MULTIFUNCTION PANEL Odometer - The indicator has 6 digits (without a decimal point) + the km symbol. - The counter is displayed without zeros to the left. - The value of the odometer is displayed with a 1% advance (with respect to the actual kilometrage). - When the odometer reaches 999999 km, it will stop counting and will not restart.
  • Page 30 MULTIFUNCTION PANEL TRIP-2 (Partial counter 2) - The indicator has 4 digits (with a decimal point) + the KM symbol. - The counter is displayed without zeros to the left. - The value of the partial counter is displayed with a 1% advance (with respect to the actual kilometrage. - When the partial counter reaches 999.9 km, the counter returns to 0.
  • Page 31 MULTIFUNCTION PANEL - The counter associated with maintenance-by-time will not activate until the vehicle has covered a distance of at least 10 km. - To do the “reset’’ the speed must be 0 km/h. - To reset the service values, we have to press the MODE button while we turn the engine on. After 10 seconds, the service icon will remain fixed. If we stop pressing MODE, we will have a 10-second time-out to press the TRIP button, which we have to keep pressed for 5 seconds until the reset is accomplished.
  • Page 32 MULTIFUNCTION PANEL Gear The vehicle is automatic. The gear will be indicated on the screen by an alphanumeric digit that can display: - N to indicate that you are in NEUTRAL. - R to indicate that you are in REVERSE GEAR. - L to indicate that you are in SHORT GEAR.
  • Page 33 MULTIFUNCTION PANEL Fuel The fuel level gauge is resistive. The display bars will be indicated as per the attached table. - There are 8 bars on the display, with the letters E (Empty) and F (Full) plus the fuel icon. - The fuel reserve alarm LED light will come on when 1/8 of the tank remains.
  • Page 34 MULTIFUNCTION PANEL Temperature The engine temperature sensor is resistive. The display bars will be indicated as per the attached table. - 8 bars appear on the display, with the letters C (Cold) and H (Hot) plus the temperature icon. - The high temperature indicator light will illuminate when it reaches 110 °C and will turn off when it returns to 100 °C. - It will indicate an open circuit when resistance values exceed 900 OHM.
  • Page 35 MULTIFUNCTION PANEL MODE - TRIP buttons INDICATORS PUSH-BUTTONS NEXT CONDITION Short MODE Short TRIP Long MODE Long TRIP TRIP 1 Hours of operation Add time TRIP 1 HOURS OF OPERATION Add time TRIP 2 TRIP 1 Reset TRIP 1 TRIP 2 Reset TRIP 2 Wheel size INCREASE HOUR...
  • Page 36 MULTIFUNCTION PANEL INDICATORS PUSH-BUTTONS NEXT CONDITION Short MODE Short TRIP Long MODE Long TRIP “1 YEAR” service “Km” service SERVICE Reset Service Decrease Increase WHEEL SIZE Store size There are 2 push-buttons, MODE and TRIP, and two types of presses, Short (< 2 secs) or long (> 2 secs). To change the size of the wheel, we access from TRIP 2 mode, pressing MODE for 10 seconds.

  • Page 37: Maintenance

    MAINTENANCE WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 38: Safety Regulations

    MAINTENANCE STANDARDS DANGER DANGER - Use original CORVUS spare parts and lubricants - Were it to be necessary to keep the engine running to carry out an intervention on the vehicle, make sure that recommended by CORVUS. Non-original or non- the work environment is well ventilated and, if necessary, compliant spare parts can damage the vehicle.

  • Page 39: Service Chart

    SERVICE CHART The maintenance requirements set out in this chart are simple and necessary for a good maintenance of your vehicle. A: ADJUST / C: CHECK / L: LUBRICATE / R: REPLACE ELEMENT Interval Daily 50 h 100 h 250 h 500 h 1,000 h 1,500 h...

  • Page 40: Maintenance

    MAINTENANCE RAISING THE VEHICLE The vehicle is equipped with an area at the front (1) and another at the rear (2) to facilitate its elevation. WARNING BEFORE RAISING THE VEHICLE, MAKE SURE THE BRAKE IS FULLY ON AND THAT THE SURFACE IS FLAT AND COMPLETELY HORIZONTAL.

  • Page 41: Underbody Protector

    MAINTENANCE UNDERBODY PROTECTOR (REMOVAL) MOUNTING THE WHEEL 1. Put the vehicle in a horizontal position. 1. Remove the 12 screws (1) from the front underbody protector. 2. Engage the parking brake. 3. Raise the area of the vehicle (front or rear) where the wheel 2.

