100-00-1 General Information 100-00-1

Section 100-00 General Information

Applicable Model: Boomday

CONTENTS PAGE
Descriptions and Operations
About This Manual......................................................................................................................... 100-00-2
General Repair Instructions ........................................................................................................... 100-00-4
Points of Attention in Circuit Repair ............................................................................................... 100-00-5
Open Circuit or Poor Contact ........................................................................................................ 100-00-6
Health and Safety Precautions ...................................................................................................... 100-00-7
Standard Repair Room Operations ............................................................................................. 100-00-15
Solvents, Sealants and Adhesives .............................................................................................. 100-00-17
Road Test/Roller Test .................................................................................................................. 100-00-18
Health and Safety Precautions for Batteries and Battery Charging ............................................ 100-00-20
Health and Safety Precautions for the Diesel Fuel System ......................................................... 100-00-21
Health and Safety Precautions for the Air Conditioning System ................................................. 100-00-22
Health and Safety Precautions for the Braking System............................................................... 100-00-23
Recommended Oil and Lubricants .............................................................................................. 100-00-24
List of Unit Abbreviations ............................................................................................................. 100-00-26
List of Abbreviations for Specific Terms ....................................................................................... 100-00-27

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100-00-2 General Information
Descriptions and Operations
About This Manual
Introduction
This manual is written in a format which can
meet the needs of all technicians. The purpose
is to use an universal format and provide similar
contents in various manuals.
This manual provides a general description of
completing diagnoses and tests with effective test
techniques. Compliance with the contents below
will help ensure operational reliability.
Special Tool
The special tool list provided at the start of each
procedure shows all the special tools which will
be used for repair purpose. Whenever possible,
pictures will be provided to help identify the
special tools needed.
Important Safety Instructions
Proper repair methods and correct repair
procedures are crucial for the safe and reliable
operation of all vehicles as well as for the personal
safety of operators.
However, it is not possible for this manual to cover
all situations or provide relevant suggestions or
warnings for each situation. Any operating personnel
who doesn’t comply with the instructions provided
in this manual must firstly ensure that the method,
tool or component which they choose to use will not
endanger their personal safety or vehicle integrity.
“WARNING”, “CAUTION” and “ATTENTION”
in This manual:
WA R N I N G : “ WA R N I N G ” m e a n s t h a t
failure to observe the procedures may
cause personal injury.
CAUTION: “CAUTION” means that failure
to observe the procedure may cause dam-
age of the vehicle or equipment.
ATTENTION: “ATTENTION” is used to
provide important supplementary
information for performing complete and
satisfactory repair.
When you read this manual, you will see pass-
ages marked with “WARNING”, “CAUTION” and
“ATTENTION”.
When applicable to multiple steps, “WARNING”,
“CAUTION” or “ATTENTION” will be placed at the
start of a series of steps. If only applicable to one
step, “WARNING”, “CAUTION” or “ATTENTION” will
be placed at the start of that step (after step number).
Special Tools and Torque Value
2011 Boomday & Boarding Workshop manual
100-00-2
Wherever special tools are needed, an illustration
will be provided to show the tool in use and its
number. The set torque value will be shown at the
relevant point of the procedure.
How to Use This Manual
This manual consists of diagnosis, test, maintena-
nce and repair procedures.
This manual is divided into several parts and
chapters. Under each part, several specific
sections are further divided.
Each part covers a specific part of the vehicle.
This manual is divided into 5 major parts, namely,
overview, chassis, power system, electrical
system & vehicle body, and paint. The first digit of
the chapter number is used as the part number.
The first few pages of the manual list all the chapters
provided in the manual. Each chapter has a table
of contents, which provides detailed information of
specification, descriptions and operations, diagnosis
and testing, on-board repair, disassembly &
assembly, removal and installation, etc..
Where a component is to be removed or disass-
embled in a sequence, this sequence will be
indicated by numbers in the illustration. The text will
also be shown with the corresponding numbers.
The left or right side of a vehicle is decided with a
forward view from the driver’s seat.
The left or right side of an engine is decided with
a forward view from the flywheel to the front
camshaft pulley.
Whenever appropriate, usage instructions for
diagnosis tools will be provided.
Test and Verification
Visual checklists, fault phenomenon lists and
other information lists (such as diagnosis
procedures) or auxiliary test procedures with
technical specifications may guide users to
implement specific test procedures.
100-00-3 General Information 100-00-3
Descriptions and Operations

Fault Symptom List

A fault symptom list may specify fault symptoms,
sources of fault and troubleshooting measures.
Accurate Testing
For electrical systems, pinpoint test is to use
logical steps to gradually identify the root cause
of fault. There are 2 columns for pinpoint test:
test conditions, and details/result/measures.
The Test Conditions column is only used for illu-
strations and icons (with or without legend), while
the Details/Result/Measures column provides
instructions of another test step or specific
correction measures.
Numbers in the brackets indicate the order of the
steps implemented.
Parts Testing
Parts testing is only used when several pinpoint
tests are performed for a part or the test procedure
is too complicated that pinpoint test contents
cannot be arranged on one page.
Diagram
A test diagram shows the measurements or tests
which need to be performed in the test steps.
Representative tester diagrams apply to voltmeter
and ohmmeter.
If multiple measurements need to be performed
in one diagram, test leads will be drawn in solid
lines until the various tests are shown separately,
where dotted lines will be used.
Double-ring test pins are used to indicate break-
off type testers. Test pins are marked with the
number of pins.

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Descriptions and Operations

General Repair Instructions

1. To ensure safety when lifting the vehicle, park 12. Before re-installation, clean all the parts.
the vehicle to be lifted on a level ground, use Meanwhile, use compressed air to clean oil
wheel support to support the front and rear holes to ensure free flow.
wheels, and ensure that the whole vehicle is 13. If necessary, apply sealant to sealing gaskets
kept level after being lifted. to prevent leakage.
2. Use a jack against the axle or frame and lift up 14. For vehicles equipped with a high-pressure comm-
the vehicle. Carry out repairs after the vehicle on rail system, Do not disconnect the fuel pump
is put on a chassis bracket. or the fuel injection pipeline before fuel presume
3. Before carrying out repairs, disconnect the is released. Otherwise, fuel will eject under very
ground cable from the battery to reduce the high pressure and cause serious accidents.
risk of cable damage or burning due to short
15. The torque specifications of bolts and nust
circuit.
should be strictly observed.
4. Cover the vehicle body, seats and floor
properly to prevent damage and dirt. 16. Before any air conditioning system component
is removed or installed, it is necessary to
5. Brake fluid and anti-freeze fluid must be properly use a vehicle refrigerant recovery and reuse
managed to prevent damage to the paint. device to discharge refrigerants from the air
6. To ensure effective and reliable inspection conditioning system for recovery and reuse in
and repair, proper tools and special tools order to prevent pollution.
must be used in accordance with the relevant
17. After completing the repair of the fuel, coolant,
regulations.
vacuum, exhaust or braking system, check
7. Use genuine JMC parts and spare parts. whether there is leakage in any pipeline
8. Whenever oil seals, sealing gaskets, gaskets, relating to these systems.
seal rings, lock washers, cotter pins, self- 18. After repair is over, check whether all the
locking nuts and some other designated repairs have been completed.
components are used, new parts must be
used. Before these new parts are installed,
residues on the fitting surface must be
removed.
9. To ensure smooth re-installation, the dissembl-
ed parts should be placed in groups at a nearby
location. The fastening bolts and nuts should
be put separately, because their hardness and
structure are different for different installation
positions.
10. If inspection and repair must be performed
when the engine is operating, ensure
that the parking brake fully works and the
transmission is in the neutral position. When
the engine rotates, make sure to keep hands,
hair, cleaning cloth, tools, etc. away from the
fan or the driving belt.
11. Before assembly, apply grease to the rotary
and sliding surfaces of all the parts.

