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

2
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

3
Important Notice
Only qualified personnel can perform maintenance and repair operations on the
variable speed transmission system.
¾LMeans there is a risk of serious injury if the instructions are not followed as
described.
¾,Means that, when performing this step, there is a risk of damaging a part or of the
components malfunctioning.
¾CVTech-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.
¾It 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 10 000 km
Stationary sheaf Visual at 10 000 km
Sliding sheaf Visual at 10 000 km
Assembled centrifuge
unit Visual at 10 000 km
Lower bearing Visual Replace at 10 000 km
Spring Visual at 10 000 km
Upper bearing Visual Replace at 10 000 km
Driven pulley Visual
General condition at 10 000 km
Stationary sheaf Visual 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
p
a
g
e 8
)
at10 000 km

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

5
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

6
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.

7
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).
,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

8
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

9
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

10
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.
LTo 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
LUse 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.

11
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)

12
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)

13
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.