  • Page 42: Engine Idling Speed

    MAINTENANCE ENGINE IDLE SPEED (ADJUSTMENT) The vehicle’s idle speed is a factory setting. If you need to adjust it, proceed as follows: 1. Warm the engine up to operating temperature. 2. Stop the engine. 3. Connect a tachometer (see manufacturer's instructions). 4.

  • Page 43: Air Filter - Cleaning

    MAINTENANCE AIR CLEANER (CLEANING THE AIR CLEANER) When cleaning the air cleaner, take care to make sure it does not become obstructed and that no dirt gets into the engine, especially when using the vehicle in dusty areas. Without fail, inspect the air cleaner before and after each use, as indicated in the service chart (see page 39). Cleaning the air cleaner 1.

  • Page 44: Engine Oil - Check

    MAINTENANCE ENGINE OIL (LEVEL CHECK) The smooth operation and durability of the transmission and the engine essentially depend on the oil being kept at the optimum level and being changed periodically, as indicated in the Service Chart (see page 39). Checking the oil level 1.

  • Page 45: Engine Oil And Filter - Change

    MAINTENANCE ENGINE OIL AND FILTER (CHANGE) You should keep the oil at the optimum level and change it periodically, as indicated in the Service Chart (see page 39). Oil and oil filter change 1. Put the vehicle in a horizontal position. 2.

  • Page 46: Transmission Oil - Check

    MAINTENANCE TRANSMISSION OIL (LEVEL CHECK) TRANSMISSION OIL (CHANGE) The smooth operation and durability of the transmission essentially Changing the transmission oil. depend on the oil being kept at the optimum level and being changed periodically, as indicated in the Service Chart (see page 39). 1.

  • Page 47: Front Differential Oil - Check/Change

    MAINTENANCE FRONT DIFFERENTIAL OIL (CHECK) To check the front differential oil level, you have to drain the oil into a calibrated container and measure the amount that has been extracted. The correct volume is 0.5 L. FRONT DIFFERENTIAL OIL (CHANGE) The oil must be changed periodically, to ensure the life of the differential, as indicated in the service chart (see page 39).

  • Page 48: 4Wd Locking Oil - Check/Change

    MAINTENANCE 4WD LOCKING SYSTEM OIL (CHECK) To check the front differential oil level, you have to drain the oil into a calibrated container and measure the amount that has been extracted. The correct volume is 0.05 L. 4WD LOCKING SYSTEM OIL (CHANGE) It is convenient to frequently check that there are no leaks and the maintenance of the oil level, for correct operation.

  • Page 49: Pre-Filter - Water Separator - Cleaning/Replacement

    MAINTENANCE WATER PRE-FILTER/SEPARATOR (CLEANING - REPLACEMENT) 1. Put the vehicle in a totally horizontal position and raise the cargo box. 2. Remove the left-hand side drawer*. 3. Close the fuel stopcock (1), to the C position. 4. Place a container under the filters (2), to collect any liquid that may spill out over the variator box (CVT).
  • Page 50 MAINTENANCE 5. Turn the nut of the socket (3) counterclockwise to loosen it. 6. Remove the socket very carefully, and empty its contents into a container used to collect pollutants. 7. Clean the inside of the socket with clean fuel. 8.

  • Page 51: Filter - Water Separator - Cleaning/Replacement

    MAINTENANCE WATER FILTER / SEPARATOR (CLEANING - REPLACEMENT) 1. Put the vehicle in horizontal position and lift the load box. 2. Remove the left-hand side drawer*. 3. Close the fuel stopcock (2), to the C position. 4. Place a container under the filters (1), to collect any liquid that may spill out over the variator box (CVT).
  • Page 52 MAINTENANCE 5. Turn the nut of the socket (3) counterclockwise to loosen it. 6. Remove the socket very carefully, and empty its contents into a container used to collect pollutants. 7. Clean the inside of the socket with clean fuel. 8.

