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Vantage Hearth truckall Operation And Service Manual

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VANTAGE PREMIUM MODEL:
®
®
TRUCKALL
& VANGO
OPERATION AND SERVICE MANUAL
ND
(2
Edition)
VANTAGE VEHICLE INTERNATIONAL, INC.

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Summary of Contents for Vantage Hearth truckall

  • Page 1 VANTAGE PREMIUM MODEL: ® ® TRUCKALL & VANGO OPERATION AND SERVICE MANUAL Edition) VANTAGE VEHICLE INTERNATIONAL, INC.
  • Page 2 The purpose of this manual is to provide you some useful information and necessary technical data on operation, maintenance, trouble-shooting and service of Vantage TruckALL & VanGO series. Since the automobile vehicles made by our plant are mounted with different engine models, and each type of engine is provided with special-purpose manual on service, this manual only gives a general description on engine.

  • Page 3: Table Of Contents

    Contents Contents Chapter I. Whole vehicle…………………………………………………………………………………………………………………………1 Section 1. General introduction……………………………………………………………………………………………………………1 Section 2. Operation of vehicle……………………………………………………………………………………………………………7 Section 3. Service and maintenance of vehicle……………………………………………………………………………………………20 Chapter II. Engine ……………………………………………………………………………………………………………………………….34 Section 1. Accessories to engine with carburetor…………………………………………………………………………………………34 Section 2. Accessories to electronic fuel injection type engine series……………………………………………………………………40 Chapter III.

  • Page 4: Table Of Contents

    Contents Chapter IV. Vehicle body………………………………………………………………………………………………………………………114 Section 1. Front door and rear slide door…………………………………………………………………………………………………114 Section 2. Rear door……………………………………………………………………………………………………………………128 Section 3. Seats…………………………………………………………………………………………………………………………130 Section 4. Instrument panel………………………………………………………………………………………………………………132 Section 5. Front windshield, rear windshield and side window…………………………………………………………………………133 Section 6. Bumper………………………………………………………………………………………………………………………136 Chapter V. A/C system…………………………………………………………………………………………………………………………138 Section 1.
  • Page 5 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter I. Whole Vehicle Chapter I. Whole Vehicle Section 1. General Introduction I. VIN and engine number location • VIN Location: VIN located at front left of the instrument panel.
  • Page 6 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Vehicle parameters Vehicle model B900, X900 B1000, X1000, C1000 & P1000 Type Straight four 4-stroke water-cooled electronic fuel injection gasoline engine Bore X stroke (mm X mm) 62×72...
  • Page 7 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter I. Whole Vehicle III. Pparameters and structure description Tire (general cross ply 165/70R13 (5.00-12ULT) Capacity parameters Fuel tank: Rim(general cross ply) 5.00×13 (4.00B×12) Engine lubricating system: 3.5L Tire pressure(general cross...
  • Page 8 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series IV Repair regulations 1. When repairing electric parts, the joint of binding post of battery negative pole should be disconnected first, in order to avoid electric shock or short;...
  • Page 9 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter I. Whole Vehicle Fig. 1.1-6 sketch of safe dais put in back side 4. When lift a vehicle with a lifting rack, guarantee that lifting arm does not contact to brake pipeline, fuel pipeline, bracket or any other parts.

  • Page 10: Section 2. Operation Of Vehicle

    Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 2 Operation of vehicle I. Operation description (I) Key Two key are provided for a vehicle (Key with code anti-theft system sees Chapter 6). Vehicle key has the following functions: 1.
  • Page 11 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter I. Whole Vehicle 1. Front seat (1) Fixing Hang two lock hoop in seat front end on projective latch hook, press the handle up to lock-up, in this way the seat can be fixed, as shown in Fig.
  • Page 12 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 3. Body CA1010, and CA1010A Mini-Cargo Car Series with single row seat, The body is full metal rear body. Body safety frame is fixed on cab rear wall board, the body can be opened in three sides.
  • Page 13 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Note: (VII) Instrument panel and control mechanism, see Fig. 1.2-15.(taking ·Seat belt is designed according to human body’s structure, so the hard plastic instrument panel as an example)
  • Page 14 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series When fuel gauge pointer points at F, the fuel tank is full; when it The engine starts, the indicator lamp should black out. If the engine points at E, the fuel tank is nearly empty, see Fig.
  • Page 15 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Note: ·Starting engine does not exceed 5 seconds each time, if the engine is If the engine starts the lamp is still bright or the lamp is lightened not started once, it must be started again after 5-10 seconds.
  • Page 16 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 3.High/low beam switch of far-reaching lamp and near-field lamp Put lamplight switch on gear 2 position. When the handle is on Rear windshield wiper, washer switch is on instrument panel; the type is middle position, near-field lamp is bright;...
  • Page 17 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (XI) Horn Horn switch is on steering panel. Press any point on the button to make the horn sound, see Fig. 1.2-25. Fig. 1.2-27 Fig. 1.2-28...
  • Page 18 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (XVIII) Ventilation unit There are 6 ventilation orifices. Pull 4 adjustable grilles, adjust blown air current direction to your satisfactory position., (XIX) Air-conditioner and heater unit 1.
  • Page 19 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Note: Pre-cooling: When you park in point-blank sunlight, you should 2. A/C control panel crank down vehicle window, and switch on air-conditioner for The A/C unit of this vehicle has the functions of ventilation, heating several minutes, to make the hot air in the vehicle blow out.
  • Page 20 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (XXII) Gearshift handle All gear positions of 5-gear type transmission are shown in Fig. 1.2-38. For 4-gear type transmission, positions of the first, second, third and fourth gears and reverse gear are all the same as the positions in the figure.
  • Page 21 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 6. Often check the temperature of wheel hub and braking drum, regulate 12. Presence and absence of abnormal sound of engine and them when it is necessary.

