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1 Introduction / 1.5 Warning and Precautions | PDF pages 15-20
1.5 Warning and Precautions
1.5 Warning and Precautions
Definition of "Tip"
1.5.1 Warning and Precautions
"Tip" states or emphasizes the necessity of employing
diagnosis or repair procedures, aiming to:
1.5.1.1 Warnings and Precautions
– Define procedures.
Definitions of "Warning", "Caution" and "Tip"
– Provide additional information for completing a
procedure.
"Warning", "Caution" and "Tip", both general and specific, are
used for the diagnosis and repair procedures in this service
– Describe the reason for operation as per the
recommended procedures.
manual. This manual, developed by Windrose, aims to
provide repair information to help after-sales service
– Provide information that facilitate the completion of the
procedures in a more efficient manner.
technicians in diagnosis and repair of the systems so as to
ensure normal operation of the vehicle. However, certain
– Provide technicians with previous experiences to make
the procedure easier.
procedures may pose danger to technicians if they do not
operate using the methods recommended herein.
"Warning", "Caution", and "Tip" are given to prevent the
above-mentioned dangers from happening, but not all
dangers are foreseeable. This kind of information is
prominently displayed in the service manual. This kind of
information is prepared to avoid the following conditions:
– Serious injury to personnel.
– Vehicle damage.
– Unnecessary vehicle repairs.
– Unnecessary replacement of parts.
– Improper repair or replacement of vehicle components.
Definition of "Warning"
"Warning" indicates that you must or you are prohibited to
take measures as necessary. If the "Warning" is ignored, the
following consequences may occur:
– Serious injury to personnel.
– Serious personal injury to the driver and/or passengers in
the vehicle, in case the vehicle is not repaired properly.
Definition of "Caution"
"Caution" indicates that you must pay special attention to
necessary or prohibited measures. If "Caution" is ignored, the
following consequences may occur:
– Vehicle damage.
– Unnecessary vehicle repairs.
– Unnecessary replacement of parts.
– Abnormal operation or performance of the maintained
systems or components.
– Damage to related systems or parts.
– Damage to fasteners, basic tools or special tools.
– Leakage of coolant, lubricant or other major fluids.
Precautions for Charging
10. Please keep the charging port dry and clean during
charging, and take corresponding measures if necessary.
warning！
11. In case the weather changes (strong wind, rain or snow)
1. High voltage and large current may be induced in the high
abruptly during charging, check the charging plug is secure
voltage system during charging. Please strictly follow the
and dry; do not touch the charging cable and the body
operation procedures, otherwise there may be risk of
when encountering lightning.
electric shock. Read throughout the charging section
carefully before charging.
12. Corresponding protective measures should be taken
during minors. Children and other non-related personnel
2. If you have been implanted with a pacemaker or
should be prevented from approaching the charging vehicle
cardiovascular defibrillator, note the following while
and charging cable as much as possible.
charging:
13. When charging, do not squeeze the charging cable to
– Do not stay in the vehicle;
avoid electric shock or fire.
– Do not enter the vehicle.
14. When charging, do not place the charging cable in the
3. Before charging, check the skin and shell of the charging
vehicle.
cable are damaged; If so, please contact the authorized
dealer of the vehicle for repair or replacement. use
15. When charging, the charging cable must be kept away
damaged charging cables.
from fire source.
4. minors are prohibited to use the charging plug because it is
16. Note the following when charging:
a high voltage electrical device. minors are prohibited to
– Do not touch the metal part of the charging port and
operate during charging.
charging plug;
– Do not touch the electric vehicle and any devices if
5. Make sure the charging port and charging plug are free of
electric sparks appear in an electric vehicle or on-board
water, other debris, rust or corrosion. If there is water or
charger. Failure to do so will result in an electric shock, or
rust on the charging port or charging plug, do not charge
even cause death or injury.
avoid short circuit or electric shock, or even death.