  • Page 53: Cvt Assembly

    MAINTENANCE CVT ASSEMBLY REVIEW Cleaning CVT air ducts WARNING THE AIR INTAKE DUCT TO THE CVT MUST BE KEPT CLEAN TO PREVENT SERIOUS DAMAGE TO THE TRANSMISSION SYSTEM. IF THE VEHICLE IS USED IN DUSTY CONDITIONS, IT IS ADVISABLE TO CARRY OUT THIS PROCESS REGULARLY. First of all, you must remove the left-hand side drawer*.
  • Page 54 MAINTENANCE Removing the CVT cover 1. Remove the eleven screws (A, B, and C) from the CVT cover. 2. Uncouple the CVT cover. WARNING PAY SPECIAL ATTENTION TO THE POSITION OF THE SCREWS OF THE CVT COVER DURING THE ASSEMBLY. SEE POSITIONS INDICATED IN THE PHOTOGRAPH OF THE DIFFERENT LENGTHS OF THE COVER SCREWS.
  • Page 55 MAINTENANCE Removing the driven belt pulley and the CVT transmission belt TECHNICAL INFORMATION: 1. Insert the ramp adjusting shim (1) into the threaded hole of Plate spacer tool: 03990000021 Transmission belt: 03190010021 the driven pulley. Tighten the driven pulley retaining screw to 70 Nm. 2.
  • Page 56 MAINTENANCE Removing the CVT drive belt pulley TECHNICAL INFORMATION: 1. Once you have removed the CVT belt (4) (see page 55). Drive belt pulley removal tool: 03990000022 Drive belt pulley locking tool: 03990000023 2. remove the bolt and retaining washer (5), using the tool to lock the Pulley retaining bolt torque: 70 Nm pulley (6).
  • Page 57 MAINTENANCE MAINTENANCE INTERVALS DESCRIPTION Every 5,000 kms or 250 h Every 10,000 kms or 500 h Drive pulley General control Removing and cleaning Fixed pulley Visual inspection Cleaning Sliding pole Visual inspection Cleaning Installation of centrifugal weights Visual inspection Replacement recommended Friction bushing Visual inspection Replacement recommended...
  • Page 58 MAINTENANCE Transmission belt inspection WARNING THE TRANSMISSION BELT MUST BE INSPECTED TO AVOID THE RISK OF PERSONAL INJURY AND/OR MECHANICAL BREAKAGE. The transmission belt should be replaced if cracks appear on the rear of the belt. The drive belt should be replaced when its maximum width decreases by from 2 to 3 mm of its original width.
  • Page 59 MAINTENANCE Removing the drive belt pulley Fixed pulley Adjusting washer (if applicable) Floating bearing Adjusting shim Spring seat Adjusting washer (if applicable) Adjusting washer (if applicable) Opening limiter Spring Sliding pulley Assembly of centrifugal weights Housing Weight Cover Friction bushing Washer (if applicable) Washer (if applicable) WARNING / DANGER...
  • Page 60 MAINTENANCE • Floating bearing (3): WARNING REMOVE EACH COMPONENT AS SHOWN IN THE Change when you manually detect irregular rotation or you hear a EXPLODED VIEW ON THE PREVIOUS PAGE. squeaking noise as the bearing rotates. Recommended checks New weight Sliding bushing Worn weight •...
  • Page 61 MAINTENANCE Aligning the fixed pulley, sliding pulley and cover Square notch Align the 2 alignment marks on the pulleys and also the square shaped notch, or make a mark on the cover to ensure that the pulley is balanced (see images). Tightening the pulley Use a torque wrench with a 30mm adapter to tighten the pulley.
  • Page 62 MAINTENANCE Removing the driven pulley Fixed pulley Washer (if applicable) Sliding pulley Friction bushing Friction bushing screw Spring Synchronizer block Elastic ring WORKSHOP MANUAL Page We reserve the right to modify the product and the design.
  • Page 63 MAINTENANCE The correct installation of the driven pulley WARNING BE SURE TO NOTE THE POSITION OF THE SPRING ON THE SLIDING PULLEY AND THE CAM, AS WELL AS THE ALIGNMENT OF THE CAM WITH RESPECT TO THE FRICTION BUSHING. Position of the spring on the sliding pulley WHEN REINSTALLING THE PULLEY, THE POSITIONS MUST and the cam.
  • Page 64 MAINTENANCE Removing the cam Rotation lock • Using a vise, position the dismantling tool (Ref: 3990000020) and • Remove the circlip with suitable pliers. tighten it to prevent the dismantling tool from turning. • Gently unscrew the bar from the threaded rod to slowly release •...
  • Page 65 MAINTENANCE Recommended inspections • Check if there are signs of wear on the cam. Sliding pulley • Check if there are signs of wear on the spring. • Perform a visual inspection of the components. • Look for wear on the pulleys due to the friction of the transmission belt Bushing - (visual inspection only;...

  • Page 66: Sliding Pulley - Maintenance

    MAINTENANCE SLIDING PULLEY - MAINTENANCE Recommended inspections The cam shoes must be replaced if they show wear of up to approximately 1 mm before making contact with the aluminium flange. After you remove the screws with a Torx No. 20 screwdriver, the cam shoes can be removed with a flat-ended screwdriver.

  • Page 67: Driven Pulley - Assembly

    MAINTENANCE INSTALLING THE DRIVEN PULLEY Installing the spring in the sliding pulley Place the spring (6) on the sliding pulley (3) in the same position noted during the removal steps. DANGER THIS REQUIRES THE USE OF THE REMOVAL TOOL TO ASSEMBLE THE SLIDING PULLEY.

