Manual de partes de Camion FAW CA1161

CA1161P1K2L2A80

CAB OVER ENGINE DIESEL TRUCK

SPARE PART CATALOGUE

CHINA FAW GROUP CORPORATION

1

Foreword

Welcome to choose FAW vehicle!

This manual is for the convenience of correct operation and maintenance purpose for drivers, workshop men and spare parts suppliers, and also for providing help for managers and technicians. It introduces parts code, description and quantity for CA1161P1K2L2A80 series cab over engine 42 diesel truck, it could be a reference for FM type cab series vehicle model. As vehciles are being constantly improved, there may be difference between product and manual contents. Please carefully carry out check as reading, contact us if it is necessary, please forgive us of not notifing about revised contents.

All rights are reserved by FAW, it is forbidden to reprint the manual.

July, 2011

2

TABLE OF CONTENTS 1. ENGINELEFT .............................................................................................................................................................................................................. 8

2. ENGINERIGHT ......................................................................................................................................................................................................... 10

3. ENGINE SUSPENSION..................................................................................................................................................................................................... 12

4. FUEL TANK AND FUEL PIPELINE ............................................................................................................................................................................... 14

5. THROTTLE CONTROL................................................................................................................................................................................................... 16

6. AIR FILTER........................................................................................................................................................................................................................ 18

7. MUFFLER .......................................................................................................................................................................................................................... 21

8. RADIATOR, PIPELINE AND FAN SHIELD.................................................................................................................................................................. 23

9. INTERCOOLER, PIPELINE............................................................................................................................................................................................ 25

10. EXPANSION TANK, BRAKCET AND PIPELINE ...................................................................................................................................................... 27

11. CLUTCH ........................................................................................................................................................................................................................... 29

12. CLUTCH CONTGROL................................................................................................................................................................................................... 31

13. TRANSMISSION MAIN CASE HOUSING .................................................................................................................................................................. 33

14. CLUTCH EXTERIOR HOUSING AND RELEASE MECHANISM.......................................................................................................................... 36

15. OUTPUT SHAFT ............................................................................................................................................................................................................. 38

16. COUNTERSHAFT........................................................................................................................................................................................................... 41

3

17. INPUT SHAFT.................................................................................................................................................................................................................. 43

18. REVERSE IDLE GEAR .................................................................................................................................................................................................. 45

19. AUXILIARY CASE .......................................................................................................................................................................................................... 47

20. CONTROL MECHANISM.............................................................................................................................................................................................. 50

21. TOP COVER....................................................................................................................................................................................................................... 1

21. TOP COVER....................................................................................................................................................................................................................... 2

22. SPEED SHIFT CONTROL MECHANISM ..................................................................................................................................................................... 4

23. MEDIUM PROPELLOR SHAFT AND SUPPORT ........................................................................................................................................................ 6

24. REAR AXLE PROPELLOR SHAFT ............................................................................................................................................................................... 7

25. REAR AXLE ASSY.SHANDONG PENGXIANG AUTO AXLE FACTORY........................................................................................................ 9

26. REAR AXLE MAIN REDUCTION.................................................................................................................................................................................11

27. BRAKE.............................................................................................................................................................................................................................. 15

28. BRAKE DRUM................................................................................................................................................................................................................. 17

29. FRAME.............................................................................................................................................................................................................................. 19

29. FRAME.............................................................................................................................................................................................................................. 23

30. FRONT STEEL LEAF SPRING ..................................................................................................................................................................................... 25

31. SHOCK ABSORBER ....................................................................................................................................................................................................... 27

4

32. REAR STEEL LEAF SPRING........................................................................................................................................................................................ 29

33. FRONT AXLE .................................................................................................................................................................................................................. 31

34. STEERING DRAG LINK ................................................................................................................................................................................................ 33

35. STEERING COLUMN BRACKET ................................................................................................................................................................................ 35

35. STEERING COLUMN BRACKET ................................................................................................................................................................................ 37

36. STEERING WHEEL AND DELIVERY DEVICE......................................................................................................................................................... 39

37. POWER REDIRECTOR AND STEERING PIPELINE............................................................................................................................................... 43

38. AIR BRAKE SYSTEM AND PIPELINE........................................................................................................................................................................ 45

39. AIR SUPPLY SYSTEM.................................................................................................................................................................................................... 47

40. FRONT AXLE BRAKE SYSTEM .................................................................................................................................................................................. 49

41. ELECTRICAL.................................................................................................................................................................................................................. 52

42. BATTERY ......................................................................................................................................................................................................................... 56

43. IGNITION SWITCH........................................................................................................................................................................................................ 58

44. COMBINED SWITCH..................................................................................................................................................................................................... 60

45. HEADLAMP..................................................................................................................................................................................................................... 62

46. DRIVER READING LAMP ............................................................................................................................................................................................ 64

47. COMBINED REAR LAMP............................................................................................................................................................................................. 66

5

48. FUSE BOX WITH RELAY.............................................................................................................................................................................................. 68

49. CONTROL BOX BOTTOM PANEL WITH CONTROL............................................................................................................................................. 70

50. NAMEPLATE ................................................................................................................................................................................................................... 72

51. CIGAR LIGHTER ........................................................................................................................................................................................................... 74

52. FOG LAMP....................................................................................................................................................................................................................... 76

53. DASHBOARD................................................................................................................................................................................................................... 78

54. SIDE TURNING LAMP................................................................................................................................................................................................... 80

55. FUNCTION SWITCH...................................................................................................................................................................................................... 82

56.FUEL SENSOR.................................................................................................................................................................................................................. 84

57. AIR PRESSURE GAUGE NYLON PIPE ...................................................................................................................................................................... 86

58. POWER RESOURCE DISTRIBUTOR BOX AND ATTACHED EQUIPMENTS .................................................................................................... 88

60. FRAME HARNESS.......................................................................................................................................................................................................... 92

61. UPPER TRIM BOARD.................................................................................................................................................................................................... 93

62. WIPER............................................................................................................................................................................................................................... 95

63. WINDSHIELD GLASS AND SEAL STRIP................................................................................................................................................................... 97

64. WINDSHIELD WASHER................................................................................................................................................................................................ 99

65. FRONT SIDE EXTERIOR BOARD............................................................................................................................................................................. 101

6

66. FRONT WALL EXTERIOR BOARD AND SEAL STRIP ......................................................................................................................................... 103

67. COLUMN PIN LOCK, BUMPING WASHER AND BRACKET .............................................................................................................................. 105

68. OPEN HANDLE AND CABLE ..................................................................................................................................................................................... 107

69. TRIM DIAPHRAM ........................................................................................................................................................................................................ 109

70. INSTRUMENT PANEL (1).............................................................................................................................................................................................111

71. INSTRUMENT PANEL2 ........................................................................................................................................................................................113

72. INSTRUMENT PANEL (3)..........................................................................................................................................................................................115



75. INSTRUMENT PANEL (6)............................................................................................................................................................................................ 121

76. WARM AIR ..................................................................................................................................................................................................................... 123

77. WARM AIR ..................................................................................................................................................................................................................... 125

78. WARM AIR PIPELINE ................................................................................................................................................................................................. 127

79. COOL AIR COMPRESSOROPTIONAL ........................................................................................................................................................... 129

80. COOLING DEVICEOPTIONAL.......................................................................................................................................................................... 131

81. FREON GUIDE PIPE, CONDENSOR AND FLUID RESERVIOR (OPTIONAL ) ................................................................................................ 133

