ZD110 Workstation Operation Instruction Manual

Cab Drop-in Installation / Front Appearance Pre-assembly Station · Illustrated version of 9 operations | Compiled from the original process card for training and display

Step 10: Lift the cab above the chassis; as shown, first align the front locating points with the frame locating points using a pry bar, then align the rear locating points. Step 20: Connect and tighten the chassis to the body with the fasteners as shown, torque 310 N·m. Step 30: Finally tighten the bolts connecting the left and right cab mounts 2 and 3 to the frame, torque 200 N·m.

Cab mount connection torque: 200±10 N·m; Chassis-to-body connection torque: 310±10 N·m

Step 10: After the cab is dropped onto the chassis, align the lower universal joint of the steering column with the steering gear spline as shown. Step 20: Once face A and face B are basically flush, insert the bolt and nut and tighten, tightening torque 53 N·m. Step 30: After tightening, check again whether faces A and B are flush; if the deviation is greater than 2 mm, loosen the bolt, check whether the limit bolt is seated in the slot, and reinstall.

Tightening torque: 53±7 N·m; The flush deviation of faces A/B must not exceed 2 mm

Step 10: Connect the brake lines of the foot valve and the seat transition air line as shown in Figure 1, securing them with cable ties. Step 20: Connect the air lines of the air reservoirs on the integrated frame and the trailer air line couplings as shown in Figure 2; connect the air lines of the air dryer, trailer control module and overflow valve; secure the lines with cable ties. Step 30: All air lines must be smooth, without sagging or kinking; minimum clearance to moving parts no less than 20 mm; line fixing spacing no greater than 300 mm.

Line fixing spacing: no greater than 300 mm; Minimum clearance to moving parts: no less than 20 mm

Step 10: The A/C piping connections inside the front compartment are shown in the figure above. Step 20: The A/C piping connections under the cab are shown in the figure on the left. Step 30: Check the refrigerant charging ports on the A/C high- and low-pressure lines.

Visual inspection: the condition of the refrigerant charging ports must be checked

Step 10: Install the outer lap castings: pre-assemble first without tightening the bolts. Step 10 (frame): Lift the integrated frame assembly above the chassis. Step 20: Position the integrated frame on the chassis assembly as shown; align the front face of the front lower cross member of the integrated frame with the 2 locating surfaces, and center the rear locating holes in the Y direction. Step 30: Connect and pre-tighten the 'integrated frame to the middle lap parts'. Step 40: Connect and pre-tighten the 'integrated frame to cab mount 4' (the figure shows the left-side position; the right side is symmetrical to the left). Step 50: Connect and pre-tighten the 'integrated frame to the outer lap parts' (the figure shows the left-side position; the right side is symmetrical to the left). Step 60: Tighten all of the above parts; the torque of the cab mount 4 fasteners is 310 N·m. Step 70: Finally tighten the fasteners of the integrated frame outer lap parts to the chassis. Note: during drop-in installation the harness and line bundles pass through the inside of the frame; when lifting, keep clearance between the sides and the body-in-white to avoid knocks and scratches.

Outer lap casting 1/2 ×2 each; Hex flange bolt (thick shank) × matching each step; Hex flange nut × matching each step; Hex flange bolt with serrated bearing face (fine thread) ×6

Cab mount 4 connection torque: 310±10 N·m; Avoid knocks and scratches against the body-in-white during lifting

Step 10: Install the left fender bracket assembly as shown. Step 20: Install the right fender bracket assembly symmetrically to the left side.

Tightening torque: 23±3 N·m

Step 10: Before installation, first confirm that the 'fender bracket assemblies have been installed'; install the left headlamp bracket as shown, tightening torque 8 N·m — the torque must be strictly controlled to avoid damaging the headlamp fixing tabs. Step 20: Install the right headlamp bracket symmetrically to the left side. Step 10 (lamp body): Install the left headlamp as shown. Step 30 (lamp body): Install the right headlamp bracket symmetrically to the left side.

Bracket tightening torque: 8±1 N·m (be careful to avoid damaging the lamp fixing tabs)

Step 10: Install the left front combination lamp as shown. Step 20: Install the right front combination lamp symmetrically to the left side.

Tightening torque: 23±3 N·m

Step 10: Pre-assemble the left fender: fix the left turn signal lamp to the fender as shown — first align the 2 locating features during installation; and fix the harness connector to the position shown. Step 20: Snap the filler block into the corresponding position on the fender. Step 25: Install the fender trim strip at the position shown, noting that the beveled end faces forward. Step 30: Install the left fender: install the left fender connection frame as shown, first aligning the locating pins with the holes, then tighten with the fasteners. Step 40: Take the left fender assembly and first engage the rear and upper sides onto the left fender connection frame assembly and the upper frame. Step 50: Then press the front end of the left fender, at the area where it mates with the combination lamp, outward and snap it onto the front combination lamp. Step 60: Fix the left fender to the body-in-white with 5 bolts, and finally secure the fender assembly to the connection frame with 1 self-tapping screw. Step right side, same principle: the pre-assembly and installation steps for the right fender are completely symmetrical to the left; follow steps 10-60 above.

Left/right fender assembly ×1 each; Left/right fender filler block ×1 each; Left/right turn signal lamp ×1 each; Left/right fender trim strip ×1 each; Left/right fender connection frame assembly ×1 each; Left/right fender upper frame ×1 each; Front cover opening handle assembly ×1; Fender cover panel body ×1; Hex flange bolt (thick shank) × matching each step; Cross-recessed pan-head self-tapping screw with flat washer assembly ×12

Tightening torque: 23±3 N·m; The locating pin/hole alignment and the 2 turn signal lamp locating features must be carefully verified

This page is compiled from the ZD110-1010 to ZD110-1120 process cards (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.