  • Page 68: Coolant - Check/Change

    MAINTENANCE COOLANT (CHECK AND CHANGE) Checking the coolant level 1. Place the vehicle in a completely horizontal position. The coolant reservoir is located under the front hood. The coolant absorbs excess heat from the engine and transfers it to the air 2.
  • Page 69 MAINTENANCE Replacing the coolant 1. Unscrew the cap from the reservoir (1) in an anticlockwise direction and wait a few seconds until the vapours disperse. 2. Place a container beneath the radiator. 3. Unscrew the radiator cap (2) anticlockwise and drain the coolant. 4.

  • Page 70: Radiator Pipes And Connections

    MAINTENANCE DANGER TO AVOID BURNS DO NOT REMOVE THE RADIATOR CAP OR TRY TO CHANGE THE FLUID WHEN THE ENGINE IS STILL HOT. WAIT UNTIL IT COOLS DOWN. WARNING REPLACE THE GASKETS WITH NEW ONES. CHECK FOR ANY POTENTIAL DAMAGE, LEAKS OR LACK OF GASKETS IN THE COOLING SYSTEM.

  • Page 71: Brake Fluid - Check

    MAINTENANCE DANGER DO NOT SPILL BRAKE FLUID ON PAINTWORK. DO NOT MIX DIFFERENT TYPES OF BRAKE FLUID. THE FLUID USED TO FILL OR RENEW YOUR CIRCUIT MUST RESPOND TO THE SPECIFIED STANDARD IN THE FLUID RESERVOIR OF EACH CIRCUIT. YOU MUST USE DOT-4. YOU SHOULD NEVER CHANGE THE SPECIFICATION, ALWAYS RESPECT THE DOT-4 SPECIFICATION.

  • Page 72: Brake Fluid - Change

    8. Restore the brake fluid level in the reservoir. 9. Perform this operation for the four brake callipers. 10. If necessary, purging is also possible using a specific vacuum pump. Contact your Corvus Technical Service. TECHNICAL INFORMATION Recommended fluid: DOT-4 brake fluid.

  • Page 73: Brake Pads - Change

    MAINTENANCE DANGER TO PREVENT DAMAGE TO THE CANOPY, DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH IT DURING BLEED OPERATIONS. IN ADDITION, WHEN BLEEDING THE BRAKE CALLIPERS, DO NOT ALLOW THE FLUID TO COME INTO CONTACT WITH THE BRAKE DISCS OR WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS RULE IS DETRIMENTAL TO THE FUNCTIONING AND EFFICIENCY OF THE BRAKING SYSTEM.

  • Page 74: Brake Pads - Check

    REAR AXLE. Wheel nuts tightening torque: 60 Nm Clamp screws tightening torque: 30 Nm WARNING WE RECOMMEND THAT YOU GO TO YOUR CORVUS DEALER TO CHANGE THE BRAKE PADS. THEY WILL ALSO CHECK FOR ANY POSSIBLE WEAR OF THE BRAKE DISCS.

  • Page 75: Battery

    MAINTENANCE BATTERY (REPLACEMENT) Maintenance is limited to checking the charge status and if necessary to recharging it. The battery does not require maintenance. These operations should be carried out every 6 months when in storage, The battery is located under the front hood. with the circuit open.

  • Page 76: Tires

    MAINTENANCE WARNING TIRES(CHECK) BATTERY IS FULLY CHARGED TO ENSURE ITS MAXIMUM Check that the tires are not worn, cracked or damaged. Also check PERFORMANCE. that they are at the correct pressure. IF THE BATTERY IS NOT CHARGED PROPERLY PRIOR TO OPERATION, IT MAY SUFFER PREMATURE DAMAGE.

  • Page 77: Steering - Alignment

    MAINTENANCE 0° +/- 0.1° 0° +/- 0.1° STEERING (ALIGNMENT) To align the vehicle properly, the measurements indicated in the graph must be respected. WARNING MEASUREMENTS AND ADJUSTMENTS MUST BE MADE WHEN THE VEHICLE IS EMPTY. WORKSHOP MANUAL Page We reserve the right to modify the product and the design.
  • Page 78 MAINTENANCE Checking the alignment: 1. Run a bar or a rope from the rear wheel to the front. WARNING THIS BAR OR ROPE MUST REMAIN PARALLEL BETWEEN THE TWO POINTS ON THE REAR WHEEL RIM. This process will project the ideal point for the front of the steering wheel.
  • Page 79 MAINTENANCE Then, Alignment of the steering wheels. 1. Centre the steering wheel. 2. Fix the position of the steering wheel to prevent movement during WARNING the alignment process. TO FACILITATE THE ALIGNMENT PROCESS, IT IS ADVISABLE TO FIT METAL SHEETS UNDER EACH 3.
  • Page 80 MAINTENANCE DANGER TECHNICAL INFORMATION ALWAYS USE A WRENCH TO HOLD THE ENDS OF The front measurement should be 0° +/- 0.1° greater THE BRACE WHEN LOOSENING OR TIGHTENING than the rear measurement. THE COUNTER-NUTS OR YOU MAY DAMAGE THEM. WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 81: Windshield Washer Fluid