17. The ambient temperature of the vehicle is recommended
6. Keep the power supply equipment, the vehicle to be
to be 32*F - 95*F during charging of the vehicle. Do not
charged, the charging cable and the charging plug away
charge the vehicle under low or high temperatures(it is not
from rain, snow and water. Do not place them close to the
recommended to charge the vehicle out these parameters).
fire source.
18. Do not charge the vehicle under direct sunlight and other
7. If there is moisture near the charging port during charging,
high temperature environment in summer.
disconnect the power supply and then the plug at the power
19. During charging, make sure the charging cable extends in
supply end while ensuring safety (do not touch the metal
a natural manner and do not hang the charging cable in the
sheet of the charging plug with your hands or other body
air.
parts, so as not to cause safety accidents in case the
charging system is faulty),unplug charging plug at the
20. When any unusual smell or smoke is detected on the
vehicle end. Wear insulating gloves if necessary, and
vehicle, immediately disconnect the power supply in a safe
contact the authorized dealer of the vehicle as soon as
manner.
possible for testing and confirmation.
21. Do not plug and unplug the charging plug with wet hands
8. If the vehicle has been exposed to wet conditions before
or standing in places with water, liquid, and snow. This may
charging, please dry the body near the charging port before
result in serious injury or death.
opening the charging port for charging. Make sure there is
22. When removing the charging plug, you should hold the
no residual moisture in the charging socket and its vicinity.
insulating part of the plug, Do not drag or pull the charging
9. When the charging system is working, do not use the
cable.
charging device in an environment where gasoline,
23. Do not remove or modify the charging port without
coatings and flammable items are used or stored, as
permission.
sparks may be generated in the charging system.
24. Please read the operation manual on the charging
equipment carefully before fast charging, and make sure
Precautions for Maintenance Safety
the fast charging plug is connected and locked. Failure to
do so will cause malfunction of the vehicle or charging
warning！
equipment.
1. The maintenance personnel should have received training
25. Minors are prohibited from charging the vehicle.
on high voltage safety and passed relevant Courses by
Windrose or an authorized partner.
26. Do not plug and unplug the fast charging plug without
permission during charging.
2. The maintenance operator should not wear metal jewelry,
such as watches and rings, and should not have metal
27. Charging or stop of charging should be performed in strict
objects in the pockets of work clothes, such as keys, metal
accordance with the operating procedures indicated on the
shell pens, mobile phones, and coins.
DC charging instructions.
3. The maintenance should be carried out in a dry
28. If smoke or unusual odors are detected at the charging
environment by personnel who are kept dry as well.
port or abnormality is found inside of the vehicle, you
should press the emergency stop button on the DC
4. The maintenance technician should ensure facilities and
charging pile in time to stop charging, evacuate the
tools are in good condition, prior to starting work.
personnel around the vehicle and follow the on-site
5. At least two people should be present when carrying out
procedures.
maintenance on the high voltage system of the vehicle.
29. Before fast charging, check for any debris, dust, water,
They can provide proper safety procedures and provide
etc. inside the fast charging socket (including the jack). If
first aid and contact authorities if an incedent occurs.
any, do not charge. Remove debris and dust inside the fast
6. Random access to high voltage components on the vehicle
charging socket (including the jack) and dry the socket. The
is not allowed in non-assembly or non-repair period.
charging cannot proceed until the charging socket is made
clean and dry.
7. Do not carry out maintenance in an environment with
explosive, flammable, corrosive gases, steam, etc.
30. Before fast charging, check the fast charging socket jack
Otherwise, it may cause fire, explosion and other accidents.
is damaged, ablated or discolored. In case any of the above
phenomena is found, do not charge and contact an
8. When maintaining the all-in-one controller, it must stop
authorized dealer.
running, the low voltage power supply must be
disconnected, and the high voltage must be cut off after 10
31. To prevent the charging system from malfunctioning,
minutes (when the capacitor discharge of the MCU and
please note the following:
between the positive and negative power supplies of other
– Close the protective cover of the vehicle charging
high voltage load end finishes). Otherwise it may cause
socket and then the charging port cover;
personal injury.
