1. Manuals
  2. Brands
  3. Mega Manuals
  4. Scooter
  5. MULTITRUCK 400 - 600
  6. Manual

Mega MULTITRUCK 400 – 600 Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

MULTITRUCK 400 – 600
Repair manual

Advertisement

Table of Contents
loading

Summary of Contents for Mega MULTITRUCK 400 – 600

  • Page 1 MULTITRUCK 400 – 600 Repair manual...
  • Page 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 Display features Tachymeter Fuel gauge Odometer Gearbox position Service...

  • Page 3: Group

    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: Table Of Contents

    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..................

  • Page 10: Important Notice

    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.

  • Page 11: Handling Tools You'll Need

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

  • Page 12: Parts Of The Transmission System

    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 ...

  • Page 13: Removing The Pulleys From The Vehicle

    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.
  • Page 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).

  • Page 15: Removing The Driven Pulley

    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. •...

  • Page 16: Disassembling And Reassembling The Pulleys

    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..

  • Page 17: Disassembling The Drive Pulley

    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.
  • Page 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.
  • Page 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.

  • Page 20: Reassembling The Drive Pulley

    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).
  • Page 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.

  • Page 22: Disassembling The Driven Pulley

    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.
  • Page 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.
  • Page 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 •...
  • Page 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. •...

  • Page 26: Reassembling The Driven Pulley

    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).
  • Page 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.

  • Page 28: Reinstalling The Pulleys On The Vehicle

    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 Grade Standard torque diameter of (newton meter) the bolt 8 mm 21 to 28 10 mm 42 to 54 To tighten the drive pulley, use a screwdriver or other tool to block the engine...
  • 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...
  • Page 36 GROUP 7 Body shell and sub frame...
  • Page 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 Analogical speedometer LCD fuel gauge LCD Odometer (daily and general) Gearbox position LCD indicator...

  • Page 40: Fuel Gauge

    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.
  • Page 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.
  • Page 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.
  • Page 43 Neiman C14-Relai de C15-Relai de C16-Relai arrêt C25-Bougie Auto radio C9 - Inter ventilateur C24 - Interconnection M oteur / tableau de bord C21 - GR C22- NO demarrage Préchauffage moteur Essuie C8 - HP glace C7- Allimentation Préchauffage 3 2 1 5 2 3 1 5 3 2 1 5 1 4 3...
  • Page 44 C 11- M oteur C 30A B atterie C 3- Pression C 4- T em pérature C 9- T herm o C 12- Pom pe lave A lternateur C 31' C 7- M asse C 31- C ontacteur frein à m ain C 32- Jauge à...
  • Page 45 Group 9 Paint...

Table of Contents