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Descriptions and Operations

Points of Attention in Circuit Repair

1. When plug-in connections are connected
or disconnected, the ignition switch should
be in the OFF position. Otherwise, electrical
components may be damaged.
2. In case of accidental touch with the electrical
connectors (such as ECM, PCM, P/S controller
and other electric-controlled devices) of
microcomputer components, human static may
damage these electrical components.
3. When plug-in connections are disconnected,
no measuring instrument (such as voltmeter,
ohmmeter, or whatever measuring instruments
of a similar kind) can be connected with the
electric-controlled device. Otherwise, the
electronic-controlled device may be damaged.
4. Do not connect ohmmeter to an electric-controlled
device which has plug-in connections. Otherwise,
the electric-controlled device and sensors may
be damaged.
5. The designated voltmeter/ohmmeter must be
used. Otherwise, the measurement accuracy
cannot be guaranteed or personal injuries may
be caused.
6. When a test probe is used to measure electrical
plug-in connections, it must be inserted from
the wire side (back) of the plug-in connections.
7. When the test probe is connected from the
end side of a plug-in connection (connection
from the harness side is impossible), special
attention must be paid not to forcibly bend the
external connector of the plug-in connection.
This will prevent the internal connector from
opening and thus facilitate connection.
8. When checking connector connections, examine
a half of the external connector to see whether it
is bent as well as a half of the internal connector
to see if it is opening too much. Also, check
whether the internal and external connectors
are blocked (loosened), corroded, contaminated
with dust deposition, etc..
9. Before measuring the voltage of each connector
end, check that the battery voltage is 12 V
or higher. When battery voltage is lower than
this voltage, checking the voltage of these
connectors will cause diagnosis errors.

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Descriptions and Operations

Open Circuit or Poor Contact

1. Though connection relays or electromagnetic
wires are sometimes faulty, most short circuits
are caused by circuit connection errors. When
connections are checked, please carefully
check suspicious lines.
2. Poor contact in the halved joint of plug-in
connections, or connectors are not fully fixed
into the housing of plug-in connection (loosened).
3. Connectors are contaminated or corroded.
In this case, connectors must be cleaned to
ensure that no impurities which may affect
correct connections is adhered to them.
Sandpaper or similar materials are prohibited
to be used for cleaning connectors.
4. Connector housings are damaged, connectors
are dampened or contaminated, or there
is wrong connector orientation or improper
connector contact.
5. Incorrect deformation or connector damage.
Carefully check problematic circuits to ensure
good contact force. In case of inadequate
contact force, please make rectification to
increase contact force or replace connector.
6. Poor contact between connector and the
conducting wire. Use hands to gently shake
each wire in the problematic line and check
whether there is poor contact in its circuit.
Once any abnormality is found, make
immediate repair or replacement.
7. If the worn or exposed part of the wire
insulation layer comes into contact with the
other lines or components of the vehicle,
intermittent short circuit will be caused.
8. Wire harness is damaged in the inner side
of the insulation layer. When this happens,
you may find that the line is still connected
after repeated checks. However, if only 1 or 2
twisted wires are not damaged in one multi-
core twisted wire, the resistance will be too
high. If any abnormality is spotted, immediate
repair or replacement should be made.