– Avoid collisions with the charging plug;
9. The mounting bolts and lead connecting bolts must be
– Avoid crushing the charging cable;
tightened to appropriate torque. Otherwise, the MCU may
– Do not pull or entangle the charging cable;
face abnormality in use, causing personal injury and
– Do not place the charging cable near a heat sources.
equipment damage.
32. After charging is completed, close the charging socket
10. If an abnormality is found in the vehicle when it is re-
protective cover and the charging port cover.
inspected after maintenance, stop operation in time and
check the equipment. Otherwise, it may impose a risk of
33. Before starting the vehicle, make sure the charging plug is
personnel injury or equipment damage.
removed from the charging port.
11. When parking or storing the vehicle is to be maintained
34. As the fast charging plug is heavy, you should plug and
and under maintenance, keep away from environments.
unplug vertically as carefully as possible to prevent damage
to the vehicle or the charging equipment.
35. The charging may stop if you accidentally touch the fast
charging plug button during fast charging. When this
occurs, you need to pull out the charging plug and
recharge.
Warning for Vehicle Lifting
Warning for Brake Dust
warning！
warning！
To avoid vehicle damage, serious personal injury, and
The following operations are not permitted when the
even death, when disassembling main components
wheel brake components are repaired:
from the vehicle and supporting the vehicle with a lift, a
– Cleaning of the wheel brake components with dry
jack stand shall be used to support the vehicle at the
brush or compressed air.
position where the component is to be removed.
warning！
Warning for Handling Anti-lock Braking
System Components
Certain models or after-sales brake components added
may contain fibers which may be mixed in the dust and
warning！
once inhaled will seriously damage human body. The
Certain parts of the ABS cannot be repaired alone, and
dust accumulated on the brake components must be
attempting to remove or disconnect certain system
removed using a damp cloth.
parts may result in personal injury and/or improper
Warning for Replacement of Brake Air Pipe
system operation. Therefore, only components that are
warning！
approved for removal and installation can be repaired.
Warning for Equipment Permitted for Repair
Install and fix the brake air pipe with care during
After Collision
replacement, and be sure to use the correct fasteners,
otherwise the brake air pipe and the brake system may
warning！
be damaged and thus cause personal injury.
To avoid personal injury from exposure to toxic fumes
Warning for Inhalation of R-134a
generated in (zinc oxide) metal arc welding or plating
when grinding/cutting any type of metal or sheet
warning！
moulded parts, it is essential to work in a well-ventilated
Do not inhale A/C refrigerant R-134a and lubricating oil
area and wear approved respirators, goggles, earplugs,
vapour or mist, because they can irritate your eyes,
welder gloves and protective clothing.
nose and pharynx when exposed to them. Work in a
Lock Out Tag Out
well-ventilated area. When discharging R-134a from the
A/C system, use repair equipment (R-134a recovery
warning！
equipment) certified to meet the requirements of
When a technician is inspecting the reported faulty
SAEJ2210. In the event of accidental fluid discharge in
condition, the vehicle shall be locked out and tagged out
the system, the work area must be ventilated before
by the repairing technician and may not be operated.
repair works are continued. For additional information
Warning for Disconnecting Battery
on health and safety, please contact the refrigerant and
lubricant manufacturers.
warning！
Warning for Cracks on Windows
Before repairing any electrical components, confirm that
the power supply of the start switch is in "OFF" mode,
warning！
and all electrical loads are "OFF (turned off)" unless
Follow the state and federal DOT guidelines for window
otherwise stated in the operating procedures. If tools or
damage and replacement.
equipment can easily contact exposed live electrical
Warning for Handling of Window and Metal
terminals, disconnect the battery negative cable. Failure
Plate
to follow of these safety instructions may result in
warning！
personal injury and/or damage to the vehicle and
vehicle components.
When disposing any glass or metal plate with sharp
edges or burrs, wear approved goggles and gloves so
as to reduce the risk of personal injury.