    MAINTENANCE WINDSHIELD WASHER FLUID TECHNICAL INFORMATION The standard volume is 1 L. The windshield wiper fluid reservoir must contain the volume required Recommended fluid: standard windshield wiper fluid. to clean the windshield properly. The reservoir is located under the front hood. 1.

  • Page 82: Lubrication

    MAINTENANCE LUBRICATION Your vehicle is equipped with grease nipples to facilitate the lubrication of certain parts (two in each rear wheel spindle, two in each cardan joint and one in the transmission cardan/output coupling joint). Daubing the cardan To perform this process and to access the cardan, it is necessary to disassemble the underbody protector (see page 41).

  • Page 83: Cable Adjustment - Accelerator, Handbrake, Gears

    MAINTENANCE ADJUSTING THE CABLES Accelerator cable To adjust the play of the accelerator cable, follow this procedure. 1. Remove the cable sheath (1). 2. Use a wrench to loosen the nut (2). 3. Adjust from point (3) until the required play value is reached. 4.
  • Page 84 MAINTENANCE TECHNICAL INFORMATION Hand brake cable The cam must be adjusted in such a way that when the parking brake is applied to its maximum extent, the To adjust the tension of the handbrake cable, follow this procedure. angle of the cam with reference to the cable has to be 85°...
  • Page 85 MAINTENANCE Gear cable To adjust the play in the gear cable, follow this procedure. 1. Use a wrench to loosen the nut (1). 2. Use a wrench to loosen the nut (2). 3. Adjust from point (3) by turning right or left, until you reach the required play value.

  • Page 86: Lighting

    MAINTENANCE LIGHTS (ADJUSTING THE HEIGHT) 1. Position the vehicle 10 meters from a wall and use the parking brake to immobilize it. 2. Open the front hood. 3. Unscrew the eleven screws from the base of the hood and remove it (see page 94).

  • Page 87: Front Low And High Beam Lights And Indicators

    MAINTENANCE FRONT LOW AND HIGH BEAM LIGHTS AND INDICATORS (REPLACEMENT) 1. Switch the vehicle off. 2. Open the front hood. 3. Remove the base of the hood (see page 94) Replacing the low / high beam lamps: 1. Unplug the electrical connector (1) of the lamp you are replacing. 2.

  • Page 88: Rear Indicators, Break And Sidelights

    MAINTENANCE REAR INDICATOR, BRAKE SIDELIGHT LAMPS (REPLACEMENT) 1. To access the rear lamps, you will have to remove the light cover that is anchored with the two screws indicated in the image (1). 2. You will then be able to see the two lamps: - Indicator (2) - Brake and sidelight (3) TECHNICAL INFORMATION...

  • Page 89: Canopy

    CANOPY WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 90: Front Fenders

    CANOPY FRONT FENDER (REMOVAL) REAR FENDER (REMOVAL 1. Loosen the twelve screws (1) holding the fender and remove it. Before you do this, you must lift out the cargo box. 1. Loosen the six screws (1) holding the fender and remove it. To remove the left fender you will need to remove the cap from the fuel tank.

  • Page 91: Rollbar Cross Member Cover

    CANOPY CROSS MEMBER ROLLBAR COVER (REMOVAL) 1. Remove the rear side fenders (see page 90). 2. Loosen the two screws (1) located on the sides of the vehicle. 3. Loosen the four screws (2) and remove the cover of the cross member rollbar.

  • Page 92: Side Drawers

    CANOPY SIDE DRAWERS (REMOVAL)* INNER DRAWERS (REMOVAL)* To remove the drawers, you have to lift up the cargo box. 1. Open the door to the interior drawer you want to remove. 1. Use the corresponding key to open the door of the side drawer. 2.

  • Page 93: Threshold Plates

    CANOPY THRESHOLD PLATES (REMOVAL) Before you remove the threshold plates you must previously withdraw the front and rear fenders (see page 90). 1. Remove the five screws (1) and remove the part. FRONT HOOD (REMOVAL) 1. Open the hood with the corresponding key. 2.

  • Page 94: Front Hood Base

    CANOPY FRONT HOOD BASE (REMOVAL) Previously, you need to remove the front hood. 1. Loosen the eleven screws (1) holding the hood base and remove it. 2. Remove the hood safety lock (2). 3. Remove the cylinder from the lock (3). TECHNICAL INFORMATION Lock screws tightening torque: 12 Nm Locking screws tightening torque: 12 Nm...