82. LEGFT EXTERUIR REAR VIEW MIRROR............................................................................................................................................................. 135

7

83. RIGHT EXTRIOR REAR VIEW MIRROR ............................................................................................................................................................... 137

84. LEFT SUNVISOR .......................................................................................................................................................................................................... 139

85. RIGHT SUNVISOR ....................................................................................................................................................................................................... 141

86. SAFETY BELT ............................................................................................................................................................................................................... 143

87. CAB SUPPORT DEVICE.............................................................................................................................................................................................. 145

88. CAB REAR SUSPENSION DEVICE ........................................................................................................................................................................... 147

89. CAB REAR SUSPENSION DEVICE ........................................................................................................................................................................... 149

90. CAB HINGE DEVICE ................................................................................................................................................................................................... 151

91. FENDER.......................................................................................................................................................................................................................... 153

92. STEP PEDAL.................................................................................................................................................................................................................. 155

93. MUDGUARD .................................................................................................................................................................................................................. 157

94. ENGINE MUDGUARD AND HEAT PROOF ............................................................................................................................................................. 159

95. CARPET.......................................................................................................................................................................................................................... 161

96. DRIVER SEATLUXURY....................................................................................................................................................................................... 163

97. PASSENGER SEAT........................................................................................................................................................................................................ 165

98. SLEEPER ........................................................................................................................................................................................................................ 167

8

1. ENGINELEFT No. Part code Part description Qty. No. Part code Part description Qty.

1 1000410-Q691 ( )NO AC

CA6DF2-24 .

CA6DF2-24 Enging assembly(including power steering oil pump and air compressor)

1

9

FIG.1 ENGINELEFT

10

2. ENGINERIGHT No. Part code Part description Qty. No. Part code Part description Qty.

1 1000410-Q691 ( )NO AC

CA6DF2-24 .

CA6DF2-24 Enging assembly(including power steering oil pump and air compressor)

1

11

FIG.2 ENGINERIGHT

12

3. ENGINE SUSPENSION

No. Part code Part description Qty. No. Part code Part description Qty. 1 1001061-Q824

F Rear suspension bracket 2 12 CQ1601250T Hex head bolt 2

2 CQ1511655TS Hex head bolt 12 CQ34012T Hex nut 2 Q40316 Elastic washer 12 Q40312 Elastic washer 2 3

Q18520140T Hex head flange bolt 2 13 1001030-2H

Upper cover assy., engine front suspension

2

Q32920T

1

I shape non metal monting part hex lock nut 2

14 1001025-2H Front suspension cushion assy.

2

41001079-263 -

Bottom panel, rear suspension 4

15 CQ1601055T Hex head bolt 8

51001015-263

Engine rear suspension cushion assy. 2

16 CQ34010T Hex nut 8

16 1001071-Q857

Left rear suspension bracket 1

Q40310 Elastic washer 8

1001072-Q857

Right rear suspension bracket 1

17 1001028-2H

Washer, engine front suspension

2

7Q1841640TS

()

Hex flange surface bolt, thick lever(standard type)

8

8 Q1841240TS Hex head flange bolt 4 9 1001037-362 Front suspension bracket 2

10 CQ1601255T Hex head bolt 6 CQ34012T Hex nut 6 Q40312 Elastic washer 6

11 CQ16116100T Hex head bolt 2 Q32916T 1

I shape non metal monting part hex lock nut

2

13

FIG.3 ENGINE SUSPENSION

14

4. FUEL TANK AND FUEL PIPELINE

No. Part code Part description Qty. No. Part code Part description Qty. 1 1101130-Q407 -

Tighten belt assy., fuel tank 2 Q40312 Elastic washer 2

2 110107-Q407 -

Ypper locate pin, tighten belt

2 13 1105010-Q803 Fuel primary filter assy. 1

3 1101109-Q407 Pull lever bolt 2 14 CQ1421040 Combined bolt 4 4 1101105-Q801 -

Bracket assy., fuel tank 2 CQ34010 Hex nut 4

5 CQ1601650 Hex head neck guide bolt 6 15 1104622-365 -

Transmit connector, to fuel filter

1

CQ34016 Hex nut 6 16 1104120-D816E -

Fuel inlet hose assy., fuel tank to fuel filter

1

Q40316 6 17 1101710-Q407 Fuel tank lock cover assy.

1

6 1101108-Q407 -

Lower locate pin, tighten belt

2 18 1104301-363 Air inlet and exhaust pipe

1

7 1101015-Q407 Fuel tank assy. 1 8 1104250-367 Fuel return pipe assy. 1 9 1105020-Q801

Fuel filter bracket assy. 1

10 1104130-D206A -

Fuel inlet hosea ssy, engine to primary filter

1

1104061-367 Hollow bolt 1 11 1104261-1H - Protect ring, fuel hose 2 12 CQ1501240 Hex head neck guide bolt 2 CQ34012 Hex nut 2 Q40112 Washer 2

15

10

12 1413

9

171516

8

11

2

6

7

54

1

3

18

FIG.4 FUEL TANK AND FUEL PIPELINE

16

5. THROTTLE CONTROL No. Part code Part description Qty. No. Part code Part description Qty. 1 1108014-50 Accelerating step pedal 1 18 Q5002516 Cotter pin 1 2 1108020-50 Bracket assy., accelerating

step pedal 1 19 1108410-Q634

Throttle control cable assy. 1

3 Q5100640 - Flat pin, accelerating step pedal

1 20 1104280-15

Single pipe clip assy., fix fuel return pipe

2

4 Q5002010 Cotter pin 2 5 Q40308 Elastic washer 6 6 CQ1500814 Tiny hex bolt 2 7 CQ34008 Hex nut 1 8 CQ1500830 Bolt 1 9 CQ1500812 Tiny hex bolt 3 10 1108330-240 Control lever bracket assy. 1 11 Q5002020 Flat pin 1 12 Q40110 Washer 3 13 1108501-50B1 Clip 1 14 CQ1500612 Hex bolt 2 15 Q40306 Elastic washer 2 16 CQ34006 Hex nut 2 17 11008056-8E

Pin shaft, throttle control 1

17

FIG.5 THROTTLE CONTROL

18

6. AIR FILTER

No. Part code Part description Qty. No. Part code Part description Qty. 1 1109220A242 Shock absorber bracket assy. 4 CQ34014 Hex nut 4 2

1109227-375 Lower body transmit bracket 1 Q40314 Elastic washer 4

3 1109228-362

Upper body right transmit bracket 1 15 CQ1461030 Combined bolt 4

4 CQ1461025 Combined bolt 4 16 1109352-362 -

Connecting hose, to air filter 1

5 CQ34010 Hex nut 8 CQ676200B

B

Worm lever hose clamp B shape 1

Q40210 Big washer 8 17 CQ676140B

B


Q40310 Elastic washer 8 18 1109353-382 A Air inlet pipe A 1 6

1109229-362 Upper body upper transmit bracket 1 19 1109351-367

-

Connecting hose, secondary air filter inlet 1

7 1109250A242

Inlet pipe assy. 1 20 CQ676170B

B


8 1109210A242

Worm lever hose clamp 1 21 1109510-367 Secondary air filter assy. 1

9 1109260-367

-

Connecting soft pipe assy-air filter 1 22 1109370-398

Secondary air filter bracket assy. 1

10 1109270-382 Seat assy. 23 CQ1461025 Combined bolt 4 11 1109276-362 Shock absorber washer 1 24 CQ1501035 Hex head bolt 4 12

CQ676230B B

Worm lever hose clamp B shape 1 Q40310 Elastic washer 4

13 1109010-435 Air filter assy. 1 CQ34010 Hex nut 4 14 5001165-Q738

C

Air filter and hydraulic pump bracket welding assy. 1 25 CQ676150B

B


CQ1501435 Hex head bolt 4 26 1109351-D553E -

Connecting hose, to engine 1

19

No. Part code Part description Qty. No. Part code Part description Qty.