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100-00-7 General Information
Descriptions and Operations
Health and Safety Precautions
Brief Introduction
Many vehicle maintenance and repair operations
may cause potential bodily injury and other
health risks. This section alphabetically lists
some of these dangerous operations and related
materials and equipment in an alphabetical order.
Confirmation should be made of the necessary
preventive measures to avoid these dangers.
This list is not exhaustive. All operations, steps
and the handling of materials should be performed
when health and safety are guaranteed.
Before any product is used, the user should firstly
refer to the product raw material safety data sheet
provided by the manufacturer or supplier.
Air Conditioning Refrigerant
Refer to Chlorofluorocarbon and Chemical Materials.
It’s highly inflammable and explosive. Fire
prohibition provisions should be strictly observed.
Direct contact with the skin can cause frostbite.
The usage instructions provided by the manufac-
turer must be observed. Avoid open flames, and
wear suitable protective gloves and goggles.
In case of direct contact with the skin or eye,
immediately use clear water to wash the affected
area. Eyes may also be washed with suitable
cleaning solution and should not be wiped. If
necessary, medical assistance should be sought.
Air Conditioning Refrigerant-Prohibited Operations
Do not put refrigerant bottles under direct sunlight
or in a heat source.
Do not put refrigerant bottles upright. When filling
refrigerant, the valve should point downwards.
Do not put refrigerant bottles into a freezer.
Do not drop refrigerant bottles.
In NO circumstances should refrigerant be
discharged into air.
Do not mix different refrigerants, such as R12
(Freon) and R134a.
Adhesives and Sealing Materials
Refer to Fire Prevention and Chemical Materials.
Highly inflammable and explosive. Fire prohibition
provisions should be strictly observed.
Generally speaking, adhesives and sealing
materials should be stored in a non-fire/smoke
area. In the using process, attention should be
paid to keeping their cleanness and neatness,
such as operating benches covered by waste
paper. If possible, separate refrigerant from
the applicator. Containers, including backup
containers, should be properly labeled.
100-00-7
Solvent-based Adhesives/Sealing Materials-
Refer to Solvents
Comply with the user’s guide provided by the
manufacturer.
Water-based Adhesives/Sealing Materials
Those polymer emulsion and rubber latex
materials may contain a small amount of volatile
toxic and harmful chemical substances. In the
using process, contact with the skin or eye should
be avoided. Proper ventilation should be provided.
Hot-melt Adhesives
In a solid state, these adhesives are harmless. In
a melt state, they may cause burns or inhaling of
toxic smoke may result in health risks.
Proper protective clothing and a temperature-
controlled heater with a thermo-sensitive safety
switch and proper extract should be used.
Resin-based Adhesives/Sealants (such as
epoxide and resin-based formaldehyde)
Because these materials may release harmful or
toxic volatile chemical substances, they should
be mixed in a well-ventilated place.
Direct skin contact with untreated resin and
hardeners can irritate the skin and cause dermatitis
and absorb toxic or harmful chemicals through the
skin. Splash may adversely affect the eyes.
Provide suitable ventilation, and avoid contact
with the skin or eye.
Anaerobic Cyanoacrylate (Super Glue) and
other Acrylic Adhesives
Most of these adhesives are irritants and can
cause skin and respiratory allergies or injury.
Some irritate the eye. The user guide provided by
the manufacturer should be complied with. Avoid
contact with the skin or eye.
Do not bring cyanoacrylate (super glue) into
contact with the skin or eye. In case of skin or eye
tissue being stuck with cyanoacrylate adhesive,
use a clean wet towel to cover the skin or eye and
immediately seek medical help. Do not attempt to
separate the stuck skin tissue. Because vapour
irritates the nose and eye, these adhesives
should be used in well-ventilated places.
For dual composite systems, refer to Resin-based
and Isocyanate Adhesives/Sealing Materials.
2011 Boomday & Boarding Workshop manual
100-00-8 General Information
Descriptions and Operations
Isocyanate (Poly Resin Acid) Adhesives/
Sealing Materials
Refer to Resin-based Adhesives.
Personnel who suffer from asthma or respiratory
sensitivity should avoid dealing with or get close
to these materials to avoid allergic reactions.
Prolonged exposure may irritate the eye and the
respiratory system. Excessive concentration will affect
the nervous system, causing drowsiness and so on.
In extreme conditions, shock may occur due to
loss of consciousness. Long-term exposure to
high-concentration vapour may cause adverse
health effects.
Prolonged skin contact will lead to degreasing
and cause allergic reactions. In some cases,
dermatitis may be resulted.
Splashes into the eye will cause discomfort and
possible damage.
Spraying had better be performed near exhaust
vents so as to make vapour and fog droplets far
from the breathing zone.
Wear proper gloves and eye and respiratory
protection devices.
Antifreezers
Refer to Fire Prevention and Solvents.
For example: isopropyl alcohol, ethylene glycol
and methanol.
Highly flammable and combustible.
Antifreezers are used in vehicle cooling systems,
air brake systems, glass washers, and so on.
When heated, the refrigeration antifreezes
(ethylene glycol) will emit vapour. Users should
avoid inhaling such vapours.
Antifreezer may be inhaled by the skin, and the
inhaled amount may reach an extent which has
a toxic or harmful effect. Incorrect in-taking of
antifreezer can be fatal, in which case medical
protection must be sought immediately.
Do not use these products for the refrigeration
of any water sources for general use or the
preparation of food or drinking water, or with any
industrial water systems.
Brake Fluid (Polyethylene Glycol)
Refer to Fire Prevention.
Splashes to the skin or eye will cause minor
irritation. Keep distance from it as much as possible
to avoid contact with the skin or eye. Because
vapour pressure is very low at room temperature,
there is no risk of inhalation of vapour.
Chemical Materials
Chemical materials include solvents, sealing materials,
adhesives, paint, resin foam materials, battery-use acids,
antifreezes, brake fluids, fuel, oil, grease and so on.
These materials must be carefully stored and handled.
They may be toxic, harmful, corrosive, irritating or highly
flammable, and generate harmful smoke and dust.
2011 Boomday & Boarding Workshop manual
100-00-8
Excessive exposure to these chemical substances
may produce an influence which can be immediate
or potential, temporary or permanent, cumulative or
superficial, or shorten or endanger life.
Chemical Materials - Operation Precautions
Please carefully read and follow the labels on the
material containers as well as the risk and protection
warnings on the accompanying leaflets, posters and
guide books. The health and safety data sheet of
the material can be obtained from the manufacturer.
After contamination, chemical materials should
be removed from the skin and clothes as soon as
possible. Replace heavily-contaminated clothes and
clean them.
In the practical work, wear protective clothing
to prevent contact with the skin or eye and the
inhalation of vapour, mist, dust or smoke. Avoid
improper container markings, burning and explosive
hazards.
After handling with chemical materials, the handling
personnel should wash their hands before the break
period and before taking food, smoking, drinking or
using the toilet.
Keep the workplace clean, tidy and free from spills.
Store chemical materials in accordance with State
and local laws and regulations.
Keep chemical materials away from children.
Chemical Materials - Prohibited Operations
Without guidance from the manufacturer, Do not mix
chemical materials. When mixed, some chemical
materials will form other toxic and harmful chemical
substances, release toxic gas or become explosive.
Do not spray chemical raw materials, especially
some solvent-based materials, in enclosed
environment, such as a vehicle seated with people.
Unless there is guidance from the manufacturer,
Do not bring chemical materials close to a heat
source or open flames. Some chemical materials
are highly flammable, and some may release
toxic or harmful smoke.
Do not keep the containers in an opened state. This
will leave the released smoke to accumulate to a
toxic, harmful or explosive concentration. Some
smoke is heavier than air and can gather in a
confined space, such as well.
Do not move chemical materials into unmarked
containers.
Do not use chemical materials to wash hands or
clothes. Chemical materials, especially solvents
and fuels, can desiccate skin and may cause
allergy and dermatitis or the absorption of toxic or
harmful dosage into the skin.
Do not use empty containers to hold other
materials, unless they are washed clean under
supervision.
100-00-9 General Information
Descriptions and Operations
Do not forcefully breathe in or smell chemical
materials. Short periods of exposure to high-
concentration smoke can be toxic or harmful.
Chlorofluorocarbon
The scientific community believes that chloroflu-
orocarbon and halogen are the culprits which
destroy the Ozone layer which filters out harmful
UV radiation. Weakened filtering of UV radiation
will increase the incidence rate of skin cancer,
cataract and immune system inhibition.
It can also reduce crop and aquatic yields.
Chlorofluorocarbon is mainly used as the refr-
igerant and aerosol propellant in vehicle air
conditioning systems. Halogen is used as a
backup extinguishing agent.
Clutch-use Fluid
Refer to Brake Fluid.
Anti-corrosion Materials
Refer to Solvents and Fire Prevention.
Highly flammable and explosive. Fire prohibition
provisions should be strictly observed.
There are many types of these materials, which
include solvents, resins and oil products. The
guidance of the manufacturer must be observed.
Avoid contact with the skin or eye. These
materials can only be sprayed in well-ventilated
and non-enclosed space.
Cutting
Refer to Welding.
Dewaxing
Refer to Solvents and Fuels (Kerosene).
Dust Removal
Powder, dust or smoke may be irritating, and
harmful or toxic. Avoid the inhalation of powder-
type chemical materials or other dust generated
by grinding operations. If there is no well-
ventilated environment, operating personnel
should wear respiratory protection equipment.
Fine dust of inflammable materials may generate
explosion risks. Avoid explosion thresholds and
fire sources.
Electric Shock
Electric shocks may come from the use of faulty
electrical equipment or from the wrong operation
of normal equipment.
Electrical equipment should be well maintained and
frequently tested. Faulty equipment should be marked
and had better be removed from the workstation.
100-00-9
Ensure that electric wires, power cables, plugs
and sockets are not worn, twisted, cut, broken or
damaged in other ways.
Ensure that electrical equipment and wires are
not exposed to water.
Ensure that electrical equipment is protected by a
correctly rated fuse.
Do not use wrong electrical equipment, and do
not use equipment in any wrong way. These may
cause fatal consequences.
Ensure that the power cables of movable electr-
ical equipment are not tangled or damaged, such
as when a vehicle is lifted.
Ensure that the assigned electricians have
received basic training on first aid.
When electric shock happens:
- Turn off power before making contact with the
victim.
- If it is not possible to push or pull the victim away
from the electric wire, use insulation materials.
- If site personnel have received special training,
they can start resuscitation rescue.
- Seek medial assistance.
Engine Oil
Refer to Lubricating Oil and Lubricating Grease.
Exhaust
Automobile exhaust contains suffocating, harmful
and toxic chemical substances, such as carbon
oxides, nitrogen oxides, acetaldehyde, lead and
aromatics. Engines should operate under non-
enclosed space with exhaust purification and
ordinary ventilation.
Gasoline Engine
Before toxic or harmful consequences occur,
there may be no corresponding warnings
against odor or irritation beforehand. These
consequences can be instant or latent.
Diesel Engine
The amount/extent of soot, discomfort and
irritation usually indicate the concentration of
harmful smoke.
Fiber Insulation Materials
Refer to Dust Removal.
Used for noise and sound insulation.
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100-00-10 General Information
Descriptions and Operations
Fiber surfaces and cut edges may irritate the skin. This
is usually a physical rather than chemical reaction.
Preventive measures, such as carefully organized
work procedures and use of gloves, should be taken
to avoid too much contact with the skin.
Fire Prevention
Refer to Welding, Foam Materials and Legal Issues.
Most materials used in or relating to vehicle repair are
highly inflammable. Upon burning, these materials
sometimes can release toxic or harmful smoke.
Inflammable materials or solvents should be stored
or handled in strict compliance with the fire safety
provisions, especially when such materials or solvents
are close to electrical equipment or welding parts.
Before electric appliances or welding equipment
is used, ensure that there is no potential danger
