ZZ-NS103 Workstation Operation Instruction Manual

Cab Assembly (Toolbox, Side Soft Trim, Rear HVAC, Drawers, Rear Lock Latch, Clothes Rail) · Illustrated version of 8 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: Apply and install the toolbox sealing strip at the positions as shown; the periphery must be pressed firmly, and special attention must be paid to pressing the corner areas tightly to prevent air and water leakage. Step 20: As shown, install the toolbox hinge and toolbox lock assembly; during installation, tighten the primary locating bolt first; at the same time install the storage cabinet light switch and connect the corresponding harness. Step 30: As shown, first sub-assemble the toolbox latch and the toolbox assembly, then assemble the toolbox process assembly; adjust the gap and surface flushness between the toolbox assembly and the side panel, which must meet DTS requirements (important control point). Tightening torque requirements: M8 bolts 23±3 N·m; M6 bolts 9±1 N·m.

Step 10: As shown, install the toolbox assembly and toolbox plugs; the plugs must be pressed fully into place. Step 20: As shown, install the toolbox lamp bracket and the lamp; after connecting the harness, clip it onto the bracket to secure it. Step 30: As shown, install the rear HVAC assembly (with PTC) onto the rear AC mounting frame, then install them together onto the cab floor and connect the harness; install the ground wire with a serrated washer, ground bolt tightening torque (M6): 9±1 N·m (safety-critical control point); bundle and secure the excess harness. Note: after installation, check that the AC pipe plugs have not fallen off, and press the rubber grommets for the high-voltage harness and drain hose passing through the floor into place. Step 40: As shown, install the rear AC lower duct with cross-recessed truss-head self-tapping screws. Tightening torques in this operation: M8 bolts 23±3 N·m; M6 bolts 9±1 N·m; cross-recessed self-tapping screws 2±0.5 N·m.

Ground bolt (M6) tightening torque must reach 9±1 N·m; safety-critical item (S-class); check the static torque by sampling 2 pieces per day (shift) and fill in the inspection record card

Step 10: As shown, install the right rear side trim panel assembly onto the right rear side. Step 20: Connect the TV audio harness: first secure the right rear side trim panel section, then connect the audio harness (optional item). During installation, adjust the surrounding gaps and surface flushness, which must meet DTS requirements (important control point). Tightening torque: M6 bolts 9±1 N·m.

Step 10: As shown, install the 220V power supply unit, connect the harness, and snap it onto the rear wall. Step 20: As shown, install the center drawer assembly and secure the harness; install the on-board refrigerator according to the configuration. Step 30: As shown, install the right drawer assembly and secure the harness. Step 40: As shown, install the rear-seat storage box. Step 50: As shown, install the rear seat belt bolts; the tightening torque must reach 50±5 N·m (safety-critical control point — involves occupant seat belt fixation; must confirm the torque is achieved). Tightening torques for the remaining bolts in this operation: M8 bolts 23±3 N·m; M6 bolts 9±1 N·m. During installation, pay attention to the surrounding gaps and surface flushness.

Rear seat belt mounting bolt tightening torque must reach 50±5 N·m; safety-critical item (S-class); check the static torque by sampling 2 pieces per day (shift) and fill in the inspection record card

Step 10: As shown, lay out the TV harness supplied with the TV; route it following the floor harness and secure with cable ties every 200-400 mm. Step 20: As shown, sub-assemble the rear AC upper duct onto the left rear side trim panel assembly, then install them together onto the body left rear side; adjust the surrounding gaps and surface flushness, which must meet DTS requirements (important control point). Step 30: As shown, sub-assemble TV bracket 1 (supplied with the TV) onto the TV. Step 40: As shown, install TV bracket 2 (supplied with the TV) onto the body left rear side with anti-vibration rubber bushings. Step 50: As shown, connect the TV harness, snap the TV onto TV bracket 2, then tighten the bracket bolts from below. Step 60: As shown, install the clothes rail (optional item). Tightening torque requirements for this operation: cross-recessed self-tapping screws 2±0.5 N·m; M8 bolts 23±3 N·m.

Step 10: As shown, sub-assemble the 220V power outlet, on-board power supply (24V), and interior temperature sensor onto the left toolbox trim panel assembly. Step 20: As shown, install the left toolbox trim panel assembly and the toolbox trim panel assembly (optional for low-spec models). Step 30: As shown, connect the harnesses of the 220V power outlet, on-board power supply (24V), and interior temperature sensor. Tightening torque: M6 bolts 9±1 N·m.

Step 10: As shown, install the sleeper switch set. Step 20: As shown, install the sleeper reading lamp. Tightening torque: cross-recessed self-tapping screws 2±0.5 N·m. Step 30: As shown, install the rear USB port.

Step 10: As shown, install the emergency hammer. Step 20: As shown, install the sleeper berth cushion assembly, sleeper berth protective net assembly, protective net latches and other parts (all optional items). Tightening torque: M6 bolts 9±1 N·m.

This page is compiled from the WH platform ZZ-NS103 cab assembly process card (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.