  • Page 95: Front Luggage Compartment

    CANOPY FRONT LUGGAGE COMPARTMENT (REMOVAL) FRONT LIP (REMOVAL) To remove the front lip you must previously remove the front fenders To remove the luggage compartment you must previously remove (see page 90). the front hood base (see page 94). 1. Loosen the four screws (1) that hold the front lip and remove it. 1.

  • Page 96: Wheel Arch

    CANOPY WHEEL ARCH (REMOVAL) FRONT MASK (REMOVAL) To remove the wheel arch you must previously remove the front To remove the luggage compartment you must previously remove fenders (see page 90). the front fenders (see page 90) and the wheel arches. 1.

  • Page 97: Cargo Box

    CANOPY 5. Remove the screws from the latches (3) of the cargo box. CARGO BOX (REMOVAL) 6. Remove the latches. 1. Raise the cargo box. 7. Raise the cargo box with the help of a crane. 2. Secure the cargo box by means of load slings. 3.

  • Page 98: Seats

    CANOPY SEATS (REMOVAL) ROOF (REMOVAL) 1. Remove the two screws (1) located in each of the two brackets 1. Remove the plugs on the inside. underneath the seat. 2. Remove the six screws (1). 2. Remove the seat. 3. Remove the roof upwards. TECHNICAL INFORMATION Screw tightening torque: 24 Nm WORKSHOP...

  • Page 99: Engine Frame Cover

    CANOPY ENGINE FRAME COVER (REMOVAL) FRAME UNDER SEAT (REMOVAL) 1. Remove the seats (see page 98). 1. Remove the seats (see page 98). 2. Remove the six top screws (1). 2. Remove the engine frame cover. 3. Remove the five bottom screws (2). 3.

  • Page 100: Windshield Wiper Engine

    CANOPY WINDSHIELD WIPER ENGINE (REMOVAL) 1. Remove the interior rear-view mirror (1) by unscrewing the two screws. 2. Remove and disconnect the interior courtesy light (2). 3. Remove the five screws (3) from the windshield wiper cover. 4. Disable the windshield wiper button (4). 5.
  • Page 101 CANOPY WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 102: Windshield

    CANOPY WINDSHIELD (Removal) Rear Front 1. Remove the two outer screws (1). Previously remove the windshield wiper assembly. 2. Release the peripheral (2) rubber from the inside. 1. Remove the two outer screws (1). TECHNICAL INFORMATION 2. Release the peripheral (2) rubber from the inside. Flange screws tightening torque: 12 Nm WARNING IT IS ADVISABLE THAT SOMEONE ELSE SHOULD...

  • Page 103: Engine

    ENGINE WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 104: Snorkel And Cvt Ducts

    ENGINE SNORKEL DUCTS AND CVT DUCTS (REMOVAL) 1. Remove the four screws (1) securing the snorkel grid and remove 2. Remove the two inner screws (2). 3. Remove the plastic plug (3) and the screw inside (4). 4. Remove the two screws (5) and loosen the snorkel. WORKSHOP MANUAL Page...

  • Page 105: Cvt Ventilation Ducts

    ENGINE CVT VENTILATION DUCTS (REMOVAL) 1. Loosen the metal flange (1) and remove the joint boot (2). 2. Remove the clamp (3) from the elbow connection (2) between the manifold DUCT and the CVT transmission cover. 3. Pull the elbow (4) downwards to release it from the housing of the duct.

  • Page 106: Engine Intake Ducts And Air Filter

    ENGINE ENGINE INLET DUCTS AND AIR FILTER (REMOVAL) 1. Loosen the metal flange (1) and remove the joint boot. 2. Remove the two screws (2) securing the air inlet duct. 3. Loosen the four metal flanges (3). 4. Remove the two screws (4) securing the air filter. 5.

  • Page 107: Silencer

    ENGINE SILENCER (REMOVAL) To remove the silencer you must first lift up the cargo box. WARNING MAKE SURE THAT THE SILENCER IS COMPLETELY COLD BEFORE YOU REMOVE IT. 1. Release the two nuts (1) from the clamp between the silencer and the exhaust manifold.

  • Page 108: Exhaust Manifold

    ENGINE EXHAUST MANIFOLD (REMOVAL) To remove the exhaust manifold you must first lift up the cargo box and remove the right side drawer*. WARNING MAKE SURE THAT THE EXHAUST IS COMPLETELY COLD BEFORE YOU REMOVE IT. 1. Release the exhaust silencer (see page 107). 2.