of catching fire.
When welding or heating equipment is used,
extinguisher should be provided.
First Aid
In addition to the legal requirements, repair rooms
should be equipped with work personnel who have
received training on first aid.
If foreign matters splash into the eye, use clear water to
rinse the eye for at least 10 minutes. The affected skin
should be cleaned using soap and water. Victims who
have inhaled gases and smoke should immediately
be transferred to a place where there is fresh air. If the
effect continues, doctors should be consulted. In case of
mistakenly taking in liquid, provide the information on the
container or label to the doctor and consult him. Do not
try vomiting, unless it is specified otherwise in the label.
Fluorine Rubber
Refer to Fluorine Rubber.
Foam Materials - Polyurethane
Refer to Fire Prevention.
Used for noise and sound insulation. Treated foam
materials are used for making seats and decorative
seat cushions.
Comply with the guidance from the manufacturer.
Unreacted parts may be irritating and harm the skin or eye.
Wear gloves and goggles.
Personnel who suffer from chronic respiratory diseases,
asthma and bronchial disease, or have a history of
allergy cannot work on or near untreated materials.
Parts, vapour or fog can cause direct irritation and
allergic reaction and even become toxic or harmful.
Do not inhale vapour or fog. These materials must
be used under the precondition of good ventilation
and breathing protection. Do not immediately remove
respirator after spraying. Instead, wait until vapour/fog
completely dissipates.
Burning of untreated parts and treated foam materials
will generate toxic and harmful smoke. Smoking or use
of open flame or electric apparatus is NOT allowed dur-
2011 Boomday & Boarding Workshop manual
100-00-10
ing foaming operation, unless the vapour has com-
pletely dissipated. Hot cutting of all foam materials
or specially-treated foam materials should be
performed under well-ventilated environment.
Refer to Vehicle Body Repair Manual.
Gasoline
Highly inflammable. Fire prohibition provisions
should be strictly observed.
Mistakenly drinking gasoline will cause oral cavity
and throat irritation. Absorption of gasoline into
the stomach will result in dizziness and loss of
consciousness. For children, even a small dosage
can also be fatal. During vomiting, choking of the liquid
into the lung can be very dangerous. Gasoline can
desiccate the skin. Long time of or repeated contact
will irritate the skin and cause dermatitis. Splash of the
liquid into the eye can cause violent pain.
Motor gasoline may contain a certain amount of
benzene. Inhaling into the human body can cause
intoxication. Gasoline vapour concentration must
therefore be controlled at a extremely low level.
High concentration can cause irritation to the eye,
nose and throat, nausea, headache, depression and
drunken state. Too high a concentration will result in
an immediate loss of consciousness. Good ventilation
should be ensured when gasoline is handled and
used. Care must be exercised to avoid gasoline
overflowing in an enclosed space, since overflow will
increase vapour concentration and inhaling of a large
amount of vapour may cause serious consequences.
In the process of oil tank cleaning and maintenance,
special preventive measures should be taken.
Gasoline cannot be used as a cleaning agent. Do not
suck with mouth. Refer to First Aid.
Light Diesel Oil (Diesel Fuel)
Inflammable
Large areas or long period of skin contact with light
diesel oil which has a high boiling point will result
in various types of skin discomfort, including skin
cancer.
Kerosene (Paraffin)
Used as a heating fuel, solvent and cleaning agent.
Highly inflammable. Fire prohibition provisions should
be strictly observed. Mistakenly drinking kerosene will
cause oral cavity and throat irritation. It is extremely
dangerous when the liquid is choked into the lung.
Contact with the liquid will cause skin drying and lead
to irritation and dermatitis. Splash into the eye can
cause minor irritation.
In normal situations, low volatile kerosene will not
release harmful vapour. Exposure to the environment
with rising temperatures should be avoided to prevent
the generation of kerosene smoke and vapour.
(Smoke is generated at the time of dewaxing).
Avoid contact with the skin or eye, and ensure god
ventilation.
100-00-11 General Information
Descriptions and Operations
Alternative Fuel
Highly inflammable. The instructions in the “NO
SMOKE & FIRE” label should be strictly observed.
When operating automobiles which use alternative
fuel, ensure that there is good ventilation. Great
care must be exercised to avoid the serious
consequences caused by inhaling a large amount
of vapour due to rising vapour concentration in an
enclosed space. Inhalation of high concentration
vapour will cause dizziness, headache, nausea
and coordination dysfunction. Too high a
concentration can result in loss of consciousness.
Direct skin contact with liquefied petroleum gas
and compressed natural gas will cause bold
burns and frostbite.
When removing or installing liquefied petroleum gas/
compressed natural gas fuel system components, the
operators should wear cotton protective clothes with long
sleeves, steel-toe safety boots and neoprene gloves.
Leakage of liquefied petroleum gas/compressed
natural gas can cause fire. Moreover, this is a
hidden health hazard and may cause personal injury,
disease or even death.
When leakage is spotted, under no circumstances
should the connector be tightened to stop leakage
unless it can be determined that the gas in the
system or parts has resumed to normal pressure.
Once tightened, the following specific steps should
be followed to check system integrity:
If the fuel tank needs to be maintained or repaired after
removal, special equipment must be used, and the
fuel tank must be emptied first in accordance with the
special procedures before operations can proceed.
Cylinder
Refer to Fire Prevention.
Gas, such as oxygen, acetylene, argon and propane
are usually stored in a cylinder at a pressure of 138
bar (2,000 P/foot2). When handling these cylinders,
particular care should be exercised to avoid damage
to them or the valve gear attached. The contents of
each cylinder should be properly marked.
Cylinders should be stored in well-ventilated rooms.
Avoid direct contact with snow or ice or exposure to
direct sunlight. Inflammable gases, such as acetylene
and propane, cannot be stored in places close to any
oxygen cylinder.
Attention should paid to avoid cylinder and pipeline
gas leakage and avoid fire sources.
Only especially trained personnel can perform
cylinder-related work.
Cylinder Gasket (Fluorine Rubber)
Refer to Fluorine Rubber.
Tools and Equipment for Ordinary Repair Rooms
All tools and equipment must be well maintained and
equipped with the right safety equipment. This is very
important.
100-00-11
Do not use tools or equipment for purposes other
than their designed functions. Do not overload
cranes, jacks, vehicle axles, chassis or hoisting
ropes and other equipment. The damage caused by
overloading usually does not appear immediately
but may cause fatal injury at the next time of use.
Do not use damaged or faulty tools or equipment,
especially grinding wheels and other equipment
with high operational speed. Damaged grinding
wheels can break apart and cause serious injury
without any signs beforehand.
When using grinding wheels, chisels or
sandblasting equipment, the operating personnel
should wear goggles.
When using sandblasting equipment and handling
asbestos-based materials or spray equipment,
the operating personnel should wear proper bre-
athing covers.
Ensure that there is adequate ventilation to control
dust, smoke and gases.
High Pressure Gas, Lubricant and Engine Oil
Test Equipment
Refer to Lubricating Oil and Lubricating Grease.
High pressure equipment, especially their
connecting and joining parts, should be kept in a
good condition and regularly maintained.
Do not point diesel injector nozzles or other high
pressure nozzles to the skin, because these
liquids can pierce through subcutaneous tissue
and cause serious injury.
Halogen Fire Extinguishing Agent
Refer to Chlorofluorocarbon.
Legal Issues
There are many legal provisions regarding health
and safety when using and handling materials
and equipment in the repair room.
To ensure a healthy working environment and
avoid environmental pollution, repair personnel
should be very familiar with the various health
and safety laws and regulations which are issued
by their country or local government.
Lubricant and Lubricating Grease
Avoid long period of or repeated contact with
mineral oil. All lubricants and lubricating grease
may irritate the eye or skin.
Transmission Fluid (Safety Guide)
Some vehicle-use transmission and power steering
system liquids may contain certain additives which
may cause skin diseases (dermatitis) if they come
into contact with the human body. Such dermatitis
may be irritation or allergy. Long period of or repeated
contact with these liquids will result in high probability
of danger. These liquids are used for initial vehicle
filling and maintenance. This section is to:
2011 Boomday & Boarding Workshop manual
100-00-12 General Information
Descriptions and Operations
-Provide information (danger information) to those
operating personnel who may come into contact
with these vehicle liquids.
-Sum up proper repair room control measures and
personnel protection equipment requirements.
-Comply with the information in the safety data
sheet for liquids (which can be obtained from
Ford’s Customer Service Department). The safety
data sheet contains detailed information about
risks and proper measures to control the risks.
Control Measures
In accordance with the repair room risk evaluation
provisions in the relevant State laws and
regulations for chemicals control, confirmation
should be made on the control of the operation
of potentially dangerous liquids and specific
operation rooms. And the relevant knowledge of
the operator should be confirmed as well. The
relevant safety data sheets (see below for details)
of chemical materials should be made easily
accessible. Such data sheets can serve as a
safety guide, containing a detailed description of
potential dangers and their control measures.
Prevent liquids to come into contact with unprot-
ected skins. In particular, avoid long period of or
repeated contact with the skin. Work procedures
should be organized to minimize the potential
possibility of skin contact. These include the use
of defrost water tray, absorbent, proper liquid
treatment equipment (funnel and so on), and repair
room affairs management measures, such as
cleaning of contaminated surfaces.
Operating personnel who are likely to make skin
contact with liquids should wear NBR-sealed
gloves made in accordance with the EN374
Standard. Such gloves can be purchased from
well-known suppliers of chemical protection
gloves (including Ansell-Admont (Solvex),
Northern Safety Products (Bei Fang nitrile rubber
gloves) and Marigold Industrial (Blue nitrile
product series).
Gloves which are worn out or internally contaminated
should be replaced immediately. Safety glasses
should be used to protect eyes. In case of wide
contact, anti-infiltration aprons, armband and other
protective goods should be used. Skin care cream
may provide assisting protective effect in the handling
of mineral oil product. However, such skin creams
should not be used on protective clothing.
In case of accidental skin contact with such liquids,
soap or skin cleaner and clear water should be
used to thoroughly clean the contact area.
In case of accidental contact with the eye, it
should be treated with the normal first aid method.
Use eyewash or clean cold water to wash eyes
for 10 minutes, and seek medical assistance.
Put off and dry clean the liquid-contaminated clothes.
Do not put liquid-contaminated cloth strip into pockets.
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100-00-12
When operations are over, the operating perso-
nnel should thoroughly clean all skin areas, which
may be exposed.
When handling liquids or transmission devices
charged with liquid, Do not smoke, take food or drink
water. These measures are designed to reduce the
potential danger of accidental intake.
Correctly mark any liquid that has been poured
out/use labels consistent with those of the original
product container.
When there is liquid overflowing, immediately use
inert absolvent to absorb it, and then use cleaning
agent and water to clean contaminated surfaces.
Safely dispose of discarded liquid as dangerous
wastes.
Used Engine Oil
Long period of or repeated contact with mineral oil
can result in the loss of natural skin fat, causing
skin desiccation, irritation and dermatitis.
In addition, used engine oil may contain potentially
harmful pollutants and may result in skin cancer.
Proper skin protection and cleaning equipment
must be provided.
Do not use used engine oil as lubricating oil.
Otherwise, it can cause skin contact.
Environmental Protective Measures
Only permitted amount of used engine oil can
be burnt in small heaters or boilers. In case of
inquiries, refer to Descriptions and Operations.
Please contact the local government department
and the authorized product manufacturer.
Used engine oil and engine oil filters should be
deposed of by an authorized waste treatment
contractor, or an authorized waste treatment place