  • Page 22: Section 3. Service And Maintenance Of Vehicle

    Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 3 Service and maintenance of vehicle 1. Routine maintenance Routine maintenance means daily maintenance before departure and after traveling, is the foundation of regular maintenance. Taking cleaning and observation as the key.
  • Page 23 Time interval: Mileage Number of months or kilometers, whichever ( X1,000km comes first Number of month Breaking-in (Month) period Engine Fan belt : degree of tightness, damage J·T J·T·G J·T·G Timing belt: degree of tightness, damage J·T·G J·T·G J·T·G J·T·G Valve clearance J·T J·T...
  • Page 24 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series III. Service and maintenance items (I) Engine 1. Water pump(fan) belt (1) Check and adjustment 1) Check the presence and absence of crack, break, distortion, abrasion and cleanliness of belt. Check belt tension force. Press the belt with thumb(about 10kg force), if it bends 6-9mm, show the tension force is appropriate, as shown in Fig.
  • Page 25 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2. Valve clearance (1) Dismount valve cover. The tightening torque of exhaust branch nut: 18-23 N· .M (1.8-2.3kg.m). (2) Check the valve clearance of air intake and exhaust, and adjust if The tightening torque of air intake branch nut: 18-23 N·m (1.8-2.3kg•...
  • Page 26 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Note: in order to prevent oil leakage, it is necessary to guarantee the (1) After engine is cooled, remove radiator cap. engine oil cleaner screwed tightly, but it is not over tight.
  • Page 27 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (4) Screw discharge orifice cock, and install the hydraulic (4) Any bad cases must be resolved immediately. accumulator at the original position. (II) Ignition system Fill up coolant into radiator, and run engine at idle speed, until affirm that engine coolant pass through one large cycle at least, then stop 1.
  • Page 28 (3) Install new spark plug, and screw the spark plug to the specified (3) Check whether distributor arm is broken, and electrode is abraded. torque. (4) If you find the bad cases mentioned above, please repair or replace The tightening torque of spark plug : 20-30N·m(2.0-3.0kg·m). them if necessary.
  • Page 29 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (4) Equip filter cartridge into air filter bowl. (2) Check visually the gasket of fuel tank cap. If there are cases of Note: After the vehicle runs in dusty area, check whether filter abrasion, break and distortion, replace the gasket.
  • Page 30 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 3. Fuel evaporation control system For the check and regulation steps of idle and idle mixture, refer to 1) Check the presence and absence of crack, damage or over bending of operation manual on engine.
  • Page 31 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (2) Pull up parking brake lever with single hand completely, to make 2) Under the condition that wheels and brake drum are dismounted, brake act fully, while pulling brake lever, listen to the total tooth gap check whether brake drum and friction facing is over-abraded, quantity that crawl lever passing carefully (each “chattering”...
  • Page 32 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 1) Check whether front wheel bearing is abraded, caught or loose. (2) Part replacement is determined according to the above-mentioned 2) Check whether rear wheel bearing is abraded, caught or loose.
  • Page 33 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig. 1.4-17 1. Filler plug 2. Discharging oil screw plug 2) Rear axle Fig. 1.4-16 Oil capacity: 1.3L 1. Transmission filler 2. Transmission oil Oil brand: 80W/90(GB13985-92) hyperbola gear oil.
  • Page 34 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 12. Suspension Note: When doing the following road test, it is necessary to select a safe (1) Check whether the presence and absence of abrasion and break of...
  • Page 35 Chapter I. Whole Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series • Check the engine and ensure smooth operation at different rpm • Check the engine and ensure no abnormalities during operation 7. Body, wheel and power train Check the body, wheels and power train, there shall be no abnormal noise, vibration and other conditions.

  • Page 36: Chapter Ii. Engine

    Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series When the ignition switch is in the position of ON, the oil pump begins to Chapter II. Engine pump and the oil is drawn from the oil tank. After being filtered by the oil filter, the filtered oil flows to the carburetor through oil pump and intake pipe.
  • Page 37 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series Therefore changed resulting cut off of contact switch (2) and electrical current and disposal of wiring magnetism as well. The diaphragm and pull rod are pushed downward under the force of gravity and elasticity, so oil in the oil chamber can push the oil valve and flow out of the oil pipe, the upper contact can be again connected.
  • Page 38 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series (2) Disassembly Oil Pump Specifications As indicated in Fig. 2.1-5, the upper and lower joints shall be marked Discharge pressure 24.5-24.3kPa ①, to recognize the angle position of upper body ② and lower body Pump capacity 1.3L/min (200r/min)
  • Page 39 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig. 2.1-6 Fig. 2.1-7 (4) Assembly (II) Intake System 1) Put the pump diaphragm on the pump rod as indicated in Fig. 1. Intake system is composed of cool air intake pipe, hot air pipe, 2.1.-6, and then insert the pump stay into the pump rod.
  • Page 40 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series (1) Operational principle third With the running of the engine, the air is drawn into the first chamber of chamber the dirt collector, and then flows into the second chamber through windmill air vane shaped diaphragm orifice ①...
  • Page 41 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Exhaust System 2) Daily cleaning Clean dirt collecting cup monthly. As is shown in Fig. 2.1-9, disassemble dirt Exhaust system is made up of intake pipe, muffler and relevant collecting cup from the dirt collector, dump the dirt and reassemble it to the accessories.
  • Page 42 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series As the exhaust manifold of engine applies compound exhausting, the Section 2 Electro Engine Series of Accessories exhaust system can be divided into two parts, namely intake pipe and I.
  • Page 43 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series 1. Harness assembly 2. Wire clip Spring 4. Guide rod 5. Pressure hose 6. Oil pump 7. Oil pump bracket 8. Oil reservoir 9. Flange 10. Caliper Fluid level sensor assembly 12.
  • Page 44 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series The operational principle of the carbon tank is as the following: The Note: vacuum generated in the engine intake system makes the fresh air be • As the demand for electric vehicle oil supply pressure is quite high, drawn from the carbon tank air port.
  • Page 45 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series • When a fire occurs, namely the engine does not run regularly after start, the engine power significantly decreases or other abnormal phenomenon which indicates there exists failures in the ignition system, please contact with service station quickly.
  • Page 46 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series (2) Technical specifications The injection order shall be grouped injection: cylinder 1 and 4 are Operational voltage 6-15V DC(according to the grouped together, and cylinder 2 and 3 are grouped together.
  • Page 47 Chapter II. Engine Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig.2.2-5 Structure Chart of Exhaust System 1.Tri-effective catalytic converter welding assembly 2. Muffler welding assembly 3. Joint component...

