ZZ-NS104 Workstation Operation Instruction Manual

Cab Assembly (Instrument Panel, Grounding, Steering Column, Left Instrument Panel Controllers) · Illustrated version of 3 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, assemble the instrument panel process assembly and the cross-beam support strut into place, tighten all involved bolts to the required torque, and connect the related harnesses. Bolt tightening torque requirements: M8 bolts 23±3 N·m; M10 bolts 53±7 N·m; cross-recessed self-tapping screws 1.5±0.5 N·m — confirm each per the corresponding specification to avoid under-tightening or over-tightening. Step 20: As shown, tighten the ground bolts; tightening torque (M6): 9±1 N·m. The ground bolts relate to reliable electrical grounding of the complete vehicle and are a safety-critical control point; each bolt must be confirmed to meet the torque, and none may be skipped or under-tightened.

Step 20: Ground bolt tightening torque (M6) shall be 9±1 N·m, checked by sampling the static torque, 2 pieces per shift (day); this is a safety-critical (S-class) item and the inspection record card must be filled in

Step 10: As shown, install the steering column assembly and tighten the steering upper/lower column connecting bolts (M10) to a torque of 53±7 N·m. This connection relates to the reliability of the steering system and is a safety-critical control point; the torque must be confirmed to meet the requirement. Step 20: As shown, install the combination switch lower cover mounting bracket. Step 30: As shown, install the steering column lock and tighten the tamper-proof bolts until they break (i.e., break off the bolt heads to prevent removal); ensure the bolt heads are completely sheared off. Step 40: As shown, install the steering angle sensor assembly, combination switch mounting bracket, and combination switch; steering angle sensor tightening torque: 2±0.5 N·m. Step 50: As shown, install the clock spring. Note: the yellow anti-rotation locking clip must not be removed (it must remain locked until installation is complete to prevent misalignment damage to the internal rotor of the clock spring — important control point). Tightening torque requirements for the bolts: M6: 9±1 N·m; M8: 23±3 N·m; M10: 53±7 N·m; cross-recessed self-tapping screws: 1.5±0.5 N·m. After installation, use the dedicated lower column fixture to lift and secure the steering lower column to prevent it from loosening or shifting.

Step 10: Steering upper/lower column connecting bolt tightening torque (M10) shall be 53±7 N·m, checked by sampling the static torque, 2 pieces per shift (day); this is a safety-critical (S-class) item and the inspection record card must be filled in

Step 10: As shown, sub-assemble the various controllers (body control module, EBS controller assembly, etc.) onto the left lower instrument panel controller mounting bracket, then place the whole assembly at the left side of the cab instrument panel; connect the harness connectors, following the top-to-bottom sequence when wiring, and plug each connector in one-to-one according to the harness labels and controller connector markings, then secure the harness. Step 20: As shown, install the left lower instrument panel controller mounting bracket process assembly, then install the left lower mounting bracket and the driving recorder bracket. Note: the bolts here only need to be lightly installed (not fully tightened for now); they will be uniformly tightened during subsequent assembly installation. Step 30: After the left lower mounting bracket is installed, plug in the 2 connectors each of the smart electrical junction box and the cockpit domain controller, and secure them. During installation, note: the harness routing must be reasonable and avoid interference with other parts; excess harness must be tied and secured with cable ties; plug each connector into the corresponding socket according to the harness connector label — a "click" sound when fully seated confirms the connection is correct. Special note: the harness routing must strictly follow the diagram and must not be changed arbitrarily. All M6 bolts in this operation have a tightening torque of 9±1 N·m.

This page is compiled from the WH platform ZZ-NS104 cab assembly process card (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.