ZZ-FDG1 Workstation Operation Instruction Manual

Roof Sub-assembly (Panoramic Roof, Sunshade, Overhead Console) · Illustrated version of 5 operations | Compiled from the original process card for training and display

About the illustrations:

The original process card for this station repeatedly notes "see attached drawing / as shown in the figure", but the images embedded in the digital export are only the company logo and the "Controlled" version stamp — there are no actual process diagrams or photos. This page therefore does not show an illustration area. To view the original drawings, please check the official process card file in the paper system or PDM. 0100

Step 10: Use the KBK and the lifting spreader to lift the roof assembly and secure it firmly on the roof sub-assembly fixture. Step 20: As shown, install the roof harness onto the roof assembly: all clips must be snapped securely, and the harness pass-through grommets must be seated in place; tuck any harness extending beyond the lower edge of the roof back inside and secure it with non-marking tape. Step 30: As shown, wipe the roof surface clean and apply the reflective markers (note the direction: start with white facing outward and end with white); no defects such as skewing, loose application, or edge lifting are allowed. Safety-critical tips: ① the harness routing must be correct and must not interfere with sharp edges or moving parts; ② electrical connectors must be fully connected or secured and seated in place, with no damage and no terminals pushed out; ③ clamps, cable ties, and harness clips must be in the correct positions and must not contact moving parts, sharp edges, or high-temperature components.

Step 10: As shown, install the left/right front clearance lamps onto the roof assembly with hex flange nuts; tightening torque (M6): 9±1 N·m. Step 20: As shown, for roofs configured with electronic rearview mirrors but not yet fitted with the harness, plug the left and right sides before the rain test; tightening torque (M6): 9±1 N·m.

Step 10: As shown, install the panoramic roof sunshade assembly onto the roof assembly with hex flange bolts; tightening torque (M6): 9±1 N·m.

Step 10: As shown, install the overhead console assembly onto the roof assembly with hex flange bolts and connect the harness; tightening torque (M8): 23±3 N·m.

Step 10: As shown, apply adhesive to the panoramic roof glass assembly (sequence: cleaner → primer → glass adhesive); after application, install it onto the roof assembly and secure it with non-marking tape. Important control point: after installing the panoramic roof glass assembly, it must rest for more than 30 minutes before the roof process assembly can be installed onto the body. After applying the cleaning activator, wait more than 5 minutes before applying the primer; after applying the primer, the glass adhesive bonding must be completed within 5 minutes; after applying the glass adhesive, bonding must be completed within 15 minutes. The adhesive bead path tolerance is ±1 mm, the cross-section dimensions are 7-11 mm (bottom) × 13-16 mm (height), and auxiliary materials must meet the technical requirements; also pay attention to the surrounding mating gaps and surface flushness. For the polyurethane glass bonding adhesive, the winter/summer changeover is: winter adhesive shall be used from October 30 to March 30 of the following year (±10 days), and summer adhesive for the rest of the year.

Adhesive bead path and cross-section inspection: bead path tolerance ±1 mm, cross-section dimensions 7-11 mm (bottom) × 13-16 mm (height); inspection method: sampling the static bead path and cross-section; frequency: 2 pieces per day (shift); importance: related to water leakage risk; control method: inspection record card (△).

This page is compiled from the WH platform ZZ-FDG1 roof sub-assembly process card (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.