  • Page 109: Engine Assembly - Transmission

    ENGINE ENGINE - TRANSMISSION ASSEMBLY (REMOVAL) 8. Remove the seats (see page 98). To remove the engine, you must previously perform the following 9. Remove the lower inner drawers* (see page 92). operations: 10. Remove the engine frame cover (see page 99) and the interior frame under the seats (see page 99).
  • Page 110 ENGINE WARNING BEFORE REMOVING THE ENGINE-TRANSMISSION ASSEMBLY, MAKE SURE THAT ALL PERIPHERAL SYSTEMS, DRIVES, ELECTRICAL SYSTEMS, COOLING, POWER SUPPLY AND IGNITION ARE SWITCHED OFF. DANGER BEFORE PERFORMING ANY OPERATION, MAKE SURE THE VEHICLE’S BRAKE IS ON, AND APPLY CHOCKS TO THE WHEELS. THE ENGINE AND TRANSMISSION ARE REMOVED UPWARDS, AND GIVEN THAT THIS IS A COMPLEX MANOEUVRE INVOLVING THE REMOVAL OF THE...
  • Page 111 ENGINE Engine removal operations: 3. Remove the connectors of the electrical 5. Loosen the metal flanges (6) and remove 1. Remove the gear shift cable by loosening system (identified in the image). the pipes of the cooling system. the nut and the counternut (1), and the ball joint nut (2).
  • Page 112 ENGINE WARNING CHECK THE CONDITION OF THE SILENTBLOCKS AND CHANGE THEM IF THEY ARE FAULTY. THE ECCENTRIC SILENTBLOCK HAS TO BE MOUNTED BY MAKING ITS SYMMETRICAL CENTRE COINCIDE, AT ITS HIGH POSITION, WITH THE MARK ON THE BRACKET. 7. Loosen the six screws (8) and remove the upper engine chassis cross brace.

  • Page 113: Suspension, Brakes And Steering

    SUSPENSION, BRAKES AND STEERING WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 114: Suspensions - Disassembly/Regulation

    SUSPENSION, BRAKES AND STEERING SUSPENSION (REMOVAL / REGULATION) For regulation, follow this procedure: The vehicle is equipped with a suspension system consisting of four WARNING shock absorbers; it is possible to adjust their preload. FIRST OF ALL LOOSEN THE LOCKING SCREW (3) WHICH IS LOCATED ON THE ACTUAL PRE-LOAD NUT To remove them, follow this procedure: (4).

  • Page 115: Front Brake Callipers

    SUSPENSION, BRAKES AND STEERING FRONT BRAKE CALLIPERS (REMOVAL) 1. Raise the vehicle at its lifting points (see page 40) until the tires are no longer in contact with the ground. 2. Remove the four nuts (1) of the corresponding wheel. 3.

  • Page 116: Rear Brake Callipers

    SUSPENSION, BRAKES AND STEERING REAR BRAKE CALLIPERS (REMOVAL) WARNING The rear wheels incorporate two brake clamps, one for the general DO NOT ALLOW THE BRAKE FLUID TO COME INTO brake (1) and the other for the parking brake (2). CONTACT WITH PAINTED, PLASTIC OR RUBBER PARTS.

  • Page 117: Brake Discs

    SUSPENSION, BRAKES AND STEERING BRAKE DISCS (REMOVAL / CHECK) It is important to monitor the discs. They must be perfectly clean, with no rust, greasy oil or any other impurities, and they must not have any deep splines. 1. Measure the disc thickness. The disks must have a minimum thickness of 3.5mm.

  • Page 118: Steering - Disassembly

    SUSPENSION, BRAKES AND STEERING STEERING (REMOVAL) Steering column 1. Remove the central plug (1) on the steering wheel. 2. Loosen the central nut (2). 3. Remove the steering wheel by pulling it forcefully. 4. Remove the four screws from the lights and indicators trim (3). 5.
  • Page 119 SUSPENSION, BRAKES AND STEERING WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 120: Steering Cardan

    SUSPENSION, BRAKES AND STEERING Steering cardan To access the steering cardan you must previously remove the dashboard. Then follow these steps: 1. Loosen the upper screw (1) holding the steering cardan to the EPS engine or to the steering column. 2.

  • Page 121: Steering Arms And Box

    SUSPENSION, BRAKES AND STEERING Steering arms and box WARNING To access the steering box you will need to have previously removed CHECK FOR ANY POSSIBLE PLAY IN THE STEERING the front wheels (see page 41). BALL JOINTS OR BAR CROSSHEADS. IF THERE IS ANY PLAY OR A MALFUNCTION, REPLACE THEM AND THEN READJUST THE STEERING ALIGNMENT.

