Mountain Top Wildtrak Programming manual

Mountain Top
® Roll
Troubleshooting manual (Wildtrak)
© 2017 Mountain Top Industries APS ISSUE 02 / 21/11-2017 / MTI 886 400
DOWNLOAD PDF
PRINT FORMAT: A5 BOOKLET

01/30
Mountain Top® Roll Troubleshooting manual (Wildtrak)Contents
THE ROLL COVER DOES NOT OPEN OR CLOSE FREELY
1.A The fl ockinglists are dry / dirty
1.B The side rails have not been aligned correctly / have shifted
1.C Side rail brackets have not been tightened correctly / have loosened
1.D The main spring has not been tightened correctly / has lost tension
p. 02
p. 03
p. 06
p. 07
1
THE ROLL COVER OPENS WHEN DRIVING ON UNEVEN TERRAIN
2.A The side rails have not been installed correctly / have shifted
2.B The roll cover has not been installed correctly / locking holes do not align
2.C The bolts holding the side rails have loosened
2.D The rear profi le is of and older type
p. 08
p. 10
p. 13
p. 15
THE LOCK SYSTEM DOES NOT WORK CORRECTLY / JAMS
3.A The roll cover cannot be unlocked with the key
3.B The roll cover does not open when the lock button is pressed down
3.C The lock button is jammed / hard to press down
3.D The lock release is jammed in its outer position
3.E The roll cover does not lock in 1/3, 2/3, or closed positions
3.F Replace the rear profi le
p. 16
p. 17
p. 18
p. 23
p. 24
p. 25
2
3
OBJECTS STORED IN THE BED BECOMES WET / DIRTY
4.A Water / dirt ingress occurs multiple places (EB3B specific)
4.B Water / dirt ingress occurs multiple places (A66+AB39 specific)
p. 26
p. 28
4

02/30
(Fig. 1) Open the roll cover completely. (Fig. 2) Clean the fl ocking lists using either a brush or
soft cloth.
(Fig. 3) Lubricate the fl ocking lists with silicone oil. (Fig. 4) Close and then open the roll cover a few times
to check if the problem has been corrected.
The fl ocking lists are dry / dirty
1.A
If not cleaned regularly, the fl ocking lists can become dry or dirty, preventing the roll cover from
operating correctly. To correct the problem, clean with a brush or cloth and lubricate the fl ocking
list using silicone oil (fig. 1 - 4).

03/30
x 2
(Fig. 7) Loosen top bolts on the rear-most brackets
slightly.
(Fig. 8) Close the roll cover completely.
The side rails have not been aligned correctly / have shifted
1.B
Make sure of cleaning properly fl ocking list and side rail (as per 1.A fi gure 2-3) prior to do
adjustment
If the side rails have not been installed correctly / in parallel to each other, the roll cover cannot clo-
se freely. Check for this problem by closing the roll cover, and then move the rear profi le from side
to side. The rear profi le should be able to move 1 to 1,5 mm from side to side (fig. 5).
To correct the problem, loosen the side rail brackets, re-align the roll cover, and tighten the side rail
brackets correctly (fig. 6 - 16).
x 4
(Fig. 5) Close roll cover, and move the rear profi le from
side to side. There should be 1 to 1,5mm of free move-
ment.
(Fig. 6) Loosen bolts on the side rail brackets slightly.
The brackets should be able to move freely.

04/30
B
A
A=B
B
A=
A
A
B
=B
A=B
x 2
(Fig. 9) Make sure the roll cover is centered correctly. (Fig. 10) Slightly tighten the top bolts on the rear-most
brackets.
10
10 Nm
x 2
(Fig. 11) Starting on one side of the roll cover, pull the
side rail slightly outwards (0,5-1 mm).
(Fig. 12) While holding the side rail in position, tighten
the top bolts of the rear-most bracket using a torque
wrench to 10±1 Nm. Repeat the process for the other
side rail.
10
X Nm
0 mm x 4 x 4
10
10 Nm
(Fig. 13) Tighten the remaining bolts by fi rst positioning
the brackets as shown, and tighten the top bolts using a
torque wrench to 10±1 Nm.
(Fig. 14) Tighten lower bolts to 10±1 Nm.

05/30
(Fig. 15) Close roll cover, and move the rear profi le from
side to side. There should be 1 to 1,5mm of free move-
ment.
(Fig. 16) Make sure the rear profi le sits correctly against
the tailgate. Refer to section 3.C, fig. 76 - 78.