27 CQ676140B B Worm lever hose clamp B shape 1

28 CQ1461025 Combined bolt 1 CQ34010 Hex nut 1

20

FIG.6 AIR FILTER

21

7. MUFFLER


1 1201010-Q687 Muffler assy. 1 2 1203040-D202 Expansion jiont 1 3 L1203075-40A Clip ring assy 1 4 CQ34008 Hex nut 8

5 1203015-D202 - ( 1203016-D202)

Muffler inhalation pipe assy. rear part(see 1203016-D202) 1

1203041-53 - Clamp muffler suspension 2 6 1203010-D202 Muffler inhalation pipe assy. 1 7 1203025-252 Gasket assy. 1 8 CQ1500820 Hex bolt 4 CQ34008 Hex nut 4 Q40308 Elastic washer 4 9 1203090-382 - Strap assy., muffler 2 10 1203050-Q625 - Bracket assy., muffler 1 11 CQ1501240 Hex bolt 4 CQ34012 Hex nut 4 Q40312 Elastic washer 4

22

FIG.7 MUFFLER

23

8. RADIATOR, PIPELINE AND FAN SHIELD

No. Part code Part description Qty. No. Part code Part description Qty. 1 1302905-362 Pull lever lower bracket 2 15 1302013-362 Block 2 2

CQ1461030 Combined bolt 4 16

CQ67660B B


CQ34010 Hex nut 4 3 CQ1460820 Combined bolt 2 4

CQ67670B B


5 1303021-362 Radiator water outlet hose 1 6 CQ1460820 Combined bolt 4 7

1309010-362 1309012-362

Fan shield assy(see 1309012-362 1

8 1303011-385 Radiator water inlet hose 1 9 1301010-Q262 Radiator assy 1 10

1302010-362 Radiator suspension bracket assy 2

11 CQ1731290

Hex bolt 2

CQ38112 Hex nut 2 Q5003030 Cotter pin 2

12 1302125A01 -

Upper block assy., radiator suspension 2

13 1302121A01 Sleeve 2 14

1302130A01 -Lower block assy., radiator suspension 2

24

2

1

2 3

14

1312

15

11

39

4

10

4

8

16

7

5

4

6

FIG.8 RADIATOR, PIPELINE AND FAN SHIELD

25

9. INTERCOOLER, PIPELINE

No. Part code Part description Qty. No. Part code Part description Qty. 1 CQ676100B

B Worm lever hose clamp B shape

6

2 1119050K1HA1 Bellow joint assy. 2

3 1119041-362 Intercooler air outlet hose 1

4 1119054-362 Intercooler air outlet connecting hose

1

5 1119010-362 Intercooler assy 1

6 CQ1460816 Combined bolt 12

7 1310050-362

( 1310051-362)

Retainer assy (see 1310051-362) 1

8 CQ1460820 Combined bolt 6

CQ34008 Hex nut 6

26

FIG.9 INTERCOOLER, PIPELINE

27

10. EXPANSION TANK, BRAKCET AND PIPELINE

No. Part code Part description Qty. No. Part code Part description Qty. 1 CQ1460820 Combined bolt 4 14 1311036-8E Pipe connector 1 CQ34008 Hex nut 4 15

CQ67622

Small worm lever delivery type hose clamp

8

Q40308 Elastic washer 4 16 1311032K1H Radiator rear degassing hose 2 2

1311040A242 Expansion tank fix bracketassy 1

17 1311029-8E Bent pipe bracket 2

3 CQ1420820 Hex bolt 3 18 1311021-Q623 Radiator degassing bent pipe 1 Q40308 Elastic washer 3 19 1311060-8E Dual pipe clip assy. 2 CQ34008 Nut 3 20 CQ1460820 Combined bolt 2 4 1304010-A1 Radiator cap 1 Q40308 Elastic washer 3 5 1311010-Q204 Plastic expansion tank assy. 1 CQ34008 Nut 3 6

CQ67635B B


7 1311033-Q433 Water return rear hose 1 8 Q68622 Single pipe clip 2 9 1311031-228 Water return bent pipe 1 10 1311032-362 Water return front hose 1 11 1311027-8E Engine front degassing hose 1 12 1311023-Q435B1 Radiator front degassing hose 1 13 1311024-1L Degassing cone bolt 1

28

FIG.10 EXPANSION TANK, BRAKCET AND PIPELINE

29

11. CLUTCH

No. Part code Part description Qty. No. Part code Part description Qty. 1

11601100E5H . Clutch driven plate, cover and release bearing assy.

1

CQ1501070 Hex bolt 12 Q40310 Elastic washer 12

30

FIG.11 CLUTCH

31

12. CLUTCH CONTGROL No. Part code Part description Qty. No. Part code Part description Qty.

1 1602015-1H Clutch pedal and bushing assy

1 17 Q40312 Elastic washer 3

1602037-50 Pedal sleeve, clutch pedal

1 18 CQ1421020 Combined bolt 1

2 1602038-50 Upper limit block, clutch pedal


3 1602039-1H Return spring 1 20 CQ1501045 - Bolt tighten master cylinder

1

4 1602041-50 Shaft, clutch pedal 1 21 CQ1501065 - Bolt tighten master cylinder

1

5 1602045E5H Bracket assy, clutch pedal

1 22 CQ35312 Nut 2

6 1602070-240 - Left bracket assy, instrument panel

1 23 CQ67616

Worm lever delivery type hose clip

2

7 1602085E5H Right bracket assy, clutch pedal

1 24 Q40206 Washer 3

8 1602091-Q50 Rivet, clutch master cylinder


9 1602096-367 Pipe, master cylinder 1 26 CQ35112 Nut 1 10 1602100-Q486 Oil reservior cup assy 1 27 1602200A367 Clutch oil pipe assy. 1 11 1602110-362 Clutch master cylinder

assy 1 28

1602097-367 Seal cover 1 12 CQ1420816 Combined bolt 1 29 1602350-D211W Clutch booster assy. 1 13 CQ1421020 Combined bolt 1 30 CQ1500830S Hex nut 4 14 CQ1461020 Combined bolt 2 Q40308 Elastic washer 4 15 CQ1500620 Hex bolt 3 16 CQ1420816 Combined bolt 1

32

FIG.12 CLUTCH CONTROL

33

13. TRANSMISSION MAIN CASE HOUSING

No. Part code Part description Qty. No. Part code Part description Qty. 1 8878618 Front housing 1 18 8874819-435J Spring 1 2 D8870278 Cup shape plug 1 19 D8870259 Clip pin cover 1 3 20 DMX-8-0856 M816 M816 Hex rivet 2 4 8881616 PTO cover 1 21 DMX-3-0801 M8 M8 Elastic washer 2 5 DMX-3-1001 M10 M10 Elastic washer 6 22 8870590 Seal gasket 1