or used oil recovery place. In case of inquiries,
please contact the local government department to
get advice from the disposal department.
It is illegal to pour used engine oil onto the ground,
put into the drains, ditches or rivers.
Noise
Some operations can generate significant noise,
which sometimes damages hearing ability. In
such situations, the operating personnel should
wear proper ear protection equipment.
Sound Insulation Materials
Refer to Foam Materials, Fiber Insulation
Materials.
O-Ring (Fluorine Rubber)
Refer to Fluorine Rubber.
Paint
Refer to Solvents and Chemical Materials.
Highly inflammable and explosive. The fire
prohibition provisions should be strictly observed.
Single Ingredient
Ingredients that contain harmful or toxic paint,
desiccant and other similar solvents. They can
only be sprayed under well-ventilated conditions.
100-00-13 General Information
Descriptions and Operations
Two Ingredients
Also contain non-reacted harmful or toxic resins
and resin enhancers. The guidance of the
manufacturer should be complied with. Refer
to Resin-based Adhesives and Isocyanate
Adhesives and Sealants in the Adhesives and
Sealing Materials section.
Spray operations had better be performed inside
a ventilated shed where vapour and spray
splashes can be kept away from the breathing
area. Personnel who work in such a shed should
wear respiratory protection devices. Personnel
who perform minor repair work in an open repair
room should wear oxygen breathing apparatus.
Pressurizing Equipment
Refer to High-Pressure Gas, Lubricants and
Fuel Test Equipment.
Welding
Solder is a metal mixture. Such metals have a
low melting point than the welded metals (usually
lead and tin). If liquefied petroleum gas/air flame
welding is used, Welding usually doesn't generate
toxic lead smoke. Oxygen-acetylene flame cannot
be used, because it has too high a temperature
and will generate toxic lead smoke.
Some smoke is generated by the burning of oil
grease on any kind of surface. Avoid inhaling
such kind of smoke.
Extra care should be exercised in the removal of
welding material to ensure that no fine lead dust will
be inhaled. The lead dust has toxic effect. Breathing
protection equipment is indispensable.
Solder overflow and raspings should be removed
altogether quickly to avoid lead-induced air pollution.
To avoid the intake of lead or the inhaling of
welding dust on clothes, it is necessary to set a
high personal hygiene standard for the operating
personnel.
Solvents
Refer to Chemical Materials, Fuel (Kerosene)
and Fire Prevention.
Such as acetone, petroleum solvent oil, toluene,
xylene and trichloroethane.
Used for the cleaning and dewaxing of materials,
paints, plastics, resins and diluting agents.
Some are highly infallible or inflammable.
Repeated or long period of skin contact will result
in skin defatting and this will in turn cause skin
irritation and dermatitis. For some substances,
100-00-13
the absorbed amount may reach a level that has
toxic or harmful effect.
Splash into the eye may cause serious irritation
and blindness.
Short time of exposure to high-concentration
vapour or smoke can cause eye and throat
irritation, drowsiness, dizziness, headache and in
the worst case, loss of consciousness.
Repeated or long period of exposure to excessive
amount of low-concentration vapour or smoke
without warning instructions will result in more
serious toxic or harmful effect.
Choking into the lung due to vomiting is the most
serious consequence of swallowing.
Avoid splashing onto the skin, eye and clothes.
Where needed, the operating personnel should
wear protective gloves, goggles and protective
clothing.
Ensure good ventilation during use. Avoid inhaling
smoke, vapour and spray and keep containers tightly
sealed. Do not use in an enclosed environment.
When sprayed materials are paint, adhesive,
coating layer and other solvent-containing
materials, use special ventilation equipment or
personal breathing protection apparatus when
there is no proper ventilation.
Unless there are detailed special instructions from
the manufacturer, Do not heat or burn solvents.
Sound Insulation
Refer to Fiber Insulation Materials and Foam
Materials.
Suspended Load
CAUTION: Do not temporarily prepare to
use hoisting pulleys.
There is always danger when a load is lifted or
hoisted. Do not operate under loads which are
hung, lifted or not supported, such as hung engine.
Ensure that hoisting equipment, such as jacks,
cranes, vehicle axle base and hoisting ropes, are
appropriate for operation, in a good state and
regularly maintained.
Transmission Brake Band
Refer to Asbestos.
Bottom Sealing
Refer to Corrosion Protection.
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100-00-14 General Information
Descriptions and Operations
Fluorine Rubber
As the vehicles of many other manufacturers,
some parts of Baodian have O-seal rings, seal
components or cylinder gasket. All of them are
made of a material called fluorine rubber.
Fluorine rubber is a type of fluorine-containing
elastic body. It is a fluorine-containing synthetic
rubber material. It is usually used in the production
of various O-seal rings, linings and seal
components. Fluorine rubber is well known as a
fluorine-containing elastic body. There are other
types, such as Fluorel and Tecmoflon.
When used under the specified conditions,
fluorine rubber is very safe. But, when exposed
to a temperature of over 400°C, the material
will break down, but will not burn up. One of the
generated substances is hydrofluoric acid. This
highly corrosive acid can, via contact, be directly
absorbed into the human system.
O-seal rings, linings and seal components
exposed to very high temperatures may be
charred or become dense black substances.
In no circumstances should people touch them or
their attached ingredients.
Consultation should be made first to determine
whether the affected O-seal rings, seal components
or linings contain fluorine rubber or other fluorine-
containing elastic bodies. There will be no danger
if they are natural or nitrile rubber. In case of any
uncertainty, care must be exercised, because the
original materials are very likely to contain fluorine
rubber or other fluorine-containing elastic bodies.
If fluorine rubber or other fluorine-containing
elastic bodies are contained, the affected areas
must be purified before operations start.
The operating personnel should always wear
throw-away danger-preventing protective plastic
gloves and use wire balls and lime (calcium
hydride) to neutralize the acid solution before
treating the broken-down fluorine rubber residues
and finally cleaning the area. After the operations,
discarded plastic gloves should be safely and
carefully disposed of.
Welding
Refer to Fire Prevention, Electric Vibration
and Cylinder.
Welding can be divided into resistance welding
(spot welding ), arch welding and gas welding.
Resistance Welding
In this operation, melted metal particles may be
generated and ejected at a high speed. Eye and
skin protection should be provided.
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100-00-14
Arch Welding
In this operation, high intensity ultraviolet radiation
will be generated. It can burn the eyes or skin of
the operator and other persons nearby. In the gas
welding process, this can be especially dangerous.
The operating personnel must wear protective
clothing and use a protective screen to shield others.
When people wearing contact lenses carry out
arch welding, it is suggested that they should
replace contact lenses with ordinary glasses.
Because the electric arc spectrum can release
microwave which can dry up the liquid between
the lens and the eye. Blindness may be caused
when the lenses are taken off.
Metal splash may occur, and proper eye and skin
protection is essential.
The heat generated by arch welding can generate
smoke and gas over the welded metals, metal rods
and the coating layers used or the contaminated
operating surfaces. These gas and smoke may be
toxic. It is necessary to avoid breathing in such smoke
and gas. Exhaust and ventilation equipment must be
used to clear smoke from the work site, especially the
places where overall ventilation is very poor or places
where much welding work is performed. In extreme
situations or limited spaces where no adequate
ventilation can be provided, the operating personnel
must wear air-supplying respirators.
Gas Welding (and Cutting)
Oxygen-acetylene flame may be used for welding and
cutting. Particular attention must be paid to prevent the
leakage of these gases from causing fire and explosion.
In this operation, metal splashes will be generated.
Eye and skin protection must be provided.
The flames can be very bright, so eye protection
equipment should be used. However, ultraviolet
radiation is much smaller than that of the arch
welding. Light filters may be used.
This operation itself rarely generates toxic smoke.
But, such smoke and gases can be generated
from the operation coating layer. In particular,
when cutting is performed on damaged vehicle
parts, inhaling of smoke should be avoided.
In cooper welding, copper solders can generate
some toxic gases. Inhaling of gases generated
by cadmium-containing cooper solders can cause
serious danger. In such situations, great care
must be exercised to avoid breathing in smoke.
Expert advice is needed.
Before welding or cutting any container which
contains inflammable materials, special preventive
measures must be adopted to prevent fuel tanks
from boiling, evaporating or other accidents.
Petroleum Solvent Oil
Refer to Solvents.
100-00-15 General Information
Descriptions and Operations
Standard Repair Room Operations
Vehicles in the Repair Room
When operating vehicles in the repair room,
ensure that:
- Use parking brake or wheel chokes to safely fix
the vehicle to prevent it from moving forwards
or backwards.
- Before performing any operation on the vehicle
head, make sure that the key has been taken
out from the starter lock.
- To start the engine, enough ventilation should be
provided, or use an exhaust pipe to clear exhaust gas.
- Where needed, there should be enough space
for lifting the vehicle and removing the wheels.
- For any operation on the engine compartment,
ensure that it is fixed with protective board.
- When performing engine operations or
operations under the vehicle or after the
vehicle is lifted, disconnect the battery.
CAUTION: When performing electric arc
welding in the vehicle, generator wiring
must be disconnected to prevent current
surge from causing damage to generator
components.
- When applying welding equipment to the
vehicle, a fire extinguisher must be provided.
Alternative Fuel
WARNING: When the fuel system is
repaired, the recommended guide must
be followed. Failure to do so may cause
personal injury.
If an odor of liquefied petroleum gas or
compressed natural gas emerges in the repair
room, warn all people inside to:
- Put out all open flames and lit cigarettes.
- Switch off electric and pneumatic equipment.
- Evacuate from the area.
- Ventilate the area.
- Contact the fire control department.
- Move the vehicle to a special ventilated area.
Alternative Fuel - Operation Precautions
- When vehicle operations are performed in a
designated area, the area should have good
ventilation, and only qualified persons can enter it.
- Mark new warning sings in the original place.
- If possible, before the vehicle is brought into the
repair area, isolate the alternative fuel tank, and
use alternative fuel to operate the vehicle until it
automatically switches over to the normal fuel mode.
100-00-15
- When the liquefied petroleum gas and
compressed natural gas system is repaired
or maintained, only use tested and confirmed
parts and pipelines.
Alternative Fuel - Prohibited Operations
- Do not discharge liquefied petroleum gas at will.
- Do not forcible squeeze out liquefied petroleum
gas from the fuel tank under normal air
pressure. Do not use any paint dryer of over
40°C on any vehicles using alternative fuels.
When a vehicle is put in a paint dryer (> 40°C)
for drying, it is necessary to remove the
liquefied petroleum gas and compressed natural
gas tank from the vehicle.
- Do not modify, without permission, the system
or install new components not especially
designed for gas-powered vehicles.
- Do not empty the fuel tank without permission,
unless the fuel tank must be moved away for
repair.
- Do not operate on fuel pipelines or system
parts, unless alternative fuel has all been
discharged and the pressure inside the system
has also reduced to the normal air pressure or
lower.
- Do not use any other materials than special
leakage detection liquids to test fuel leakage.
Pay attention to situations which can cause
leakage of liquefied petroleum gas or compressed
natural gas, such as:
● Hot weather.
● Park close to heaters.
● Lift the vehicle close to the heater on the shed top.
Only comprehensively-trained technicians who
are familiar with the local operating standards can
operate on vehicles using alternative fuel.
Towing Vehicle
WARNING: When performing towing
operations, the ignition switch must be in
the II position (the steering lock is on, and
the warning light flashes). Only under this
condition can the steering wheel, steering
signal light, horn and parking light operate
normally. Failure to comply with this
guidance may cause personal injury.
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100-00-16 General Information 100-00-16
Descriptions and Operations