06/30
x 4 0 mm
(Fig. 17) Loosen the top and lower bolts. (Fig. 18) Position the brackets as shown, making sure
the bracket sits fl ush to the bracket behind it, as indica-
ted.
x 4
10
10 Nm
(Fig. 19) While keeping the bracket in the correct
position, tighten the top bolts using a torque wrench to
10±1 Nm.
The side rail brackets have not been tightened correctly / loosened
1.C
If the 4 brackets supporting the side rails are not tightened correctly, they can bend inwards, pre-
venting the roll cover from operating correctly. To correct the problem, loosen the 4 brackets and
re-tighten the bolts in the correct order (fig. 17 - 20).
x 4
10
10 Nm
(Fig. 20) Tighten lower bolts using a torque wrench to
10±1 Nm.

07/30
(Fig. 21) Locate the pinion on the right side of the roll
cover canister.
(Fig. 22) Press the pinion inwards to release its locking
mechanism.
(Fig. 23) Turn the pinion clockwise to increase the
spring tension.
(Fig. 24) Close and then open the roll cover a few times
to check if the problem has been corrected.
The main spring has not been tightened correctly
1.D
Overtightening the the main spring may cause additional damage to the roll cover.
Before tightening it further, make sure nothing else is preventing the roll cover from opera-
ting correctly!
The speed and force of the roll covers opening mechanism is controlled by the main spring. If the
spring has not been tightened correctly, it will not be able to open the roll cover correctly. To corre-
ct this problem, tighten the main spring by turning the pinion on the right side of the
canister (fig. 21 - 24).

08/30
The side rails have not been aligned correctly / have shifted
2.A
If the side rails have not been installed correctly / in parallel to each other, the locking mechanism
will not be able to fully close the roll cover. To correct the problem, loosen the side rail brackets, re-
align the roll cover, and tighten the side rail brackets correctly (fig. 25 - 33).
x 4 x 2
0 mm
(Fig. 25) Loosen bolts on the side rail brackets slightly.
The brackets should be able to move freely.
(Fig. 26) Loosen top bolts on the rear-most brackets
slightly.
(Fig. 27) Close roll cover, and move the rear profi le from
side to side. There should be 1 to 1,5mm of free move-
ment.
(Fig. 28) Position the brackets as shown, making sure
the bracket sits fl ush to the bracket behind it, as indica-
ted.

09/30
x 4
10
10 Nm
x 4
10
10 Nm
(Fig. 29) While keeping the bracket in the correct
position, tighten the top bolts using a torque wrench to
10±1 Nm.
(Fig. 30) Tighten lower bolts using a torque wrench to
10±1 Nm.
10
10 Nm
x 2
(Fig. 31) Tighten the top bolts of the rear-most bracket
using a torque wrench to 10±1 Nm.
(Fig. 32) Move the rear profi le from side to side. There
should be 1 to 1,5mm of free movement.
(Fig. 33) Make sure the rear profi le sits correctly against
the tailgate. Refer to section 3.C, fig. 76 - 78.

10/30
The roll cover is installed incorrectly / locking holes do not align
2.B
If the side rails have not been installed correctly / off -center from eachother, the locking pins will be
mis-aligned. Check for this problem by closing the roll cover to the 2/3 position, and checking the
angles between the side rails and the rear profi le (fig. 34).
To correct the problem, loosen the side rail brackets, re-align the roll cover, and tighten the side rail
brackets again (fig. 35 - 48).
x 2
x 2 x 2
(Fig. 34) Measure the angles between the side rails and
the read profi le. The angles should be 90°.
(Fig. 35) Remove the 2 rubber plugs.
(Fig. 36) Loosen the front bolts slightly. (Fig. 37) Loosen top bolts on the rear-most brackets
slightly.

11/30
x 4
(Fig. 38) Loosen bolts on the side rail brackets slightly.
The brackets should be able to move freely.
(Fig. 39) Re-align the side rails.
x 2
4,8 Nm
T30
(Fig. 40) Check the angles between the side rails and
the read profi le again. If they are still not at 90°, try
re-aligning the side rails again.
(Fig. 42) Tighten the front bolts to 4,8±1 NM using a
torque wrench.
x 2
10
10 Nm
x 2
(Fig. 43) Re-insert the rubber plugs covereing the front
bolts.
(Fig. 41) Tighten the top bolts of the rear-most bracket
using a torque wrench to 10±1 Nm.