6 DMX-8-1001 M10X20

HD M10X20 Hex rivet HD 6

23

7 DMX-8-1001 M10X20

HD M10X20 Hex rivet HD 1

24

8 12152 Hose clip 1 25 8882415 Gear select shaft bush 1 9 D20815 Hang ring 1 26 X8870542 8.0 16 8.0 diameter 16 rivet 2 10 DX11245 M10 M10 washer 1 27 11 DMX-9-1001 Nut 1 28 DMX-8-1003 M1035 M1035 Hex rivet 1

12 MX-8-1080

M10-58 Hex flange bolt M10-58 17 29 DMX-3-1001 M10 M10 Elastic washer 1

13 30 DX11245 M10 M10 washer 3 14 MX-9-1005 Nut 17 31 8878822 Hang ring 1 15 X8880519 -/ Washer, oil adding/draining 1 32 16 DX8874942 Oil adding plug 1 33 17 8873654 Neutral gear position base 1 34 8878620 Middle housing 1

34

13. TRANSMISSION MAIN CASE HOUSING

No. Part code Part description Qty. No. Part code Part description Qty. 35 8882415 Gear select shaft bush 1 52 36 53 3774010G685 Neutral position swith 1 37 8878727 Idle gear cover panel 1 54 2771532 Reverse gear position switch 1 38 DMX-8-0811 M820 M820Hex rivet 7 55 39 DMX-3-0801 M8 M8Elastic washer 7 56

40 X8880519 -/ Oil adding and draining

washer 1

57

41 DX8874941 Magnetic plug 1 58

42 2771532 High/low speed gear

position switch 1

59

43 X8870711 - 14 Steel ball-diameter :14 1 60 U8878480 - Front end oil injection pipe 1

44 MX-8-1080

M10-58 Hex head flange boltM10-58

8 61

8878821 Hang ring 4

45 62

46 MX-9-1005 Nut 8 63

MX-8-1079 M10-40 Hex head flange boltM10-40

4

47 DMX-8-1062 M1030 M1030 hex head bolt 8 64 U8878729 Filter screeb assy. 1 48 DMX-3-1001 M10 M10Elastic washer 8 65 X8880469 Filter screen washer 1 49 U8878649 Oil pump assy. 1 50 X8870543 16X30.5 Locate pin 16X30.5 2 51 X8871377 Bush 1

35

FIG.13 TRANSMISSION MAIN CASE HOUSING

36

14. CLUTCH EXTERIOR HOUSING AND RELEASE MECHANISM


1 DMX-7-1806 M18X90

M18X90 Hex head flange bolt 9

2 F96780 Clip ring 2 3 F96779 Washer 2 4 F96777 Steering pin 1 5 F96778 Separate ring 2 6 MX-7-1404 M14X50 Bolt M14X50 1 7 8878769 Release fork 1

8 DMX-7-1807 M18X150

M18X150 Hex head flange bolt 1

9 X2014001 Clip ring 2 10 F96781 Bearing 1 11 F96782 Block 1

37

FIG.14 CLUTCH EXTERIOR HOUSING AND RELEASE MECHANISM

38

15. OUTPUT SHAFT


1

X8878463 Output shaft front bearing

1

17

8878777 1. 2 Synchronizer taper1st/2nd synchronizer

2

2 X8878180 60 Clip ring-outer diameter

60 1 18 8878784 - 1. 2 Synchronizer ring-1

st /2nd synchronizer

2

3

8878777 3. 4

Synchronizer taper3rd/4th synchronizer

2 19

8878594 1. 2 Sliding gear sleeve1st/2nd

speed

1

4 8878784 - 3. 4 Synchronizder ring-3rd/4th

synchronizer 2 20 8878775 - 1. 2 Fix gear seat-1st/2nd speed

1

5 8878594 3. 4 Sliding gear

sleeve3rd/4th speed 1 21 8878020 1st speed gear 1

6 8878776 - 3. 4 Fix gear base-3rd/4th speed 1 22

7 X8870356 Roller

columnsynchronizer 3 23 X8878022 - Roller needle bearing-1

st speed gear

2

8 8870352 Basesynchronizer 3 24 8878445 Input shaft pin 1 9 8870444 Springsynchronizer 3 25 8878446 Output shaft 1 10 8878376 3rd speed gear 1 26 X8878041 Roller needle bearing 2 11 8878373 Bush3rd speed gear 1 27 8878040 Gearcreeper gear 1

12 X8878041 Roller needle bearing3rd

speed gear 2 28 8878518 Meshing gearcreeper gear

1

13 29 8878518 Meshing gearcreeper gear

1

14 8878030 Bush2nd speed gear 1 30 8878517 . Fix gear seatCreeper/reverse gear

1

15 X8878029 Roller needle bearing2nd speed

1 31 X8878172 68 Diameter 68 inner clip ring 1

16 8878028 2nd speed gear

1 32

8878044 . Sliding gear sleeveCreeper/reverse gear

1

39

15. OUTPUT SHAFT

No. Part code Part description Qty. No. Part code Part description Qty. 33 34 8878518 Meshing gear-reverse gear 1 35 8878051 Reverse gear 1 36 X8878033 Roller needle bearingreverse gear 1 37 8878053 Thrust washer 1 38 X8878682 Output shaft rear bearing 1 39 40 8878689 Oil bush 1 41 8878102 Sun gear 1 42 8878103 Locate baffle board 1

43 X8870699 M1645

M1645 Hex rivet 1

40

FIG.15 OUTPUT SHAFT

41

16. COUNTERSHAFT


1 F88891 Washer 1 2 8878261 79.56.1 Washer diameter 79.56.1

1

3 U8877534 Clip ring 1 4 X8880820 Taper bearing 1 5 U8878705 Countershaft sub-assy. 1 6 X8880820 Taper bearing 1

42

FIG.16 COUNTERSHAFT

43

17. INPUT SHAFT


1 8878360 802.40

Diameter 802.40 mm clip ring 1

2

3 X8878681

Inputshaft rear bearing 1

4 8878693

Inputshaft 1

44

FIG.17 INPUT SHAFT

45

18. REVERSE IDLE GEAR

No. Part code Part description Qty. No. Part code Part description Qty. 1 8870343 Thrust washer,idle gear 2

2 X8872478 Roller needle bearing assy., idle

gear 2

3 8872479 Separate ring 1 4 8878150 Idle gear 1 5 6 8878687 Reverse idle gear shaft 1

46

FIG.18 REVERSE IDLE GEAR

47

19. AUXILIARY CASE

No. Part code Part description Qty. No. Part code Part description Qty. 1 CQ1700820 Bolt 6 18 DX11245 M10 M10 washer 3 2 Q40308 Elastic washer 6 19 DMX-3-1001 M10 M10 Elastic washer 3 3 8878110 Fix plate 1 20 DMX-8-1063 M10 M10 bolt 3 4 8878223 Low speed gear synchronizer taper 1 21 1701621D685 Worm lever 1 5 22 1701643B435J Separate sleeve 1

6 23 1701447-4E - Connector-speedometer flexible shaft

1

7 X8870543 16X30.5 Locate pin 16X30.5 1 24 Q7341912B O O shape ring 1

8 8878622 Rear housing 1 25 1701446-1H -

Driven gear, speedometer delivery

1

9 X8875292 O O shape ring 1 26 10 8878240 Shaft bush 1 27 1701611-435J - Gearbox rear cover 1 11 X8878258 O O shape ring 1 28 X8878144 Outputshaft bearing 1 12 8878163 Piston 1 29 8878624 Rear cover seal 1 13 X8878166 O O shape ring 1 30 20807 Oil seal 1 14 14345 O O shape ring piston pull lever 1 31 15 32