  • Page 48: Chapter Iii. Chassis

    Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series When the clutch is jointed, diaphragm spring outer rings are tightly presses on the pressure plate which tightly presses the friction pad on the Chapter III. Chassis flywheel.
  • Page 49 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Disassembly 3. Clutch pressure plate The prerequisite for disassembling the clutch is that the transmission Check the friction spring rivet of the clutch pressure plate to find has been disassembled in the correct order.
  • Page 50 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Route of clutch pulling thread V. Maintenance 1. Free stroke of clutch pedal A directional view Suspension framework ① Press the clutch pedal, stop pressing when feels the clutch...

  • Page 51: Section 2. Transmission

    Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Gear shifting control Section 2 Transmission I. Introduction 1. Gear shifting control system is mainly composed of the following The transmission is gear meshed type, and has five (four) driving parts.
  • Page 52 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 1) Gearlever Check each component to see whether there exist wearing, damage or ① Disassemble the front gearlever assembly. deformation. If occurs, they shall be exchanged. ② Disassemble the shift flexible shaft from the gearlever.
  • Page 53 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig.3.2-3 1. Fork arm lever arm 2. Cylindrical roller 3. Gearing shifting handle axle arm ⑤ Install the iron ball, springs and screws, and screw the screws to the specified torque 8-14N·m.
  • Page 54 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2) Speed operating flexible lever and speed operating lever 4) Flexible lever Assemble according to the reverse order of disassembly. The installation position shall not be mixed when install the speed...
  • Page 55 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 5. Maintenance Adjustment of flexible shaft Note: • Each lubricating part listed in Fig.3.2-4 must be checked before adjustment to ensure adequate lubrication and there exists no wearing on the lining and other components.
  • Page 56 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 995 CC MODELS series micro vehicle adopts two types of III. Transmission (five gear type) transmissions: five gear type transmission is installed on 456 series 1. Introduction engine and four gear type transmission is installed on 462 series engine.
  • Page 57 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Reverse gear shifting fork High gear shifting fork ：Low gear shifting fork Reverse driving gear The third gear Deceleration drive gear The first gear The second gear...
  • Page 58 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 13) Disassemble the transmission rear bracket from the body. 2. Each gear ration of transmission 14) Disassemble the transmission. The first gear 3.652 4. Breakdown The second gear 1.947...
  • Page 59 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series ⑥ Disassemble the thrust washer and the reverse gear lining from the Examine whether there exists wearing, damage or discoloration on each second axle. part. If any problem occurs, replace a new part.
  • Page 60 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 8) Chamfered edge tooth of synchronizing ring (outer tooth) and outer ring (inner ring) Clearance between gearing ring and tooth The synchronizing ring and commutating ring has three grooves...
  • Page 61 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 10) Sizing spring of declutch shift shaft If the problem of “gear slides out of mesh” occurs, measure the free Slide block groove width Standard Operation limit length of spring.
  • Page 62 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Then use the hydraulic press machine to install the first gear lining ③ Install the countershaft reverse gear and five gear to the countershaft. and the two linings on the second gear are the same.
  • Page 63 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series ④ Install the first axle and the second axle to the lower cover body. Others ⑤ Sealant shall be coated evenly on the matching surface of the A certain amount of gear oil shall be infused in the transmission lower cover body.
  • Page 64 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig.3.2-12 Tightening Torque Specification...
  • Page 65 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series The first axle assembly 2. Needle bearing 3. The first axle bearing 4. C type lock ring 5. Collar ring 6. Oil seal 7. The second axle 8. Cylindrical roller 9. Thrust washer 10. The first gear 11.
  • Page 66 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series The first gear The third gear The second gear High gear shifting fork Low gear shifting fork High gear shifting fork Under drive gear Shaft2 Shaft 1...
  • Page 67 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Note: Please refer to the content of five gear type transmission for the ① Disassemble the countershaft connected with gear. unmentioned aspects. ② Disassemble the countershaft rear bearing.
  • Page 68 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series ⑤ Press the reverse gear lining. Prevent the cylindrical rollers ② The two matching surfaces of the upper and lower cover body must installed based on the step ④ fall out during operation.
  • Page 69 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 3 Driving Axle I. Introduction The driving axle in the vehicle is single section, open type and coreless dual universal joints structure. The front end is connected to...

  • Page 70: Section 4. Rear Axle

    Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Disassembly Section 4 Rear Axle 1. Lift the vehicle. I. Introduction 2. Disassemble the driving axle bolt and nut. 3. Pull the driving axle. The rear axle structure of the vehicle is hypoid gear single stage main...
  • Page 71 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Disassembly 4) Pull the right side bearing from the differential housing by using 1) Release parking brake lever. special tool. 2) Lift the vehicle and disassemble the real wheel.
  • Page 72 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series δ Firstly, press the outer ring of driving conical gear rear bearing and computation expression: H=C-A-B A=85+ driving conical gear front bearing respectively. Then install the in the formula: C means the actual assembly distance of master...
  • Page 73 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Mesh mark of driving and driven conical gear and clearance adjustment Adjustment method Mesh mark of driving and driven conical gear Convex side (positive driving) Concave side (negative driving)
  • Page 74 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 7. Tighten the differential bearing cover bolt by applying the · Differential end bearing tightening torque of 50-60N· m after adjusting the gear meshing mark. Install the bearings into the differential housing by applying special tool.
  • Page 75 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2. Assemble the rear axle housing assembly 11) Connect the parking brake pulling arm to the parking brake cross 1) The rear axle housing assembly must be cleaned and no foreign matter bracing wire and install the brake shoe on it.
  • Page 76 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Assembly data of rear axle Tightening torque unit: N·m Items Specification Standard value Pretension load of driving conical gear bearing (excludes oil seal resistance moment) 30305/P6 30306/P6 0.3-0.7...