ATTENTION: The movable tow ring (if WA R N I N G : M o s t s o l v e n t s m u s t b e

equipped) has left hand thread and must handled with care. Some are harmful.
be fully tightened before the start of Refer to Health and Safety Precautions
towing. and the instructions about safety
When a vehicle needs to be towed, the tow ring precautions from the manufacturer.
should be used. The rope must be safely tied to Failure to comply with these guidelines
the tow ring and the other end of the rope must may cause personal injury.
be tied to another vehicle in the same way so that Various solvents can be used for cleaning vehicle
the rope will not entangle the vehicle body. parts. Some special parts, such as hydraulic
When towing vehicles with an automatic brake parts and electric apparatus assembly,
transmission, the shift lever must be placed can only be cleaned using designated solvents -
in the neutral position. Do not perform towing Refer to Solvents, Sealants and Adhesives or the
operations at a speed faster than 50 KM/h. If parts-related sections in this manual.
long-distance vehicle towing operation must be
performed, the driving wheels must be completely Calibration of Important Measuring Equipment
lifted off ground. WARNING: Certain equipment which
Vehicles can also be towed using drop frame requires regular calibration must be
trailers and trailers. calibrated in accordance with the
Parts Cleaning instructions of the manufacturer. Failure
To avoid the entry of dust, accumulated loose to follow these instructions may cause
dust and oil grease must be cleared before the personal injury or damage to parts.
parts or assembly is disconnected or removed. Certain basic equipment, such as torque wrench,
Thoroughly clean the parts before the reassembly multimeter, exhaust gas analyzer or rolling road,
check. should be regularly calibrated in accordance with
Cleaning Methods: the guidance from the manufacturer. This is very
- Dry clean. important.
- Use soft brush or electric brush to clear accum-
ulated loose dust.
- Use metal or wooden sheet to scrape dirt.
- Use rag to wipe off dust.
WARNING: When high-pressure air gun,
steam cleaner, power cleaner or other
equipment is used to clean vehicle parts,
the cleaning personnel should wear eye
protection equipment.
Failure to comply with this guidance may
cause personal injury.
CAUTION:
Compressed air is sometimes very “damp” and
should be used with care, especially when opera-
ting the hydraulic system.
To avoid damage to the junction box inside the
engine compartment, do not use steam or power
cleaner or other cleaning equipment to clean the
engine compartment.
Use high-pressure air guns to blow off dust.
Use vacuum equipment to suck up dry dust.
Dust (asbestos particles) on friction lining sheet
materials must be cleared using this method.
Steam cleaning.