16

33DMX-8-1059 M10115

M10115Hex head flange bolt 6

17 8878165 Cylinder 1 34 8878676 Flange 1

48

19. AUXILIARY CASE

No. Part code Part description Qty. No. Part code Part description Qty. 35 1701668C8S Bolt 1 52 8870444 Springsynchronizer 9 36 8873917 Countershaft cover plate 1 53

8878506 - Gear seat-high/low speed gear

1

37 DMX-3-1201 M12 M12 Elastic washer 4 54X8878133 Synchronizer bearing gear

seat 1

38 DMX-8-1209 M1225

M1225Hex rivet 4

55X8878134 Clip ring 1

39 U8878601 Planetary gear assy. 1 56 X8878487 M90 M90 clip ring 1

40 8878222 High speed gear

synchronizer taper 1

41 X8878488 M115 M115 clip ring 1

42 8878503 178 Taper synchronizer ring

178 2

43 8878136 Gear ring 1

44 8878547 /

Gearbox speed shift shaft high/low speed gear

1

45 X8878665-53A Pin 1

46 8878112 - Speed shift fork-high/low

speed gear 1

47 X8878137 Clip ring 1

48 8878504 - Gear sleeve-high/low

speed gear 1

49 X8878134 Clip ring 1

50 X8870355 Roller

columnsynchronizer 9

51 8870352 Basesynchronizer 9

49

FIG.19 AUXILIARY CASE

50

20. CONTROL MECHANISM

No. Part code Part description Qty. No. Part code Part description Qty. 1 X8870277 10.0*34.6 Diameter 10.0*34.6 pin rivet 1 2 8873691-CA Rivet 1 3 8874755-CA Guide block 1 4 8878254 - 3. 4 Speed shift fork-3rd /4th speed 1 5 8878297 - 1. 2 Speed shift fork -1st/2nd speed 1

6 8878252 .

Speed shift forkCreeper/reverse gear

1

7 Z37628 - Speed shift fork shaft board 1 8 8878326 H Dual H fork shaft 1 9 Z37629 Counterlock board 1

51

FIG.20 CONTROL MECHANISM

1

21. TOP COVER


1 8878768-Q664 Gear shift arm 1

16X8874450 25.0

Diameter 25.0 outer clip ring 2

2.

DMX-9-1001 DMX-3-1001

M10X1.5 M10

Nut M10X1.5 M10 Elastic washer

1 1

17

8876567 Spring baffle piece

1

3 DMX-8-1007 M10X50 M10X50 hex bolt 1 18 8876566 Spring baffle piece

1

4

DMX-9-1001 DMX-3-1001

M10X1.5 M10

Nut M10X1.5 M10 Elastic washer

1 1

19

x8880299 Bush 1

5 X8875259 Protect cover 1 20 1702115-Q824F Top cover sub-assy. 1 6 1702126-Q824F O O shape ring 1 21 8880986 Stop column plug 2 7 Z37422 Gear select end 1 22 8881592-435J Reverse spring 1 8 DMX-8-0853 Bolt 4 23 1702111-Q744 Washer 1 9 Z8881880 - Housing, gear select 1 24 X8880301 Screw cover 1 10 Z8881872 Lever 1 25 X8871378-53A Pin rivet 1

11 X8874450 25.0 Diameter 25.0 exterior clip

ring 2 26 1702121-Q824F Gear shift shaft 1

12 8873645 Compressed spring 1 27 1702120-Q824F

Gear shift shaft and spline sleeve assy.

1

13 X8880639 O O shape ring, end cover 1 28 DMX-8-1007 M10X50 M10X50 hex bolt 1 14 MX-8-0810 M8X30 Rivet M8X30 4 29 X2014210 Vent plug 1 15 8880477 End cover 1 30 Z37677-Q824F Gear select arm 1

2

21. TOP COVER

No. Part code Part description Qty. No. Part code Part description Qty. 31 DX8871486 Insert piece 1 32 1702129-1H Tighten rivet 1 33 X8881481 Oil seal, gear shift shaft 1 34 ZX8881874 Bush 1 35 Z8881875 Locate sleeve 1 36 Z8881873 Gear select shaft 1 37 ZX8881871 Bush 1

3

FIG.21 TOP COVER

4

22. SPEED SHIFT CONTROL MECHANISM

No. Part code Part description Qty. No. Part code Part description Qty. 1 1703040-Q107

Speed shift hanle assy., provided by FAW transmission

1 18 1703070-Q186 Front bracket assy., cear sleeve steel cable

1

2 1703027B240

-

Seal sleeve, speed shift control lever dust proof

1 19 Q1840816 Hex flange bolt 4

3 1703012-D280

Upper dust proof assy., speed shift control

1 20 1703180-Q107T Gear select steel cable assy.

1

4 CQ35118 Hex thin nut 1 21 1703181-Q857 Gear select and shift steel cable assy.

1

5 1703005-D280 Speed shift control lever assy.

1 22 CQ1501020 Hex neck guide bolt 12

6 CQ1461040 Combined bolt 6 23 1703170-Q857 Gear shift steel cable assy. 1 7 Q40310 Elastic washer 1 24 1703331-D450F (

) Air supply pipe assy., (provided together with transmission )

1

8 CQ34110 Hex nut 1 9 Q32912 1

I shape non metal nouting hex lock nut

1

10 1703025-240

Speed shift control lever lower dust proof assy.

1

11 1703056-240 - Pin shaft, angle shape arm 1 12 1703030-240 Speed shift control lever seat 1 13 1703041-240 Big bush 1 14 1703043-240 Washer 1 15 1703044-240 Washer 1 16 1703046-240 Tiny bush 1 17 1703050-362 Angle shape arm assy. 1

5

FIG.22 SPEED SHIFT MECHANISM

6

23. MEDIUM PROPELLOR SHAFT AND SUPPORT


2206010-Q107

Middle propeller shaft and support assy. 1

1 2205030C6H

Spider shaft and roller needle bearing assy. 1

2 2201023-50A Flange fork 1

3 2205041C6H Circlips for hole 4

4 2202110C6H

Middle support bearing seat and bearing assy. 1

5 2202039-50A - Countershaft flange 1

6 1701471-11 Nut 1

7 2201126C6HA - Bearing bracket, middle support 1

8 2206117C6H - Press plate, middle support 1

9 2206015-Q107 .

Propeller shaft sleeve, welding fork and spline shaft assy. 1

7

24. REAR AXLE PROPELLOR SHAFT


2201010-X374

Middle axle propeller shaft and universal joint assy. 1 2205073C6H

Balance piece

1 CQ1611455T

Bolt, tighten universal jointflange 8 2205074C6H

Balance piece

2 2201023-50A Flange fork 2 2205075C6H Balance piece

3 Q32914 Nut 8 2205076C6H Balance piece

4 2205030C6H

Spider shaft and roller needle bearing assy. 2 2205077C6H

Balance piece

5 2205041C6H Retainer 2205078C6H Balance piece

2205042C6H Retainer 2205079C6H Balance piece A required

2205043C6H Retainer

8 2205015-X374

.

Middle axle propeller shaft and universal joint sub-assy. 1

2205044C6H Retainer 2205045C6H Retainer 2205046C6H Retainer 2205047C6H Retainer

Choose 8 pieces

2205048C6H Retainer 2205020C6H Spline shaft fork assy.

6 2205020C6H Spline shaft fork assy. 1 7 2205071C6H

2205072C6H

8

FIG.24 REAR AXLE PROPELLOR SHAFT

9

25. REAR AXLE ASSY.SHANDONG PENGXIANG AUTO AXLE FACTORY No. Part code Part description Qty. No. Part code Part description Qty.