  • Page 77: Section 5. Suspension System

    Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 5 Suspension System I. Introduction Front suspension: slide column oscillating arm type independent suspension, coil spring and being installed with antis-way bar. Bilateral hydraulic solid bowl type retarder. Please refer to Fig.3.5-1.
  • Page 78 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series (3) Release the nut of the retarder piston rod upper end to facilitate the (3) Disassemble the rear nut of stabilizing pull rod. next disassembly work to the retarder and coil springs.
  • Page 79 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series (2) Put the coil spring on the spring bottom base of the retarder and match its end and the ladder part of the spring bottom base. (3) Install the piston rod cushion cover to the piston rod. Pay attention to its direction and do not reverse install it.
  • Page 80 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series (3) Install the antis-way bar to the cantilever by applying cushion pad, 3. Cantilever washer, bolt nut. Disassembly Front Screw the nut to the extent (1) Support the vehicle and disassemble the wheels.
  • Page 81 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 4. Antis-way bar (5) Pull the spring eye bolt out and disassemble the leaf spring form the Disassembly steel plate pin. (1) Support the vehicle and hang up the front suspension.
  • Page 82 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Leaf spring The side must be aligned for each leaf spring Spring upper Rear Front chair Spring upper chair Center bolt and nut 25-35N·m Bolt 40-70N·m Body center...

  • Page 83: Section 6. Steering System

    Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Front end Section 6 Steering System I. Introduction Steering system consists of rack and pinion system and corresponding Rack steering echelon form assembly. Rack and pinion is composed of gear...
  • Page 84 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Disassembly 1. Steering wheel Please refer to Fig.3.6-2 to see the steering gear assembly. 1) Disassemble the negative wiring of the battery. 2) Disassemble the steering wheel horn cover.
  • Page 85 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2) Disassemble the joint bolt between the steering shaft connector and 5. Steering cross pull rod gear shaft axle part. 1) Support the vehicle and disassemble the wheels.
  • Page 86 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 9) Lubricating grease shall be slightly coated on the sliding part which the plunger against the pinion, sealant shall be coated on the adjusting bolt. Then screw the locking nut to its maximum value and rotate it 0-90º...
  • Page 87 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series IV. Assembly 1. Steering gear assembly 1) Set the front wheels (left and right) at the right front driving position. 2) Rotate the gear shaft to adjust the length of the pinion to reach the indicated value in Fig.3.6-7, set the steering pinion at the straight...
  • Page 88 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 5) Connect the steering longitudinal pull rod to the steering boom and 2) Install the steering gear shaft (lower) to the universal joint boom on screw the groove type nut within specified torque range. Please refer to Fig.3.6-9.
  • Page 89 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 8) Install the steering wheel horn cover. V Maintenance and service 1. Examine the steering bearing frame assembly to avoid accidental damage. 1) Examine the smoothness of the steering gear shaft rotation. If any 14-17 poor condition occurs, replace the gear shaft.
  • Page 90 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 7. Steering gear dust proof cover Note: Maintenance data of front alignment Each time to make regular maintenance and service or lift the vehicle Toe-in Bevel wheel...
  • Page 91 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Checks shall be done before adjusting the front wheel localization to ensure the precision of the front wheel localization adjustment: 1) Check all the tires to see the suitableness of charged pressure and whether Front end the wearing condition of the tire surfaces is the same.
  • Page 92 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 6. Turing angle The items marked with * need to be regularly examined. Turning angle Inner side ±3 Outer side ±3 Check the toe-in and turning angle by applying special apparatus after replacing the steering cross pull rod, steering cross pull rod ball pin and master steering arm.
  • Page 93 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 7 Brake System I. Introduction The vehicle applies dual pipe hydraulic brake system, front wheel disc brake, rear wheel drum brake (brake clearance is self adjustable). The brake has brake proportional valve.
  • Page 94 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Front Wheel Disc Brake Note: Do not use sand paper to polish the liner as the hard particles on (I) Disassembly the sand paper will be attached on the liner and damage the brake disc.
  • Page 95 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Surface B shall keep equal distance to the oil cylinder A on Fig.3.7-2 the whole circumference (III) Notes for assembly Reassemble the front wheel brake according to the reverse order of Fig.3.7-3...
  • Page 96 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2) Loosen the wheel nut, do not take it down. 3) Support the vehicle by using a lifting jack and support it on the safety Tightening torque board, disassemble the wheel nut and take the wheels down.
  • Page 97 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2. Brake shoe Check whether the brake drum is clean, measure the inner diameter of If wearing of the friction liner exceeds the operation limit, the brake shoe the brake drum and examine the wearing of the brake surface.
  • Page 98 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 8) Check whether brake drum can rotate smoothly without obstruction and has the normal brake effect. Then lay the supported vehicle down and carry on brake test.
  • Page 99 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Brake pedal Rear brake wheel cylinder Brake shoe support board Brake shoe Parking brake draw Sizing spring pin Release spring Fig.3.7-9 V. Brake Master Cylinder Adjusting nut (I) Disassembly 1) Disassemble the negative wiring from the battery.
  • Page 100 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 19) Disassemble the brake master cylinder from the vacuum booster. (II) Disassembly 1) As is indicated in Fig.3.7-11, take the spring out, blow the first piston by using compressed air. Prevent the first piston from bouncing bout during disassembly.
  • Page 101 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series (III) Examine the components 3) Install the first piston to the oil cylinder. 1. Examine the internal components of brake master cylinder 4) Push the first piston slightly inward, install the sizing screw and screw Examine whether there exists wearing or corrosion on the it to the specified torque 1.5-3N·m.
  • Page 102 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series c. Install the steering column to the body and screw the steering column bolt to the specified torque. Screw the steering shaft connector bolt to the specified torque.
  • Page 103 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series VI. Vacuum Booster (I) Disassembly 1) Disassemble the vacuum booster from the body by applying the same method of disassembling brake master cylinder. 2) Disassemble the brake master cylinder from vacuum booster.
  • Page 104 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Special tool I Special tool II Clearance between special tool and piston rod is 1.0-1.5mm 1. Brake master cylinder 2. Piston Fig.3.7-18 Special tool I Special tool II 1.
  • Page 105 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series (III) Note for assembly (1) As is indicated in Fig.3.7-21, check the distance between the fork pin hole and vacuum booster front end which shall be within 106.5-107.5mm.
  • Page 106 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Tightening torque N·m Pipe connecting bolt 14-18 Brake hose connecting bolt 20-30 Fig.3.7-24 1. Vacuum booster 2. Vacuum pipe connector 3. Vacuum hose 4. Collar clamp VII. Brake Pipe...
  • Page 107 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series VIII. Maintenance and service 1. Leakage of brake fluid Examine the brake oil cylinder for liquid level. If the liquid level in the brake oil cylinder is slightly decreased, it shows that the decreasing is due to normal wearing of friction pad.
  • Page 108 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 9. Examine brake disc 2) When the stop lamp switch is disassembled, please correctly The brake disc shall be regularly examined based on maintenance assemble it according to the specifications in “Adjust the stop lamp schedule.
  • Page 109 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series e) Parking brake handle has been pulled several times by the force of 20kg. ③ The brake drum shall not have “dragging” condition after loosening the adjusting nut to adjust the stroke as is indicated in Free stroke of pedal 1-8mm 14.
  • Page 110 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series d) When the hydraulic pressure in the brake oil cylinder nearly exhausted, press the brake pedal and rescrew the exhaust screw. e) Repeat the previous steps until there is no bubble in the exhausted...
  • Page 111 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 8 Wheel And Tire b) Start the engine as pressing the pedal. If the pedal stroke is slightly increased, it shows its function is normal. While if the pedal stroke do I.
  • Page 112 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 1. Bumping driving 2. The tire is damaged or the tire foundation is broken 3. Rapid wearing to the tire central wheel track The following conditions will occur if the tire pressure is lower than the specified air pressure: 1.
  • Page 113 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series V. Disassemble the wheels Static unbalance will cause uneven wearing to the tire. 1. Loosen the nut for about half a round. Dynamic unbalance will cause the front wheels to vibrate.
  • Page 114 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 4. Screw the steering knuckle nut to the specified torque. Lock it by using cotter pin. 5. Screw the caliper nut to the specified torque. 6. Press the brake pedal and keep pressing, screw the brake pedal bolt to the specified torque.
  • Page 115 Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series 4. Operation And Maintenance X. Assemble And Adjust The Front Hub Part Of Drum Brakes (1) As to the second class maintenance (6000-8000km), disassemble the 1. Disassemble the wheel hub and bearing front hub, clean the hub inner chamber and hub bearing, fill in new (1) Support the vehicle and disassemble the vehicle.