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100-00-17 General Information 100-00-17
Descriptions and Operations

Solvents, Sealants and Adhesives

WARNING: Extreme care should be

exercised in the handling of all solvents,
sealants and adhesives. Some contain
or release health-harming chemical
substances and smoke. The guidance
from the manufacturer should be
observed. In case of any doubt about any
substance, especially solvent, do not use
it.
CAUTION: In case of any doubt about the
applicability of solvents or sealants used
for special purposes, one may contact the
product manufacturer to ask for information
about storage, handling and use.
The section Health and Safety Precautions
has provided instructions about some common
chemicals and raw materials, the possible risks
in their use and the safety protection measures
which should be adopted.

2011 Boomday & Boarding Workshop manual

100-00-18 General Information
Descriptions and Operations
Road Test/Roller Test
There are many reasons for carrying out road
tests or roller tests. The following provides a detailed
test flow, which includes pre-test check, engine
startup and shutdown, pre-driving check, during-test
check and final check before the end of the test.
It is not necessary to carry out the complete road
test, unless the integrity of vehicle performance
needs to be checked. Instead, only specific items
relating to the checked system are tested.
Pre-test Check
WARNING: Where problems are spotted
of a low fuel level in the hydraulic brake
system, overlimit of pedal travel or liquid
leakage, do not carry out vehicle road test
until the reasons for these problems are
found and corrected.
It is suggested that before road test or roller test is
performed, pre-test check and functionality test be
carried out on systems and circuits such as brake,
vehicle light and steering system which can affect
vehicle safety and legitimate operations.
After extinction, check:
- Engine oil level.
- Engine coolant level.
- Tire check to ensure that tire pressure is
normal, consistent tire type and tire tread, and
wear is within the permitted range.
- There is sufficient fuel in the fuel tank for
completing the test.
- Check the conditions in the periphery of engine
and transmission and also the conditions
underneath the vehicle to prevent the leakage
of engine oil, coolant, liquid and fuel.
- Mark any obvious leakage, and clear the
surrounding area so as to determine the
leakage spot after test.
Start Engine
ATTENTION: Within the first 1.5 Km of driving
from static startup, do not press the accelerator
pedal to the half position unless vehicle speed
is over 25 KM/h. Do not rev up the engine to a
high speed or press the accelerator pedal to the
end when there is no engine warm-up.
After shutting down the engine, check:
- Parking brake has been applied.
- The shift lever is in the neutral position.
- All meters (except the fuel quantity meter)
have a reading of 0.
After starting up, check:
- The warning light of ignition control is already on.
2011 Boomday & Boarding Workshop manual
100-00-18
- The engine thermometer displays a reading which
is the same as the actual engine temperature.
- The fuel quantity meter displays a reading which
is the same as the fuel level in the fuel tank.
- Operation of park brake warning light and fuel
level warning light.
Road Test or Roller Test
CAUTION: In case of road test, brake
operation under low speed driving needs
to be checked before further test is taken.
If the brake pushes to one side or other
faults are displayed, do not continue road
test until the faults are corrected.
In road test or roller test, check:
- Clutch pedal operation is neither rigid nor
heavy.
- Smooth initial meshing of gear teeth and there
is no clutch resistance.
- Parking brake control operation is smooth and
brake can be completely and rapidly applied.
- Smooth clutch movement, without any slide or
vibration.
- Smooth gear shift, and the transmission case
is free of any abnormal noise and vibration.
- Engine power output is smooth and reaches
full power. Acceleration is smooth, and
acceleration pedal operations are free from
any rigid or heavy feeling. Engine rotation can
correctly return to the idle mode.
- Under normal driving, heavy load or over-
limit conditions, the engine does not generate
excessive smoke or smoke with abnormal
colors.
- Power steering (if equipped) and other steering
operations are smooth and accurate, without
any problem of overload, racing or vibration.
- The steering wheel does not tilt towards one
side. After cornering, it can automatically and
smoothly return to the middle position.
- Th odometer, coolant thermometer and the
tachometer (if equipped) display the correct
readings and operate correctly. The control
operation is smooth and clear. The warning
and indicator lights operate correctly, and
the steering indicator can be automatically
cancelled after the steering wheel is reset.
- The heating and ventilation system can
operate correctly and effectively.
- Operation and efficiency of the brake system.
100-00-19 General Information 100-00-19
Descriptions and Operations

Brake Test

WARNING: When brake test is conducted,

avoid the inhaling of the smoke emitted
by hot brakes. It may contain harmful
asbestos dust. Failure to comply with this
guidance may cause personal injury.
Refer to section Health and Safety Precautions
for more information.

