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Mountain Top Wildtrak Troubleshooting Manual

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

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  • Page 1 Mountain Top Roll ® Troubleshooting manual (Wildtrak) DOWNLOAD PDF PRINT FORMAT: A5 BOOKLET ISSUE 02 / 21/11-2017 / MTI 886 400 © 2017 Mountain Top Industries APS...

  • Page 3: Table Of Contents

    Contents Mountain Top Roll Troubleshooting manual (Wildtrak) ® THE ROLL COVER DOES NOT OPEN OR CLOSE FREELY 1.A The fl ockinglists are dry / dirty p. 02 1.B The side rails have not been aligned correctly / have shifted p. 03 1.C Side rail brackets have not been tightened correctly / have loosened...

  • Page 4: A The Fl Ockinglists Are Dry / Dirty

    The fl ocking lists are dry / dirty 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 (fi...

  • Page 5: B The Side Rails Have Not Been Aligned Correctly / Have Shifted

    The side rails have not been aligned correctly / have shifted 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.
  • Page 6 A A B (Fig. 9) Make sure the roll cover is centered correctly. (Fig. 10) Slightly tighten the top bolts on the rear-most brackets. 10 Nm (Fig. 11) Starting on one side of the roll cover, pull the (Fig. 12) While holding the side rail in position, tighten side rail slightly outwards (0,5-1 mm).
  • Page 7 (Fig. 15) Close roll cover, and move the rear profi le from (Fig. 16) Make sure the rear profi le sits correctly against side to side. There should be 1 to 1,5mm of free move- the tailgate. Refer to section 3.C, fi g. 76 - 78. ment.

  • Page 8: C Side Rail Brackets Have Not Been Tightened Correctly / Have Loosened

    The side rail brackets have not been tightened correctly / loosened 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 (fi...

  • Page 9: D The Main Spring Has Not Been Tightened Correctly / Has Lost Tension

    The main spring has not been tightened correctly 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.

  • Page 10: A The Side Rails Have Not Been Installed Correctly / Have Shifted

    The side rails have not been aligned correctly / have shifted 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 (fi...
  • Page 11 10 Nm 10 Nm (Fig. 29) While keeping the bracket in the correct (Fig. 30) Tighten lower bolts using a torque wrench to position, tighten the top bolts using a torque wrench to 10±1 Nm. 10±1 Nm. 10 Nm (Fig. 32) Move the rear profi le from side to side. There (Fig.

  • Page 12: B The Roll Cover Has Not Been Installed Correctly / Locking Holes Do Not Align

    The roll cover is installed incorrectly / locking holes do not align 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...
  • Page 13 (Fig. 38) Loosen bolts on the side rail brackets slightly. (Fig. 39) Re-align the side rails. The brackets should be able to move freely. 10 Nm (Fig. 41) Tighten the top bolts of the rear-most bracket (Fig. 40) Check the angles between the side rails and using a torque wrench to 10±1 Nm.
  • Page 14 10 Nm 0 mm (Fig. 44) Position the brackets as shown, making sure (Fig. 45) Slightly tighten the top bolts on the rear-most the bracket sits fl ush to the bracket behind it, as indica- brackets. ted. 10 Nm (Fig. 47) Close roll cover, and move the rear profi le from (Fig.

  • Page 15: C The Bolts Holding The Side Rails Have Loosened

    The bolts holding the side rails have loosened 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 (fi g. 49 - 58). 10 Nm (Fig.
  • Page 16 0 mm (Fig. 53) Re-insert the rubber plugs covering the front (Fig. 54) Position the brackets as shown, making sure bolts. the bracket sits fl ush to the bracket behind it, as indica- ted. 10 Nm 10 Nm (Fig. 55) Tighten top bolts using a torque wrench to (Fig.

  • Page 17: D The Rear Profi Le Is Of And Older Type

    The rear profi le is of an older type Check which type of profi le you have, by locating the serial number on the label on the front of the rear profi le (fi g. 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.

  • Page 18: A The Roll Cover Cannot Be Unlocked With The Key

    The roll cover cannot be unlocked with the key 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 (fi g. 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 (fi...