  • Page 116: Chapter Iv. Vehicle Body

    Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body I. Front door glass and front door glass regulator Section 1 Front door and rear sliding door (I) Disassembly Disassemble front door glass and front door glass regulator according to The main assembly parts included in front door refer to Fig.
  • Page 117 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Chapter IV Vehicle body 7) Fixing screw for front door glass bearer, see Fig. 4.1-4. 8) Pull up the rear side of front door glass, take out front door glass with front door glass bearer, and see fig.
  • Page 118 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series (II) Inspection 1. Check whether front door glass regulator gear is abraded or damaged. 2. Check whether front door glass regulator spring is loose. (III) Assemble front door glass and front door glass regulator in a reverse sequence.
  • Page 119 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Fig. 4.1-9 Fig. 4.1-8 1. Glass bearer 2. Glass bearer rubber gibs 2) When assembling glass on glass bearer rubber gibs, daub soap water on glass bearer rubber gibs, and use rubber hammer to rivet slightly glass.
  • Page 120 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series II. Door lock 4) Use adhesive agent to adhibit front door seal membrane on door (I) Front door lock inner panel tightly, see Fig. 4.1-11. The main parts included in front door lock see Fig. 4.1-13.
  • Page 121 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Fig. 4.1-13 1. Front door outer handle assembly 2. Front door lock cylinder assembly 3. Front door inner handle assembly 4. Front door lock body assembly 5.
  • Page 122 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series Fig. 4.1-14 Fig. 4.1-15 1. Outer handle assembly 2. Lock connection rod mechanism assembly 3. Inner handle assembly 4. Lock body assembly 1. Common screwdriver(disconnect door opening control slide rod)
  • Page 123 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body (IV) Installation Install front door lock and rear side slide door lock in the reverse sequence of disassembling .Pay attention to the following when installing. 1. Outer handle dragrod...
  • Page 124 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series 4. Rear side slide door inner handle Install inner handle to make it in place according to Fig. 4.1-20. After handle 2 in full open state touch slightly to door lock toggling plate 3, screw bolt.
  • Page 125 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Fig. 4.1-22 Front door lock 1. Lock body assembly 2. Lock ring assembly 3. Lock ring Fig. 4.1-21 Lock ring regulation 1. Lock ring assembly 2. Door lock regulating plate 3.
  • Page 126 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series III. Front door Front door joints vehicle body through the upper and lower hinges. In order to open the door easily, it is necessary to pour lubricating oil on the upper and lower hinge axes, see Fig.
  • Page 127 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body 2) After finishing installation, regulate front door lock ring position, to make front door in place rightly. (III) Regulation of front door 1) Unscrew front door hinge bolt, regulate front door position along all directions, fasten bolts after regulation.
  • Page 128 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series Front C (Skid surface) Fig. 4.1-27 1. Rear side slide door 2. Rear side slide lower roller arm 3. Rer slide door slide hinge 4. Rer side slide door upper roller arm 5.
  • Page 129 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Rear side Front side Front side Fig. 4.1-30 Fig. 4.1-29 1. Vehicle body(rear side ) 2. Vehicle body (front side) 3. Door rer end 4. Door front end 5.

  • Page 130: Section 2. Rear Door

    Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series 4) Regulate rer side slide stop block and screw the screw. See fig. Section 2 Rear door 4.1-31. 5) Lock ring position regulation refers to the above description.
  • Page 131 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body I. Rear door support bar Note: Because support bar cylinder is full of gas, it shall not be disassembled. If dismounted rear door support bar is rejected, not use...

  • Page 132: Section 3. Seats

    Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 3 Seat III. Disassembly 995 CC MODELS serial passenger car has 3 rows of seat, for 6, 7 or 8 Rear door may be disassembled in the following sequence: persons riding.
  • Page 133 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body Note: Keep the seat surface clean, to avoid strong acid substance to spatter on the seat surface. Smoker must note not to throw away dog-end on the seats.
  • Page 134 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 4 Instrument cluster I. General Instrument cluster structure as shown in Fig. 4.4-1(taking hard plastic board as an example) Fig. 4.4-1 1. Instrument cluster body 2. Cross-recessed flat-round-head screw 3.
  • Page 135 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body II. All parts disassembly (as shown in Fig. 4.4-1) Section 5 Front windshield, rear windshield 1. Instrument cluster body 1 is installed on vehicle body with...
  • Page 136 Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2. Installation Note: ●Glue must be daubed evenly on the glass, when adhibiting, good placement must be done in advance, to avoid glass misplacement. II. Rear windshield 1.
  • Page 137 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body 2. Installation 2. Installation As shown in Fig. 4.5-2, first install the inner decorative As shown I Fig. 4.5-2, install the inner decorative moulding of rear side...