Warning for Road Test
Precautions Regarding Disposing
Electrostatic Discharge Sensitive Components
warning！
caution
Test the vehicle on the road in accordance with traffic
Electrostatic discharge (ESD) can damage many solid-
regulations while ensuring safety. Never try any
state electrical components. Components that are
operation that may endanger vehicle control. Violating
susceptible to electrostatic discharge are not always
the above safety instructions will cause serious
marked with an electrostatic discharge symbol, hence
personal injury and damage to the vehicle.
you must take care when disposing electrical
Precautions Regarding Removal of Exterior
components. Please observe the following safety
Label
instructions to avoid damage from electrostatic
caution
discharge:
When removing labels/nameplates, use plastic flat-
•
Before repairing any electronic components,
edged tools to avoid damage to paints.
disconnect the power line, and touch a metal
Precautions Regarding Fasteners
ground point to discharge static electricity in your
body (especially after sliding on a vehicle seat).
caution
•
Do not touch the exposed terminals which may be
Please use appropriate fasteners at the correct
connected to a circuit that can be easily damaged
position. The number of the component to replace the
by electrostatic discharge.
fastener must be correct. For fasteners that need to be
replaced or the fasteners that require the use of thread-
•
When repairing the connector, do not touch the
locking adhesives or sealant, it is particularly specified
exposed terminals with tools.
in the repair procedures that, paints, lubricants, or
•
Do not remove components from the protective
corrosion inhibitors shall not be applied on fasteners or
casing unless required.
fastener attachment surfaces, unless otherwise noted.
•
The coatings may affect the torque and clamping force
The following operations are not allowed unless
of the fastener, thus damaging the fastener. When
specifically required by diagnostic procedures:
installing fasteners, you must follow the correct
– axle or ground components or connectors.
tightening sequence and tightening torque to avoid
– Connect the test equipment probe to the component or
damage to parts and systems.
the connector. When using the test probe, connect the
ground lead at first.
Before opening the protective casing of the component,
ground it first. Do not place solid components on a
metal workbench or on top of a radio and other
electrical equipment.
Precautions Regarding Avoiding Twist or Bend
When Installing Hoses
caution
The inlet and outlet hoses shall not be twisted during
the installation process, and the hoses shall not be bent
or deformed to facilitate installation, otherwise
components may be damaged.
Precautions Regarding Damage to Machined
Surfaces
caution
Do not cut, scratch or damage the sealing surface. If the
sealing surface is a machined surface, it may be
damaged, resulting in leakage.
Precautions Regarding Power System Control
Precautions Regarding Damage to Edges of
Module and Electrostatic Discharge
Windows
caution
caution
Do not touch the connector pins or welded components
To avoid damage to vehicle window due to impact of
on the circuit board to prevent damage to the electronic
exposed edges, the window must be 1 mm (0.025 in.)
control module on the vehicle as a result of electrostatic
lower than the sheet metal surface.
discharge.
Precautions Regarding Use of Scan Tool
caution
Before diagnosing the vehicle, you must pay attention to
the following conditions, otherwise the control module
may be damaged.
– The software version of the scan tool and terminals
must be up to date.
– The vehicle battery must be fully charged with a
voltage of 12-14V.
– The scan tool and terminal cables must be securely
connected.
– When programming the control module, the battery
charger must not be connected to the battery.
Precautions Regarding Steering Wheel in
Steering Limit Position
caution
The steering wheel shall not be set to the steering limit
position for more than 5s, otherwise the steering motor
may be damaged.
Precautions Regarding Test Probe
caution
Do not insert test equipment probes (digital multimeter,
etc.) into the harness connector or fuse box terminals. A
majority of the terminals will be deformed as a result of
the diameter of the test probes, leading to poor contact
and system failure. Thus, special tools must be used to
detect the terminals from the front. Never use a paper
clip or other substitutes to detect the terminals.
caution
When using special tools to test the components, make
sure that the selected terminal test adapter matches the
size of the connector terminal. Do not choose the
terminal test adapter visually, since the hole of certain
connector terminals may be larger than the actual
terminal in the hole. The use of large terminal test
adapter can damage the terminals.