2400010-Q625 4.875 Rear axle assy single i0=4.875 1 17 2403083-4EB1 - Bolt, axle shaft 20

1 Z2401010B10D Rear axle housing assy 1 18 SQ3502565B03D Rear brake drum assy 2

2 W2401024B01D Rear wheel hub inner bearing retainer

2

19 3502015-A0A Rear left brake assy 1

3 CQ61806 screw plug 1 20 3502020-A0A Rear rught brake assy 1 4 Q62104 Oil outlet screw plug 1 21 CQ1501435 Bolt 8 5 SQ2401068B-A01 Rubber vent plug assy 1 22 Q40314 Spring washer 8 6 2403090D1H Axle shaft oil seal assy 2 23 3506328-505 Rear axle air pipe bracket 1 7 2401053-4E - Nut rear wheel hub

bearing 2

24 Q150B1018 Bolt 2

8 2401058-4E Lock piece 2 25 Q40310 Spring washer 2 9 CQ1500816 bolt 6

10 Q40308 Spring washer 6 11 2402010D1H-QD

4.875 Shock absorber and differential assy4.875

1

12 2402016D1H - Bolt, tighten retarder 8 13 2402017D1H - Bolt, tighten retarder 4 14 W2403082D1HB1 Right half axle 1 15 W2403081D1HB1 Left half axle 1 16 2403084-4E - Gasket of half axle 2

10

2

2 25

267

8

1 09

1 8

1 81 9

2 0

2 1 2 3

1 2

1 3

1 1

1 7

1 61 4

1 61 5

1 7

1 9

6 7 8

1 09

13 2 3

2 2

4

FIG.25 REAR AXLE

11

26. REAR AXLE MAIN REDUCTION No. Part code Part description Qty. No. Part code Part description Qty. 2402010D1H-Q

D 4.875

Rear axle master retarder assy4.875 1

2401084D1HB1 -(3.37-3.39)

Adjust gasket -drive taper gearbearing(3.37-3.39)

1

1 SQ2402119-A01 -

Bolt- tighten differential bearing cover

4

2401086D1HB1 -(3.47-3.49)


1

2 SQ2402019D1H - Cover differntial bearing cover

2

2401087D1HB1 -(3.57-3.59)


1

3 2402018D1H Retarder exterior housing 1

2401088D1HB1 -(3.67-3.69)


1

4 Q62510 Oil filling screw plug 2

2401089D1HB1 -(3.77-3.79)


1

5 2402049D1H - Bearing seat for drive taper gear

1

13 2402055D1H - Oil seal assy-drive taper gear 1

6 2402097D1H -t=0.5

Adjust gasket -master taper gear beaing seatt=0.5

1

14 2402065B09D Drive taper gearflange assy 1

2402098D1H -(t=0.2)

Adjustgasket -master taper gear beaing seat(t=0.2)

1

15 2402071D1H - Nut, drive taper gear flange 1

2402099D1H -(t=0.1)

Adjustgasket -master taper gear beaing seat(t=0.1)

1

16 CQ1501440 -

Bolt, tighten master taper gear beaing seat

8

7 42708K

Column roller bearing 1

17 2403038A31 Flat gasket 8

8 2402036E1H 4.875drive taper gear4.875 1 18 2402037E1L 4.444 Driven taper gear4.444 1 9 9278/9220 -

Taper roller bearing-drive taper gear

1

19 2402063D1H -

bolt tighten driven taper gear ans differntia

12

10 30613B -

Taper roller bearing-drive taper gear

1

20 2403017D1H -4.875 Left housing for differential4.875

1

11 2402091-D1HB1 -

Adjustgasket -drive taper gearbearing

21 2403018D1H - Right housing for differential 1

12 2401081D1HB1 -(3.07-3.09)

Adjustgasket -drive taper gearbearing(3.07-3.09)

1

22 2403023D1H - Bolt, tighten differential housing

12

2401082D1HB1 -(3.17-3.19)

Adjustgasket -drive taper gearbearing(3.17-3.19)

1

23 594A/592A Bearing assy 2

2401083D1HB1 -(3.27-3.29)

Adjustgasket drive taper gear bearing(3.27-3.29)

1 24 CQ1501020 - Bolt, thrust piece 4

12

12

34

91 21 3

1 4

1 61 7

181 9

2 0

2 1 1

27

22

2 3

2 3

2 4252 6

27

2 7

28

29 2 9

30

3 0

31

3 1

3 2

15

1 15

810

76

4

2

FIG.26 REAR AXLE MAIN REDUCTION

13

26. REAR AXLE MAIN REDCUTION No. Part code Part description Qty. No. Part code Part description Qty.

25 Q40310 Spring washer 4 20 26 SQ2403072B01D - Thrust piece, adjust ring 2 2 27 2403071D1H Adjust ring 2 1 28 2403053D1H - Washer, half axle gear 2 1 29 2403051D1H Axle shaft gear 2 8 30 2403058D1H - Washer, planetary gear 4 8 31 2403056D1H Planetary gear 4 1 33 2403061D1H - Spider shaft for differential 1 2 2

14

12

34

91 21 3

1 4

1 61 7

181 9

2 0

2 1 1

27

22

2 3

2 3

2 4252 6

27

2 7

28

29 2 9

30

3 0

31

3 1

3 2

15

1 15

810

76

4

2

FIG.26 REAR AXLE MAIN REDUCTION

15

27. BRAKE


3502015-A0A Rear left brake assy 3502125-A0A - Left bracket assy., rear

brake cam 1

3502020-A0A Rear right brake assy

14

3502130-A0A - Right bracket assy., rear brake cam

1

3502026-363 Left brake bracket 1 15 3502120-1H - Oil sealbrake bracket 2 1 3502026-363 Right brake bracket 1

16 3502129D240 Joint bearing-cam shaft

brakcet 2

2 3501396-4E Bush 2 17 3502123-1H - Oil seal,cam shaft bracket 3 3502391-4E Rear brake shoe 2

18 3501156-01 Adjustgasket A

required 4 3502407-4E Friction disc 8 3502205-A0A Left adjust arm assy 1

3502151D240 Rear left brake cam 1 19

3502205-A0A Right adjustarm assy 1 5 3502152D240 Rear right brake cam 1 20 Q5006035 Cotter pin 2

6 3501134-4E Cam gasket 2

21 3502016-1H - Bolt, tighten rear brake bracket

16

7 3502436-4E Return spring 2 22 CQ1500610 - Bolt, dust proof plate 16 8 3502082-4E Brake shoe 4 23 Q40306 Spring washer 16 9 3501086-4E Brake shoe shaft baffle

plate 2

10 CQ1501016 bolt 2 11 Q40310 Spring washer 2 12 3502031D240

Rear brake left upper/right lower dust proof plate

2

13 3502032D240

Rear brake left lowerright upper dust proof plate

2

16

16

17

18

119

108

34

2 4

7

5

1

216

213

151 4

19

20

231 2

22

FIG.27 BRAKE

17

28. BRAKE DRUM


SQ3502565B03D Rear wheel hub assy 2

1 SQ3502571-B03D Rear wheel hub 2

2 SQ3104011-B03D Rear hub 2 3 30621 Inner shaft, hub 2 4 7819E Outer shaft, hub 2 5 W3104045B01D Oil seal, hub 2 6 3104051-4EC1 Wheel bolt 2 7 3103070-4E Wheel nut 20