  • Page 138: Section 6. Bumper

    Chapter IV Vehicle body Operation and Service Manual on VANTAGE TruckALL & VanGO Series front fog lights are installed on the right and left of bumper lower part Section 6 Bumper respectively. I. Front bumper Front bumper is composed of front bumper bracket A, front bumper bracket B and front bumper assembly, as shown in Fig.
  • Page 139 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter IV Vehicle body The front bumper assembly method is as shown in Fig. 4.6-1, screw II. Rear bumper out the nuts on front bumper bracket A and the screws, the front When disassembling rear bumper, as shown in Fig.

  • Page 140: Section 1. Heating System

    Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter ⅤAir-conditioner system The function of vehicle air-conditioner system is to make air mass, temperature and humidity in the vehicle be regulated, meet the requirement of occupants for air comfort degree maximally.
  • Page 141 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system III. Disassembly (2) Disconnect wiring harness connector, see Fig. 5.1-3. 1. Speed control resistor Speed control resistor is installed on the driver side of heater shell.
  • Page 142 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series (3) Dismount screws (3 pieces). Check the connection state of heater hose, and also check whether it is (4) Dismount motor and fan impeller. broken, if necessary replace it. See Fig. 5.1-6 Fig.

  • Page 143: Section 2. Cooling System

    Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system The user should identify them when reading this manual. In order to help Section 2 Cooling system I. Refrigeration system composition the user understand the bought car much better, taking the common type...
  • Page 144 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series Refrigeration system is composed of compressor, condenser, stock solution drying bottle, evaporator, connection pipes and electric Table 5.2-1 Technical parameters of compressor appliance control. The refrigeration system of 995 cc models adopts environmental protection type refrigerant (R134a).
  • Page 145 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system 2. Condenser assembly Condenser is installed on left lower side of the body. Function of condenser is to condense the high temperature and high pressure gas condensed by compressor into liquid, and emit the heat absorbed by evaporator to the outside of vehicle.
  • Page 146 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series 3. Stock solution drying bottle is installed under right front seat of the 4. Evaporator assembly body. Stock solution drying bottle has three functions: the first is to 995 CC MODELS mini-car evaporator layout has two types.
  • Page 147 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system 5. Refrigeration pipe All assembly of refrigeration system is connected through refrigeration pipe. The induction pipe and outlet elbow of compressor and the induction pipe and outlet elbow of 995 CC MODELS mini-car all adopt hose connection.
  • Page 148 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series After this kind of fog-like gas and liquid mixture enter into evaporator to evaporate and absorb inside heat, it besoms low temperature and low pressure gas, which is sucked into compressor to carry out another circulation.
  • Page 149 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system 995 CC MODELS mini-car with non-electronic fuel injection engine 2. Air conditioner /fan switch control adopts air conditioner amplifier to carry out center control, (The Air conditioner/fan switch signal closes, automatically open vacuum automatic control of air conditioner of 995 cc models with electronic magnetic valve, attract and engage magnetic clutch 0.8 second later,...
  • Page 150 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series Acceleration switch signal is negative logical signal, low level O shows having acceleration signal. When amplifier receives acceleration switch signal, close vacuum magnetic valve and cut off magnetic clutch automatically, and open vacuum magnetic valve 9.2...
  • Page 151 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system IV. Maintenance and inspection of air conditioning system 3. Correct operation of air conditioning system 1. Current maintenance of air conditioning system In order to bring air conditioner into full play and extend its life, besides Current maintenance is routine checking, if any problems are found good service and maintenance air conditioner must be operated correctly.
  • Page 152 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series Appropriate Inadequate Although there are a few See that bubbles flow See that fog-like substance flow bubbles, they float up and down along with engine running...
  • Page 153 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system place air volume switch on max. gear, temperature switch on the min. 10) When disassembling refrigerant pipe or filling refrigerant, never temperature position(MAX COOL), open the door, to make engine close to the face, to avoid the unexpected damage to eyes.
  • Page 154 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series Table 5.2-10 Adaptor tightening torque (2) Check items and check points Joint Aluminium pipe size and Locking torque N•m(kgf• The general routine check items and check points see Table 5.2-11.
  • Page 155 Ⅴ Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter Air-conditioner system Table 5.2-11 Check items and check points of air conditioning system Check items Check points Check positions Check methods The temperature of compressor high pressure side outlet, condenser, stock solution dryer, expansion valve inlet is very high, if the temperature of some sections is high and that of other sections is low, which shows those sections may be jammed.
  • Page 156 Ⅴ Chapter Air-conditioner system Operation and Service Manual on VANTAGE TruckALL & VanGO Series (3) Inspection with compound pressure gage The judgment on air conditioning system operation state with compound pressure gage(manifold pressure gage) sees Table 5.2-12 Table 5.2-12 Judgment on air conditioning system operation state with compound pressure gage...