12/30
0 mm x 4
10
10 Nm
(Fig. 44) Position the brackets as shown, making sure
the bracket sits fl ush to the bracket behind it, as indica-
ted.
(Fig. 45) Slightly tighten the top bolts on the rear-most
brackets.
x 4
10
10 Nm
(Fig. 46) Tighten lower bolts using a torque wrench to
10±1 Nm.
(Fig. 47) Close roll cover, and move the rear profi le from
side to side. There should be 1 to 1,5mm of free move-
ment.
(Fig. 48) Make sure the rear profi le sits correctly against
the tailgate. Refer to section 3.C, fig. 76 - 78.

13/30
The bolts holding the side rails have loosened
2.C
If the roll cover is not regularly tightened, the side rail bolts may become loose. Loose bolts can
prevent the locking mechanisms from operating correctly.
To correct the problem, tighten the loose bolts again (fig. 49 - 58).
10
10 Nm
x 2
(Fig. 49) Tighten the top bolts of the rear-most bracket
using a torque wrench to 10±1 Nm.
x 2
(Fig. 51) Remove the 2 rubber plugs.
x 2
4,8 Nm
T30
(Fig. 52) Tighten the front bolts to 4,8±1 NM using a
torque wrench.
(Fig. 50) Move the rear profi le from side to side. There
should be 1 to 1,5mm of free movement.

14/30
x 2
(Fig. 53) Re-insert the rubber plugs covering the front
bolts.
0 mm
x 4
10
10 Nm
(Fig. 54) Position the brackets as shown, making sure
the bracket sits fl ush to the bracket behind it, as indica-
ted.
(Fig. 55) Tighten top bolts using a torque wrench to
10±1 Nm.
x 4
10
10 Nm
(Fig. 56) Tighten lower bolts using a torque wrench to
10±1 Nm.
(Fig. 57) Move the rear profi le from side to side. There
should be 1 to 1,5mm of free movement.
(Fig. 58) Make sure the rear profi le sits correctly against
the tailgate. Refer to section 3.C, fig. 76 - 78.

15/30
The rear profi le is of an older type
2.D
Check which type of profi le you have, by locating the serial number on the label on the front of the
rear profi le (fig. 59 - 60).
If the number following the fi rst letter (”R” in this example) is lower than 14811, refer to the
Technical Service Bulletin number 16-2008.
(Fig. 59) Locate the label on the front right side of the
rear profi le.
Serieno.: R14811
Typzeichen:
(Fig. 60) Locate the serial number.

16/30
The roll cover cannot be unlocked with the key
3.A
If the roll cover is unable to be unlocked with the key, check to see if the serial numbers on the
lock cylinder and key match (fig. 61).
If the roll cover is used in icy weather conditions, ice or snow can block the lock cylinder. Correct
the problem by thawing the ice around the lock using a hairdryer or similar (fig. 62).
(Fig. 61) Locate the numbers for the key and lock cylin-
der.
(Fig. 62) Remove ice or snow using a hair dryer or simil-
ar.

17/30
(Fig. 63) Remove snow or ice using a hairdryer or simil-
ar.
The roll cover does not open when the lock button is pressed down
3.B
If the roll cover is being operated in icy weather conditions, snow or ice can block the rear profi le or
lamellas, preventing the roll cover from operating correctly. Remove ice or snow using a hairdryer
or similar (fig. 63).

18/30
The lock button is jammed / hard to press down
3.C
If the roll cover has not been aligned correctly during installation, it will press against the tailgate,
preventing the roll cover from operating correctly.
Pull back on the lock handle, and press the lock button down. If the button moves freely when the
handle is pulled back, the pressure is too high. (fig. 64). If the lock button is still jammed, try ope-
ning the tailgate and press the lock button down again (fig. 65).
To correct the problem, fi rst try decreasing the tension on the main spring (fig. 66 - 69).
If the main spring is tightened correctly, re-align the roll cover to decrease the pressure on the
tailgate (fig. 70 - 86).
1
2
(Fig. 64) Pull back on the lock handle, then press the
lock button down. The lock button should then move
freely.
(Fig. 66) Locate the pinion on the right side of the roll
cover canister.
(Fig. 67) Press the pinion inwards to release its locking
mechanism.
(Fig. 65) Open the tailgate, and press the lock button
down. The lock button should then move freely.