ZD106 Workstation Operation Instruction Manual

Middle axle / torque rod / shock absorber / battery pack sub-assembly workstation · 5 operations, illustrated edition | Compiled from the original process cards for training and display-board use

Step 10 Hoist the sub-assembled middle axle onto the axle installation lift trolley and locate it. Step 20 Move the lift trolley to the workstation, push it under the frame, and align the position. Step 30 Use lifting equipment or the overhead crane to raise the middle axle. Step 40 Raise the middle axle to the installation position; first align it with the middle axle mounting holes on the X-link and thread on the nuts (apply thread-locking adhesive), tightening to 700 N·m. Step 50 Then adjust the middle axle position to align the air springs with the mounting holes on the frame and connect them, tightening to 180 N·m; install the left and right air springs symmetrically. Step 60 During assembly, ensure that the air spring upper bracket fits flush against the lower flange surface of the frame rail. Step 70 Use tie-down straps to secure the axle to the frame to prevent it from dropping; then lower the lift trolley and remove it. Step Air spring-frame: tighten the air spring-to-frame connection points with the matching bolts and nuts.

Tightening torque: 700±50 N·m; Air spring connection torque: 180±15 N·m; Air spring upper bracket fits flush against the frame rail lower flange (visual)

Step 10 Connect the No. 2 drive motor high-voltage cable to the motor end as shown, then open the line clamp beside the terminal (the motor comes with 2 clamps, but only 1 is used) and secure the cable. Step 20 Use the line clamp to fix the cable to the inside of the frame rail; align the front vertical edge of the positioning mark on the cable with the rear vertical face of the line clamp. Step 30 Temporarily fix the cable in front of the clamp above the motor.

Visual inspection

Step 10 Install the left longitudinal torque rod first. Step 20 Connect and tighten the longitudinal torque rod to the torque rod bracket per the figure; apply thread-locking adhesive to the fasteners. Step 30 Then connect and tighten the torque rod to the axle end, applying thread-locking adhesive to the fasteners as well. Step 40 Tighten the fasteners to 550 N·m. Step 50 Install the right longitudinal torque rod symmetrically to the left side. Step 70 Pay special attention to the installation direction of the lower torque rod assemblies: ① middle axle left side and rear axle right side — the "axle end" marking faces down; ② middle axle right side and rear axle left side — the "axle end" marking faces up.

Tightening torque: 475-598 N·m; Carefully verify the installation direction (orientation of the "axle end" marking)

Step 10 Install the rear shock absorbers at the positions shown; note the installation position of the lower shim. Step 20 When inserting the shock absorber pin shaft (mounting bolt) into the hole, keep the pin shaft surface clean — applying grease is prohibited. Step 30 Tighten the fasteners to 550 N·m.

Tightening torque: 475-598 N·m; The pin shaft must be clean before insertion; applying grease is prohibited

Step 10 Installation of battery pack 3: hoisting preparation. Step 20 Battery pack assembly 3 is installed directly below battery pack assembly 1, shifted down 380 mm (i.e., 190 mm further down than battery pack 2); the installation structure, method, and technical requirements are the same as for battery pack assembly 1 (refer to the hoisting and support fixing illustrations in ZD104-1050). Step 30 Ground strap installation for battery pack assembly 3: position as shown in the left figure; installation requirements are the same as the ground strap of battery pack assembly 1. Step 40 Battery pack assembly 6 and its ground strap are installed symmetrically to battery pack 3.

NCM battery pack assembly 3 ×1; NCM battery pack assembly 6 ×1; Outer battery support (NCM) ×3 each; Outer battery bracket double-hole (NCM) ×2 each; Hex flange bolt (coarse shank) × matched per step; All-metal hex flange lock nut × matched per step; Hex bolt with spring and flat washer assembly ×1; Type 1 hex nut ×1; Conical lock washer ×1

Support tightening torque: 165-195 N·m (per the battery pack 1 installation requirements); Visual inspection

This page is compiled from process cards ZD106-1010 ~ ZD106-1050 (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training display only; official production shall follow the controlled process documents.