  • Page 157: Section 1. Power Supply System

    Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle Climatic conditions Density (g/cm2) at 15℃ Chapter VI Electric of Vehicle fully charged Winter Summer In area where temperature is lower 1.310 1.250 than -40℃ in winter.
  • Page 158 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 1. Sulfuration of Pole Plate 2. Self-discharge Sulfuration of pole plate refers to a layer of thick, hard Self-discharge refers to automatic capacity loss of fully charged battery recrystalisation of plumbum sulfate formed on pole plate.
  • Page 159 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle (III) Parameters Model JF132 JF158 JFZ162-2 JFZ162-1 JF138 Normal working voltage Max output current Polarity Negative pole earthed. Built of regulator Built-out Built-in Effective diameter of pulley φ65mm...
  • Page 160 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (IV) Trouble Shooting NOTE: ● Never mix up the polarity of Terminal IG and Terminal L. ● Prevent short-circuit from being formed between Terminal IG and Terminal L.
  • Page 161 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle 1. Disassembling (3) Disassemble alternator driving belt regulation bolt, and alternator (1) Disassemble the negative connection wire of battery. fixing blot. (2) Disassemble the connection wire of alternator.
  • Page 162 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (2) Disassemble the casing bolts from the alternator. See Figure 6.1-6. Marks Figure 6.1-5 1. Front casing 2. Rear casing Figure 6.1-6 (3) Insert a stick into between stator core and front casing, to separate the front and rear casings of the alternator.
  • Page 163 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle While using a vice, put a piece of clean cloth between the rotor and chop in order not to damage the rotor. Figure 6.1-9 1. Front casing 2. Guard screw (7) When disassembling the rear casing, please use a hydraulic machine tool.
  • Page 164 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Figure 6.1-11 1. Screw 2. Battery terminal screw (9) Use a searing iron of big power (over 180W) to separate the weld Figure 6.1-13 from the regulator to the rectifier assembly. Disassemble the stator lead.
  • Page 165 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle Figure 6.1-15 Figure 6.1-16 1. Brush 1. Rectifier 2. Diode lead 3. Three groups of diode 3. Checking (1) Check the fan belt for looseness and soundness.
  • Page 166 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Use the same method and steps as above to check the conductivity NOTE: between each lead of three groups of diode. Conductivity should only ● The position of wire connection must be correct rather than wrong.
  • Page 167 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle For fuse box cover of 797cc model series carburetor vehicle, see V. Relay Socket Figure 6.1-17. For fuse box cover of 995 cc model series electronic injection vehicle,...
  • Page 168 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Section 2 Starting System I. Circuit of Starting System II. Starting Motor The starting system consists of battery, starting motor, ignition switch and related electrical wires. See Figure 6.2-1 for circuit diagram.
  • Page 169 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle (I) See Figure 6.2-2 for structure. Figure 6.2-2 1. Casing cover of driving mechanism 2. Driving mechanism lining 3. Casing of driving mechanism 4. Armature ring 5. Armature stopping ring 6. Overspeed clutch 7.
  • Page 170 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (II) Parameters 6. Disassemble the armature. Model QD1226 7. Disassemble the overspeed clutch. QD121A 8. Pull the brush out of the brush support. Output power (V) Inspection 0.8KW...
  • Page 171 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle Mica insulator Inspection of collector Standard Limit 0.5—0.8 mm non-roundness Under 0.05 mm 0.4 mm (0.0196—0.0314 inch) collector Correct Figure 6.2-4 Incorrect (3) Check the outer surface of collector for wearing. If the outer Figure 6.2-5...
  • Page 172 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 3. Check the brush. 5. Inspect the driving lever. Measure the length of every brush to check whether the brush is worn. Check the driving lever and spring for wearing. Replace it if worn.
  • Page 173 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle 3. Coil return: Disassemble the negative lead from the electromagnetic switch casing, and at this time check if core has retracted inwardly. If the core does not retract, the electromagnetic switch should be replaced.
  • Page 174 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (3) Code key A code key is an ignition key whose handle is equipped with a code transponder inside. Each code antitheft unit is equipped with two code keys, one is red and the other black.
  • Page 175 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle 3. Definition of antitheft controller socket and terminal (See Figure When the ignition switch is turned off, the antitheft unit will enter 6.3-5.) antitheft alertness status automatically. In this case, the LED flashes once every 2.5 seconds, for purpose of warning.
  • Page 176 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series III. Key Imitating Process NOTE: The point for the antitheft system to imitate the key lies on An antitheft controller has two statuses—non-imitated status and vehicle owner’s proper keeping of the “red key.”...
  • Page 177 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle At the moment the two controllers are connected for the first time. Both 1. Insert the red key, turn on the ignition switch, and turn it off within of them use a special request and answer code to show that it is in the 2 seconds.
  • Page 178 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series Trouble Code Section IV. Electrical and Accessories LED always on The antitheft controller and I. Parameter of Power-consuming Equipments electronic injector controller Circuit system: 12V, single line system, with negative pole grounded do not match.
  • Page 179 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle III. Wiper Intermittent Relay Regulator Transistor type, with Built-in alternator For wiring position and internal principle of wiper intermittent relay, see Starter Output capacity: 0.8KW Figure 6.4-2.
  • Page 180 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series IV. Headlamp Relay V. Windshield Power Wiper and Washer For wiring position and internal principle, see Figure 6.4-3. (I) Power Wiper 1. Structure The power wiper mainly consists of motor 1, driver (linkage) 2 and blade 3.
  • Page 181 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle (1) Whether the knob of driving mechanism is apart, or the nut of wiper 2. Operation of Wiper arm and blade shaft is loose (2) When there is abnormality at wiper stopping or starting, check the crankshaft linkage for alignment.
  • Page 182 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series 2. Washing fluid In summer add proper quantity of rust preventive and detergent into 205ppm water. In winter proper quantity of methanol or glycol should also be added.
  • Page 183 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle (2) Operation of rear window washer Press the washer knob on the rear wiper and washer switch, and the rear Mark for wiper switch (white) washer will be on and washer fluid will be sprayed from the nozzle.
