ZZ-NS101 Workstation Operation Instruction Manual

Cab Assembly (Plugs, Pedals, Regulator Glass, Harness) · Illustrated version of 9 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: As shown, install the door sill outer decorative cover and press it firmly into place by hand. Step 20: As shown, install the patch (Φ30 mm), hex flange bolts, plug (Φ12 mm), and plug (Φ16 mm) in sequence. Note: before assembly, keep the surface clean, press all parts fully into place, and no edge lifting is allowed; the door sill outer decorative cover position shall be controlled at approx. 140 mm as shown. All M6 bolt tightening torques: 9±1 N·m.

Step 10: As shown, first install the storage box bracket assembly and the air suspension controller assembly onto the cab floor assembly with hex flange nuts; tightening torque (M6): 9±1 N·m. Step 20: As shown, install the accelerator pedal assembly onto the cab front bulkhead assembly with hex flange bolts; tightening torque (M6): 9±1 N·m. Step 30: As shown, first pre-assemble the brake signal transmitter assembly with the brake pedal assembly (torque 35±3 N·m), then adjust the free play of the brake pedal to be less than 5 mm; then install the steering column mounting bracket 1 and steering column mounting bracket 2 onto the cab front bulkhead assembly; M8 bolt tightening torque: 23±3 N·m; M10 bolt tightening torque: 53±7 N·m.

Step 10: As shown, install the upper rail assembly: first tighten the primary locating point, then the secondary locating point, and finally the remaining points. Step 20: As shown, install the center rail assembly: likewise first tighten the primary locating point, then the secondary locating point, and finally the remaining points. M6 bolt tightening torque: 9±1 N·m.

Step 10: As shown, install the pressure relief valve on the outside of the rear bulkhead (note the installation direction), press firmly, and ensure all retaining claws are snapped into place (important control point).

Step 10: As shown, install the window regulator assembly onto the cab side inner panel (the left/right markings in the original are inconsistent; see the page data notes): first tighten the primary locating point, then the secondary locating point; M6 bolt tightening torque: 9±1 N·m; finally snap the harness into place. Step 20: As shown, tighten the thermos holder bracket assembly; M6 bolt tightening torque: 9±1 N·m.

Step 10: As shown, snap the left quarter window sealing strip onto the left rear quarter window glass assembly, then install the whole assembly onto the cab left side; after installation, check that the sealing strip is pressed fully into place (important control point). Step 20: As shown, install the left window regulator mounting rail assembly and the left lower window regulator mounting rail assembly onto the cab left side; during installation, first apply a certain pushing force to the rear side of the left rail, then tighten. M6 bolt tightening torque: 9±1 N·m; screw tightening torque: 3.1-4.1 N·m. Step 30: As shown, snap the left glass run channel assembly onto the left window regulator mounting rail assembly; note: check that the right-angle datum is seated in place (important control point).

Step 10: As shown, insert the left regulator glass assembly from between the rail and the side outer panel down until it reaches the left window regulator of the cab, then install the bolts; M6 bolt tightening torque: 9±1 N·m. Step 20: As shown, install the left inner belt molding assembly onto the cab left side.

Step 10: As shown, install the left window cover panel assembly (before installation, apply primer to the 3M adhesive bonding area on the sheet metal). Step 20: As shown, install the left outer belt molding assembly onto the cab left side: first tighten the primary locating point, then the secondary locating point; screw tightening torque: 1.5-3 N·m. Step 40: As shown, install the left headliner harness and right headliner harness; ground bolt (M6) tightening torque: 9±1 N·m.

Step 10: As shown, install the floor harness: press the front bulkhead pass-through grommet into place by hand; strictly no pulling on the harness directly (safety-critical, to avoid harness damage). Ground bolt (M6) tightening torque: 9±1 N·m. Step 20: Connect all connectors of the air suspension controller, brake signal transmitter, accelerator pedal, left window regulator and other harnesses; bundle and secure the excess electric step controller harness and bar harness. Step 30: As shown, install the left body waterproof film (I) and press it firmly along the periphery. Step 40: As shown, install the left headliner harness and right headliner harness, connect them to the floor harness, and secure the connectors at the roof, floor, panoramic roof sunshade, etc. Ground bolt (M6) tightening torque: 9±1 N·m. Step 50: As shown, install the TV audio harness supplied with the TV; route it following the floor harness and secure with cable ties every 200-400 mm; for models not equipped with a TV, also bundle and secure the TV branch wires of the floor harness. Safety-critical tips: before the cab assembly rain test, seal and protect the harness protruding from the roof, and temporarily bundle and secure any excess.

Ground bolt (M6) tightening torque requirement: 9±1 N·m; inspection method: sampling the static torque; frequency: 2 pieces per day (shift); safety-critical item (S-class); controlled with the inspection record card.

This page is compiled from the WH platform ZZ-NS101 cab assembly process card (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.