  • Page 122: Eps Engine

    SUSPENSION, BRAKES AND STEERING EPS engine* 2. Loosen the lower screw (2) of the cardan gasket. To access the EPS engine you must previously remove the dashboard. Then follow these steps: 1. Disconnect the ECU from the general wiring (1). 3.
  • Page 123 SUSPENSION, BRAKES AND STEERING 4. Loosen the three screws (4) that hold the EPS engine to the spider. 5. Remove the EPS engine from its housing. WARNING CHECK FOR ANY POSSIBLE PLAY IN THE STEERING BALL JOINTS OR BAR CROSSHEADS. IF THERE IS ANY PLAY OR A MALFUNCTION, REPLACE THEM AND THEN READJUST THE STEERING ALIGNMENT.

  • Page 124: Transmission

    TRANSMISSION WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 125: Cardan And Coupling

    TRANSMISSION CARDAN AND COUPLING (REMOVAL) 1. Remove the two reinforcement panels located in the middle of the chassis by removing the six nuts and screws (1) securing each of them. 2. Loosen and remove the six nuts and screws (2) on either end of the cardan.

  • Page 126: Front Axle Shaft

    TRANSMISSION FRONT AXLE SHAFT (REMOVAL) 1. Loosen the four nuts (1) from the front wheel. 2. Raise the front of the vehicle to facilitate the removal of the front wheel. 3. Remove the four nuts (1) from the front wheel. 4.
  • Page 127 TRANSMISSION 14. Check for any possible bearing play, the condition of the constant velocity joints and the suspension ball joints. WARNING WHEN REMOVING THE STUB SHAFT, TAKE CARE NOT TO DAMAGE THE SPLINES OF THE AXLE SHAFT. THE NUT (3) MUST BE REPLACED IN THE ASSEMBLY.

  • Page 128: Rear Axle Shaft

    TRANSMISSION REAR AXLE SHAFT (REMOVAL) 1. Loosen the four nuts (1) from the rear wheel. 2. Raise the front of the vehicle to facilitate the removal of the rear wheel. 3. Remove the four nuts (1) from the rear wheel. 4.
  • Page 129 TRANSMISSION WARNING THE NUT (3) MUST BE REPLACED IN THE ASSEMBLY. WHEN REMOVING THE STUB SHAFT, TAKE CARE NOT TO DAMAGE THE SPLINES OF THE AXLE SHAFT. TECHNICAL INFORMATION Axel shaft nut tightening torque: 225 Nm. Screw tightening torque/axle stub shaft to swingarm: 47 Nm. Calliper screws tightening torque: 30 Nm.

  • Page 130: Front Differential

    TRANSMISSION FRONT DIFFERENTIAL (REMOVAL) Before you disassemble the front unit, remove the axle shafts, the cardan and the oil, as well as all peripherals that may interfere with the removal. To remove it, follow this procedure: 1. Disconnect the electrical connector of the 4WD locking actuator (1). 2.

  • Page 131: Electrical System

    ELECTRICAL SYSTEM WORKSHOP MANUAL Page We reserve the right to modify the product and the design.

  • Page 132: Fuses

    ELECTRICAL SYSTEM FUSES To access the fuse box you will need to remove the 2 screws on the cover located to the left of the driver’s seat. LOT 1 LOT 2 Element Element F1 - Heaters F1 - Glow Plug F2 - GPS supply F2 - EPS F3 - Radiator blower...
  • Page 133 ELECTRICAL SYSTEM SPEEDOMETER VJ10 VCN15 HCN15 HCN14 VCN14 VJ09 Gear position S17A S17A S17A S17A S17B S17B S17B S17B S17A S17A S17A S17A S17D sensor Warning switch HCN16 VCN16 VJ11 S17B Speed km/h sensor VJ12 VCN18 HCN18 HCN17 VCN17 VJ60 Fuel level sensor Lamp...
  • Page 134 ELECTRICAL SYSTEM DESCRIPTION DESCRIPTION Ident. DESCRIPCIÓN Ident. DESCRIPCIÓN VJ01 Luz corta izq. Left low lamp VJ39 Actuador bloqueo diferencial Rear diff. lock VJ02 Luz corta der. Right low lamp VJ40 Electroventilador Electric motor fan VJ03 Bocina Horn VJ41 Botón bloqueo diferencial trasero Rear diff.
  • Page 136 HEADQUARTERS CENTRO DE INGENIERÍA Y DESARROLLO C/ Paraje la Loma-parcela 1 C/ Energía, 50 Polígono Industrial Cabecicos Blancos Polígono Industrial Pla dels Vinyats II www.corvus-utv.com 30892 Librilla 08250 St. Joan de Vilatorrada (Murcia) Spain (Barcelona) Spain WORKSHOP T. (+34) 968 785 201 T.

Table of Contents

Save PDF