  • Page 184 Chapter VI Electric of Vehicle Operation and Service Manual on VANTAGE TruckALL & VanGO Series (III) Test and Service of Defroster Wire of rear window defroster is very thin and small, so try to use soft cloth when cleaning the rear window glass. If the frost cannot be...
  • Page 185 Operation and Service Manual on VANTAGE TruckALL & VanGO Series Chapter VI Electric of Vehicle 3. Failure check of power window regulator Failure Cause Remedy One piece of glass can There is perhaps an open circuit in the Repair only move to one of the control wire between sub-switch and main directions.
  • Page 186 Appendix Trouble shooting Fault Reasons Remedy Start does not run. 1. Fuse is loose or blown. Repair or replace 2. Contact in ignition switch is not good or short. Repair or replace 3. Battery is exhausted. Charge or replace 4. Starter magnetic switch is out of work. Replace 5.
  • Page 187 Trouble shooting Appendix Continued Fault Reasons Remedy Fault of inside engine 1. Cylinder ring Replace 2. Valve clearance is not proper Adjust 3. Valve spring has deficient elasticity or break Replace 4. Intake manifold loosen, air is sucked into cylinder. Screw down and replace gasket if necessary 5.
  • Page 188 Appendix Trouble shooting Continued Fault Reasons Remedy 2. Gasoline pump is damaged. Repair or replace Gasoline filter is fouled. Replace Choke mechanism is damaged. Repair or replace Float level is maladjusted. Adjust Fuel pipe line is fouled. Clean or replace Fuel tank outlet is fouled.
  • Page 189 Trouble shooting Appendix Continued Fault Reasons Remedy Fuel system fault Gasoline filter is fouled. Replace Gasoline pipe line is kinked. Check and replace if necessary Gasoline pump is faulty. Replace Air intake manifold or carburetor gasket has leakage. Repair or replace Float level is maladjusted.
  • Page 190 Appendix Trouble shooting Continued Fault Reasons Remedy Air intake manifold, carburetor or cylinder gasket leak. Repair or replace Float level is maladjusted. Adjust Choke mechanism is damaged. Adjust or replace Fuel cut off magnetic valve to occur fault. Replace Inspect according to fault code(vehicle with electronic fuel injection engine) Adjust or replace Idle is not steady Others...
  • Page 191 Trouble shooting Appendix Continued Fault Reasons Remedy Ignition system fault Ignition timing is improper. Adjust The calorific value of spark plug is improper. Replace with spark plug with proper calorific value Inspect according to fault code(vehicle with electronic fuel injection Adjust or replace engine) Fuel system fault...
  • Page 192 Appendix Trouble shooting Continued Fault Reasons Remedy The abnormal noise of engine Note: Before Crank shaft makes noise checking noise, guarantee the following Bearing is abraded, causing gap over big. Replace points: Connecting-rod bearing is abraded. Ignition timing has been adjusted Connecting-rod is distorted.
  • Page 193 Trouble shooting Appendix Continued Fault Reasons Remedy Carburetor air nozzle is dirtied or fouled. Clean Air cleaner core is fouled. Sweep or replace Inspect according to fault code(vehicle with electronic fuel injection engine) Adjust or replace Inside engine fault Compression pressure is deficient. Refer to the above description High fuel consumption Valve joint is not good.
  • Page 194 Appendix Table Trouble shooting Continued II. Carburetor Fault Reasons Remedy Gasoline overflow 1. Float valve is dirtied or abraded. Clean or replace from carburetor 2. Float level set is too high. Adjust 3. Float is broken, and with some fuel. Replace 4.
  • Page 195 Fault inspection Appendix Continued Fault Reasons Remedy 1. Clutch pedal free travel is improper. Adjust Replace 2. Diaphragm spring elasticity is deficient or diaphragm spring end is abraded. Clutch action is retarded. 3. Transmission input shaft spline is abraded or damaged. Replace 4.
  • Page 196 Appendix Trouble shooting Continued Fault Reasons Remedy 1. Synchronizer spring has deficient elasticity or is damaged. Replace 2. Inner ring groove of synchronizer ring is abraded. Replace Gear can not de-mesh. 3. Synchronizer ring is seized on friction conical surface. Replace synchronizer lock ring 4.
  • Page 197 Fault inspection Appendix Continued VII. Driving shaft Fault Reasons Remedy The gear of universal joint spider is abraded or broken. Replace Driving shaft distorts. Replace Oscillation or emitting noise Driving shaft imbalance exceeds standard. Adjust or replace Driving shaft bolt is loose. Screw down 1.Universal joint is abraded or damaged.
  • Page 198 Appendix Trouble shooting Continued Fault Reasons Remedy Brake pedal free travel is over big. Braking fluid within braking oil tank is deficient. Supplement There is air in braking pipe line. Discharge The braking system of rear wheel is not adjusted well (automatic regulation Repair mechanism is faulty.) Brake shoe distorts.
  • Page 199 Fault inspection Appendix Continued Fault Reasons Remedy Tire inflation pressure is improper. Adjust Front wheel pendulates. Repair of replace The difference of tire diameter of left and right wheels is too big. Use the same tires. Wheel hub nut is loose. Screw down Wheel bearing is abraded or damaged.
  • Page 200 Appendix Trouble shooting Fault Reasons Remedy Emitting noise when steering Steering gear bolt or nut is loose. Screw down Wheel bearing is abraded or damaged. Replace Steering gear is maladjusted. Adjust Steering shaft connection is abraded. Replace The ball pins of steering horizontal or longitudinal pull rods are abraded. Replace Steering return capacity is poor.
  • Page 201 Fault inspection Appendix X. Starter Fault Reasons Remedy The small gear of starter clutch is abraded. Replace Starter runs, but small gear and tooth Spline is damaged. Replace ring do not mesh. Bush is abraded. Replace Tooth ring wheel tooth is abraded. Replace Battery fault Battery has no charge.
  • Page 202 Appendix Trouble shooting Fault Reasons Remedy Water pump belt is loose or broken. Adjust or replace Battery wiring is loose or pope connector is eroded. Clean and screw down Battery electrolyte acidity is over strong, or electrolyte level is too low. Replace or supplement electrolyte Battery discharge is over fast.
  • Page 203 Fault inspection Appendix XIII. Fuel gage Fault Reasons Remedy Connector contact is not good. Repair Sensor contactor is burned or bimetal components distort. Replace Wrong indication of Instrument Float movement is irregular. Repair or replace Sensor or fuel gage ground is not good. Repair Instrument circuit is opened.
  • Page 204 Appendix Trouble shooting XVI. Engine oil pressure warning lamp Fault Reasons Remedy Warning light is not bright when Fuse is blown. Replace ignition switch is put in the ON position Lamp is damaged. Replace (engine is not started), warning light is Circuit is cut off.
  • Page 205 Appendix Trouble shooting XIX. Turn indicator light Fault Reasons Remedy Left and right indicator lights both are Fuse is blown. Replace not bright, or do not flash. Connector is loose. Repair Flasher is faulty. Repair or replace The rated power of used lamp is lower than specific value. Replace Flash frequency is high only on one side, Lamp ground is not good.
  • Page 206 Appendix Tool set Tool set Content Tool bag Open-ended spanner 8 ×10 Open-ended spanner 12×14 Open-ended spanner 13 ×16 Dual-purpose screwdriver Screwdriver handle Slip joint pliers Socket wrench for spark plug Shank—spark plug socket wrench Square-head spanner Wheel spanner Jack Jack handle...

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