8 3103071-4E Nut 20

18

76

23

9

4

5

1 8

FIG.28 BRAKE DRUM

19

29. FRAME

No. Part code Part description Qty. No. Part code Part description Qty. 22- 28000010-Q691 Frame and bracket assy. 1 7 2801164-Q210 Right connecting board 1 1 2801082-Q655A Front cross beam 1

Q4501442 - Rivet, tighten connecting board

9

Q4501438 - Rivet, tighten cross beam 12 8 2801162-D76 Cross beam 2 CQ1501435T - Bolt, tighten cross beam 4 Q4501230 - Rivet, tighten cross beam 16 CQ32614 Nut 4 Q4501246 - Rivet, tighten cross beam 4 2 2902442-362 - Right front bracket, front steel leaf

spring 1 9

2801162-D76 Cross beam 2 2902517-242 -

Bolt, tighten front steel leaf spring right front bracket

2 Q4501230 - Rivet, tighten cross beam 16

2902617-242 -

, tighten front steel leaf spring right front bracket

2 Q4501246 - Rivet, tighten cross beam

8

Q4501455 -

, tighten front steel leaf spring right front bracket

3 102801174-Q211 Right connecting board 1

3 2801030-Q691 Right vertical beam and reinforced board assy.

1 Q4501442

- Rivet, tighten connecting board 4

4 2902444-Q801 -

Right bracket., front steel leaf spring lifting ring

1 112806016-01 Hook 1

Q4501240 -

Rivet , tighten front steel leaf spring lifting ring bracket

2 2806018-01 Spring lock piece 1

Q4501450 -

Rivet , tighten front steel leaf spring lifting ring bracket

3 CQ1501670 Hex head neck guide bolt

1

52801134-Q625 Right upper connecting board 2 CQ1511885 Hex head neck guide bolt 1

Q4501240 - Rivet, tighten connecting board 6 CQ34016 Hex nut 1

62801133-Q625 Left upper connecting baord 2 CQ34118 Hex nut 1

Q4501240 - Rivet, tighten connecting board 6 Q40316 Elastic washer 1

20

FIG.29 FRAME

21

29. FRAME No. Part code Part description Qty. No. Part code Part description Qty.

Q40318 Elastic washer 1 15 2801180-Q318 Rear cross beam 1 12

2809092-Q111 Right connecting board 1

Q4501240 - Rivet, tighten rear cross beam 16

CQ1501645 Hex head neck guide bolt 2

16 8500058-01

Lower angle iron, tighten cargo 2

CQ34016 Hex nut 2

Q4501240 -

Rivet, lower angle iron, tighten cargo 4


17 2912443-Q210 -

Rear bracket, rear steel leaf spring 2

13 2809015-Q333

Rear protect cross beam assy

1

Q4501460 -

Rivet, tighten rear steel leaf spring

16

CQ1601435 Hex head bolt 4 18 2801173-Q211 Left connecting board 1

2809013-Q333 -End, rear protect cross beam 2

Q4501442 -

Rivet, tighten connecting board 4

2809014-Q333 - Clip, rear protect 4

19 2913441-116 -

Bracket, auxiliary steel leaf spring

4

14 2809091-Q111 Left connecting board 1

Q4501460

-

Rivet, tighten auxiliary steel leaf spring bracket 16


20 2912441-116 -

Front bracket, rear steel leaf spring 2


Q4501260

-

Rivet, tighten rear steel leaf spring 4

CQ34016 Hex nut 3

Q4501460

-

Rivet, tighten rear steel leaf spring

12

CQ34018 Hex nut

1 21 2801163-Q210 Left conneciting board 1

Q40316 Elastic washer

3 Q4501442 -

Rivet, tighen connecting board 9


22 2801150-Q691 Middle cross beam 1

22

FIG.29 FRAME

23

29. FRAME

No. Part code Part description Qty. No. Part code Part description Qty. Q4501232 -

Rivet, tighen middle cross beam

16 292902441-362

- Left font bracket, front steel leaf spring

1

23 2801130-D79 Middle cross beam assy 1 2902517-242 -

Bolt, tighten front steel leaf spring right front brcket

2

CQ1501240T -

Bolt, tighten middle cross beam assy.

16 2902617-242 -

Nut, tighten front steel leaf spring right front brcket

2

CQ34012 Hex nut 16 Q4501455 -

Rivet, tighten front steel leaf spring right front bracket

3

Q40312 Elastic washer 16 30 2806016-Q417 Insert pin socket 1 24

8500058-01 Lower angle iron, tighten cargo 2

2806011-Q468 Insert pin 1

Q4501240 Rivet 4 Q5005050 Cotter pin 1 25 2902443-Q801 -

Left bracket, front steel leaf spring lifting ring

1 CQ1501450 - Bolt, tighten socket 6

Q4501240 -

Rivet, front steel leaf spring lifting ring bracket 2

CQ34014 - Bolt, tighten socket 6

Q4501450 -

Rivet, front steel leaf spring lifting ring bracket

3 Q40314 - Washer, tighten socket 6

26 2801025-Q691 Left side rail and reinforced panel assy.

1

27 2905411-8E

Shock absorber upper bracket

2

2905888-D96 Cushion panel 2

Q4501244 -

Rivet, tighten shock absorber upper bracket

8

28 2902436-8E Locat e bracket 2 Q4501236 - Rivet, tighen locate bracket 4

24

FIG.29 FRAME

25

30. FRONT STEEL LEAF SPRING


1 2902015-Q101 Front spring assy, lh 1 15 2902471-318 - Pin, front steel leaf spring front bracket (LH) 1

2902020-Q101 Front spring assy, rh 1 16 2902471-362 - Pin, front steel leaf spring front bracket (RH)

1

2 CQ1511275 Bolt 2 17 CQ1511280 Bolt 2 3 CQ1511270 Bolt 2 4 CQ34112 Nut 6 5 Q40312 Elastic washer 6 6 CQ70190 Bent neck lubricating nozzle 4 7 2902471-116 -

Pin, front steel leaf spring lifting bracket 2

8 2902465-1H Front steel leaf spring lifting ring and bush assy. 2

2902466-1H - Lifting ring, front steel leaf spring 2

2912121-03 - Bush, front steel leaf spring lifting ring 2

9 CQ70001 Lubricating nozzle, straight vent 2

10 2902481-1H - Pin, front steel leaf spring lifting ring 2

11 2902406-40B1 - Cover plate, front steel leaf spring 2

12 2902432-40 - Cushion, front steel leaf spring 2

13 2902412-D96F U - U shape bolt, tighten front steel leaf spring 4

14 2902413-03 Nut 8

26

FIG.30 FRONT STEEL LEAF SPRING

27

31. SHOCK ABSORBER


1 2905010-8EA1 Front shock absorberassy 2 17 2905422-8E Washer 2

2 2905416-02 Mounting plate,shock absrober rod 4 18 2905419A-02 Rubber cushion, shock absorber lever 2

3 2905419-02 Rubber cushion,shock absrober rod 2

4 2905421-02 Middle mounting plate, shock absrober rod 4

5 2905411-8E - Upper bracket,front shock absorber 2

2905888-D96 Spacer plate 2

7 CQ35116 Nut 4

8 CQ34124 Nut 2

9 Q40324 Elastic washer 2

10 Q40124 Washer 2

11 2905417-1H Lower connecting pin,front shock absorber rod 2

12 2905433-1H Inner washer,rubber liner 2

13 2905418-1H - Rubber liner,front shock absorber 4

14 2905434-1H Outer washer,rubber liner 2

15 Q40318 Lock washer 2

16 CQ34118 Front shock absorberassy 2

28

FIG.31 SHOCK ABSORBER

29

32. REAR STEEL LEAF SPRING

No. Part code Part description Qty. No. Part code Part description Qty. 2912010-Q210 Left rear steel leaf spring assy. 1 2912471-03 -

Pin, rear steel leaf spring brakcet

2

2912020-Q210 Right rear steel leaf spring assy.