  • Page 19: B The Roll Cover Does Not Open When The Lock Button Is Pressed Down

    The roll cover does not open when the lock button is pressed down 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 (fi...

  • Page 20: C The Lock Button Is Jammed / Hard To Press Down

    The lock button is jammed / hard to press down 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.
  • Page 21 (Fig. 69) Close the roll cover, and check if the problem (Fig. 68) Turn the pinion anticlockwise to decrease the has been corrected. spring tension. (Fig. 71) Loosen the front bolts slightly. (Fig. 70) Remove the 2 rubber plugs. (Fig. 73) Loosen bolts on the side rail brackets slightly. (Fig.
  • Page 22 (Fig. 75) Move the roll cover slightly forwards. (Fig. 74) Close the roll cover, and open the tailgate. (Fig. 76) Close the tailgate while holding 2 pieces of (Fig. 77) Starting on one side, carefully pull on the paper between the tailgate and the roll cover. paper.
  • Page 23 10 Nm (Fig. 80) Re-insert the rubber plugs covereing the front (Fig. 81) Tighten the top bolts of the rear-most bracket bolts. using a torque wrench to 10±1 Nm. 0 mm (Fig. 82) Open the tailgate, and move the rear profi le (Fig.
  • Page 24 (Fig. 86) Open the tailgate, and move the rear profi le from side to side. There should be 1 to 1,5mm of free movement. 22/30...

  • Page 25: D The Lock Release Is Jammed In Its Outer Position

    The lock release is jammed in its outer position In rare cases, the locking mechanism can jam in its outer position within the rear profi le. Find the lock striker on the back of the rear profi le. It should only extend slightly from the rear profi le (fi...

  • Page 26: E The Roll Cover Does Not Lock In 1/3, 2/3, Or Closed Positions

    The roll cover does not lock in the 1/3, 2/3, or closed positions If the roll cover does not lock correctly in both side rails, fully open the roll cover to activate the lock striker, then check if the problem has been corrected (fi g. 89 - 90). Alternatively, activate the lock mechanism by pulling the pullstrap to the left, then check if the pro- blem has been corrected (fi...

  • Page 27: F Replace The Rear Profi Le

    (Fig. 93) Close the roll cover. The lock mechanism should click when passing the 3 lock positions on both side rails. Replace the rear profi le If the locking system still doesn’t work correctly or jams, and all methods described in this section have been used, please replace the rear profi...

  • Page 28: A Water / Dirt Ingress Occurs Multiple Places (Eb3B Specifi C)

    Water / dirt ingress occurs multiple places (EB3B specifi c) Water and dirt ingress can occur at the areas listed below. Follow the steps mentioned for each area to prevent further water or dirt ingress. Plastic bed liner: Locate the plugs, and apply a silicone seal (fi g. 94 - 97). Side rail plug: Remove the plugs, and apply a silicone seal (fi...
  • Page 29 (Fig. 98) Remove the 2 rubber plugs. (Fig. 99) Turn the plug over, and apply silicone. (Fig. 100) Re-insert the rubber plugs covereing the front bolts. 27/30...

  • Page 30: B Water / Dirt Ingress Occurs Multiple Places (A66+Ab39 Specifi C)

    Wildtrak / truck bed: Apply a silicone seal between the Wildtrak bar and the truck bed as indicated (fi g. 101 - 104). Wildtrak top covers: Remove 2 covers on the top of the Wildtrak bar, and apply a silicone seal as indicated (fi g. 105 - 107).
  • Page 31 (Fig. 103) Apply silicone in the gap on the outer sides of (Fig. 104) Apply silicone around the Wildtrak bars front the bulkhead. brackets, and up along the front of the side rails. (Fig. 105) Remove the plastic covers on top of the Wild- (Fig.
  • Page 32 (Fig. 111) On both sides of the roll cover, fi nd where the (Fig. 112) Lift the rubber sealing slightly, and apply sili- rubber sealing edge meets the crease in the Wildtrak cone into the crease, and under the rubber sealing.
  • Page 36 Customer Service +45 4810 2950 (08:00 - 16:00 CET) +45 4810 2960 Support info@mountaintop.dk Website www.mountaintop.dk Address Pedersholmparken 10, 3600 Frederikssund, Denmark...

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