CAUTION: Avoid conducting brake test

on busy roads, because it may cause
inconvenience or danger to other vehicles
or pedestrians on the road.
For heavy brake equipment, brake test cannot
be carried out after a new brake block/brake disc
or brake lining/brake drum has been changed,
unless the component is fully embedded. New
brake friction components cannot reach their best
performance until they are fully embedded.
Within the normal operating range, acquire
various speeds by adjusting the depressing
force applied to the pedal to test the brake. Pay
attention to any tendency of grabbing, pushing or
pulling as well as improper delays in the applying
or releasing process.
Allow the vehicle to slide on a slope, and pay
attention to any tendency of tilting to one side or
brake constraint.
After parking (cannot stop immediately
after forcible braking), carefully check brake
temperature. If one brake disc or brake drum
emits heart or is slightly hotter than others, it
shows brake constraint.
After test, check:
- Oil, coolant, hydraulic pressure, air and fuel
leakage.
- Abnormal temperature with moving parts or
assembly (e.g., wheel hub, transmission case,
axle) may be caused by excessive tightness or
lack of lubrication.

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100-00-20 General Information 100-00-20
Descriptions and Operations

Health and Safety Precautions for Batteries and Battery Charging

WARNING: Batteries usually generate
some explosive gases. Do not allow any
open flame, spark or burning object get
close to batteries.
CAUTION: Use excessive current or
voltage of over 16 volts to quickly charge
batteries will cause battery damage.

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100-00-21 General Information 100-00-21
Descriptions and Operations

Health and Safety Precautions for the Diesel Fuel System

WARNING: Hot liquids must be handled with
great care. Liquid splashed onto the naked
skin must be immediately washed off.
WARNING: Large area or long period of
skin contact with diesel oil with a high
boiling point may cause serious skin
problems, including skin cancer.
Manufactured fuel injection equipment should
be accurately operated in accordance with the
specified time intervals. An absolutely clean
working environment is very important for the
operation of these parts.
Ensure that vehicles are neat and free from dust
in their repair region.

ATTENTION: The accumulation of large

amounts of dangerous smoke is often
accompanied with strong warning signs
such as dense smoke, discomfort and
irritation.

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100-00-22 General Information
Descriptions and Operations
Health and Safety Precautions for the Air Conditioning System
WARNING: Only qualified technical
personnel can operate on the air conditi-
oning system. Air conditioning system
components may become very hot or icy.
When handling refrigerants, the handling
personnel should wear goggles and fluorine
rubber-made protective gloves.
No leather or fiber gloves can be used.
Before repairing, ensure that the air conditioning
system is under normal temperature.
In case of accidental liquid refrigerant contact
with the skin, serious frostbite will be caused.
Immediately wash the frostbitten area for
15 minutes with water. Also, seek medical
assistance immediately.
In case of accidental refrigerant contact with
the eye, immediately use large amounts of
clear water to wash the eye for 15 minutes,
and seek medical treatment immediately.
If the refrigeration is brought into contact
with an open flame or a hot surface, it will
generate toxic gases (fluorine and phosgene).
These gases can be smelled even when their
concentration is very low.
Refrigerant is inflammable and explosive.
Ensure that the relevant local provisions
for air conditioning system operations are
observed in actual work.
Ensure that no refrigerant bottle is exposed
to high temperatures of over 45°C.
Ensure that refrigerant bottles are tightly
covered.
When refrigerants are heated, the toxic gases
generated are harmful to human health. The
gases emit an irritating odor and can cause
lung damage. The symptoms will last for a
long time after contact with these gases. Even
a very small content of such gases can cause
lung damage.
Gaseous refrigerants have a bigger density
than air. There is a danger of suffocation
during operations close to the ground or in
underground wells.
Sufficient ventilation must be provided when
refrigerants are handled.
Do not release refrigerants into air.
Only the special tools, equipment and
lubricants which are compatible with the
refrigerant can be used.
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The repaired pressurized container CANNOT
be filled with too much refrigerant. When
temperature rises, it must be
ensured that there’s sufficient room for
refrigerants to inflate.
Comply with the correct component repair
operation procedures provided by the
manufacturer.
CAUTION: Do not mix coolant oil for different
types of coolant. Do not mix differ-ent types
of coolant, or mix the equipment specially
designed for a certain coolant with other
equipment.
When the filling system is connected under
low pressure, only gaseous refrigerants can
be used for filling.
When the filling system is connected under
high pressure, only liquid refrigerants can be
used for filling.
Refrigerants can corrode plastics. Only the seal
components suitable for refrigerants can be used.
In case of air compressor damage, the fixed
ventilation pipes will be blocked by metal
particles.
Any blocking of refrigerant passageways
will cause irreversible damage to the air
compressor.
If the air conditioning system has operated
for over 2 hours, new receiver desiccant must
be installed. This can increase exhaust time
by at least 2 hours.
ATTENTION: New air compressors must
be installed after they have been filled
up in advance. The refrigerant oil of new
air compressors contains Teflon. It is in
a form of visible white particles but does
not damage the system.
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Descriptions and Operations

Health and Safety Precautions for the Braking System

WARNING: Brake fluids contain polyethylene
glycol ether and polyethylene glycol. Avoid
fluid contact with the eye. Thoroughly wash
hands after handling bake fluids. In case of
accidental brake fluid contact with the eye,
immediately use flowing cold water to wash
the eye for 15 minutes. If the symptoms
continue, immediately go to see a doctor. In
case of accidental intake, immediately drink
water and force vomiting, and seek medical
assistance immediately.
CAUTION: In case of brake fluid splash onto
the paint, use cool water to immediately
clear the contaminated area.

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Descriptions and Operations

Recommended Oil and Lubricants

Part Recommended Grease
Engine ESSO-Rear Axle Super Engine Oil (10W-30)
Transmission ESSO-EZL401 (ESSO)
Power steering fluid ESSO-EZL401 (ESSO)
Rare Bridge GL-5,80W-90
Hydraulic brake system and clutch system FMVSS 116 DOT.3
Engine cooling system antifreezer Ethylene glycol antifreezer
Diesel engine GB252-87
Gasoline engine SH0041-1993

Lubrication Part

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Descriptions and Operations

Item Description Item Description

1 Engine 6 Wheel bearing
2 Power steering mechanism 7 Differential
3 Brake system 8 Front propeller shaft
4 Transmission 9 Clutch
5 Propeller shaft

Replacement cycle:

ATTENTION: Whichever comes first shall

apply.
Engine oil: Once every 3 months or 5,000 Km.
Power steering fluid: Once every 30 months or
50,000 Km.
Brake liquid: Once every year or 20,000 Km.
Transmission fluid: Once every 2 years or 40,000 Km.
Propeller shaft lubricating grease: Once every 3
months or 5,000 Km.
Wheel bearing lubricant: Once every year or
20,000 Km.
Differential lubricating oil: Once every year or
20,000 Km.
Clutch liquid: Once every year or 20,000 Km.

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Descriptions and Operations

List of Unit Abbreviations

Abbreviation Description Abbreviation Description
A Ampere mg Milligram
dB Decibel MHz Megahertz
ft Foot ml Milliliter
g Gram mm Millimeter
gal Gallon mpg Miles/gallon
Hz Hertz mph Miles/hour
in Inch mV Millivolt
kg Kilogram Megohm
kHz Kilo hertz N Newton
km Kilometer Nm Newton • meter
km/h Kilometer/hour No. Number
kPa Kilopascal rpm Rotation per minute
KW Kilowatt V Volt
Kiloohm W Watt
lb Libra (pound) ya Yard
lb-in Libra (pound) – inch m Meter
lb-ft Libra (pound) – foot mA Milliampere
L Liter

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Descriptions and Operations

List of Abbreviations for Specific Terms

2011 Boomday & Boarding Workshop manual

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Descriptions and Operations

2011 Boomday & Boarding Workshop manual