1 CQ1611270 -

Bolt, tighten rear steel leaf spring lifting ring pin

2

2913010-Q210 Auxiliary steel leaf spring assy.

2 2902481-1H -

Pin, front steel leaf spring lifting spring

2

2912406-Q101 - Cover plate, rear steel leaf spring

2 2912473-Q210

Wedge shape lock pin 2

CQ36324T1 - U Nut, tighten U shapr bolt 8 CQ34112 Hex head bolt Hex head bolt 2

2912430-D79 Rear steel leaf spring cushion assy.

2

2912431-01 - Fix plate, rear steel leaf spring cushion

2

2912411-Q210 U - U shapr bolt, tighten rear steel leaf spring

4

CQ1501225 - Bolt, tighten cushion 4 CQ34012 Nut 4 Q40312 Elastic washer Elastic washer 10 CQ70001 Grease nozzle 6 2912473-01 Wedge shape lock pin 2 2912471-03 - Pin ,rear steel leaf spring

bracket 2

2912465-Q402

Rear steel leaf spring lifting ring and bush assy.

2

2912466-Q402 Rear steel leaf spring lifting ring

2

2912121-Q402 - Bush, rear steel leaf spring lifting ring

2

30

FIG.32 REAR STEEL LEAF SPRING

31

33. FRONT AXLE

No. Part code Part description Qty. No. Part code Part description Qty. 3000010G116 Front axle assy. 1 16 Q5510832 Key 3 17 CQ38730 Nut 3 1 3001011-116 Front axle 1 18 Q5006060 Cotter pin 3 2 3001021-Q237 Left steering joint 1 19 CQ38720 Nut 2 3 3001022-Q237 Right steering joint 1 20 Q5004040 Cotter pin 2

4 CQ1500816 Bolt 18 21 3003050-A328 Steering tie rod assy. 1 5 Q40308 Elastic washer 18 22 3001046-12 -

Wedge shape lock pin, steering joint master pin

2

6 3001047-8N -

Cover plate, steering joint master pin orifice


7 3001048-8N -

Gasket, steering joint master pin cover plate

4 24 CQ34014 Nut 2

8 3001026-8N Bush 2 9 917/45.1 ZSV

Taper cone roller bearin g

2

10 3001044-8N Master pin, steeringjoint

2

11 3001042-8N Adjust washer A required

12 3001026-8N Bush 2 13 3001031-8NA2 Left steering joint

arm 1

14 3001032-8NA2 Right steering jointarm

1

15 3001034-Q237 Steering jointupper arm

1

32

FIG.33 FRONT AXLE AND STEERING TIE ROD

33

34. STEERING DRAG LINK

No. Part code Part description Qty. No. Part code Part description Qty. 3003010-Q620 Steering drag link

assy. 1

1 3003016-Q620 Steering drag link 1 2 3003056-8E - Hook, steering tie

rod 2

3 3003060-A1S

Connector assy., steering drag link

2

4 CQ1501255 Bolt 2

5 Q40312 Elastic washer 2 6 CQ34012 Nut 2

34

FIG.34 STEERING VERTICAL ROD

35

35. STEERING COLUMN BRACKET

No. Part code Part description Qty. No Part code Part description Qty.

3403010-240 Steering column bracket and hinge assembly 1

403031-15 Bolt

1

1 3403015-240 Steering column bracket assembly 1 3403032-15 Washer 1

3403011-15 Steering column bracket 1 -6 3403033-15 Lever 2

3403012-15 Right Steering column bracket 1 -7 3403034-15 Pin rivet 1

3403017-15 Clutch pedal location limiting piece 1 -8 3403036-15 Hexical spring 1

Q36406 Welding square Nut 3 -9 3403037-15 Protect board 1

Q36408 Welding square Nut 3 -10 CQ1500612 Bolt 1

3403019-15 Bracket 1 -13 CQ35012 Nut 1

3403021-15 A A plate 1 -14 CQ39606 Hex flange nut 1

3403022-15 B B plate 1 -16 Q40312 Elastic washer 1

3403027-15 Washer 1 -18 Q50110 Lock pin 2

2 3403013-15 A Tube A 1 -19 3403055-15 Steering column support column assy. 1

3403014-15 B Tube B 2 3403056-15 Lever 1

3 3403023-15 Sleeve 1 3403057-15 A A board 1

3403024-15 Sleeve 1 3403058-15 B B board 1

3403026-15 Sleeve 1 -20 3403050-15 Left lever assy. 1

4 CQ1601290 Bolt 2 -21 3403060-15 Right lever assy. 1

5 3403030-15 Bolt and washer assembly 1 3403064-15 Lever 2

36

FIG.35 STEERING COLUN BRACKET

37

35. STEERING COLUMN BRACKET

No. Part code Part description Qty. No Part code Part description Qty.

3403066-15 Washer 2

CQ35112 Nut 2

-22 3403074-15 Hexical spring 1

-23 3403075C116 Sleeve and washer assy. 1

3403076-15 Sleeve 1

3403078-15 Washer 2

-26 3403090-240 Lock handle assy. 1

-27 3403095-15 Washer and locate piece assy. 1

3403096-15 Washer 1

3403097-15 Locate piece 1

-28 3403098-15 Nut 1

-29 Q40208 Washer 1

-30 CQ1480814A Combined bolt 1

-33 3403108-15 Pin rivet 1

-34 3403109-15 Washer 1

38

FIG.35 STEERING COLUMN BRACKET

39

36. STEERING WHEEL AND DELIVERY DEVICE


3404010-15 Steering shaft and transmission shaft assy 1 6 CQ1500514 Bolt 1

1 3404015-15 Steering column tube and bracket assy 1 7 3404032-15 Universal joint fork 1

3404011-15 Lower bracket,steering column tube 1 8 3404031-15 Cross shaft 2

3404013-15 Steering column tube 1 9 3404033-15 Cross shaft oil seal 8 3404016-15 Ignition lock switch bracket 1 10 3404040-15 Neddle bearing assy 8 3404017-15 Support spacer 1 11 3404041-15 Circlip for hole 3404018-15 Steering column upper bracket 1 3404042-15 Circlip for hole 3404019-15 Locking bracket 1 3404043-15 Circlip for hole 2 3404020-15 Steering shaft assy 1 3404044-15 Circlip for hole

As required

3404021-15 Steering shaft lock coller 1 12 3404022-15 Screw plug 2 3404026-15 Steering shaft 1 3404049-15 Gasket 2

3 3404025-15 Upper bearing assy, steering shaft 1 13 3404030-15 Propellor shaft and universal joint assy 1

3404027-15 Bearing support 1 3404034-15 Universal joint fork 1 3404028-15 Outer ring 1 3404039-15 Propeller shaft 1

3404029-15 Roller and retainer 1 14 3404035-15 Slinding bush and unversial joint forkassy 1

4 3404023-15 Lock nut 1 3404036-15 Slinding bush 1 5 180204 Ball bearing,steering shaft 1

40

FIG.36 STEERIGN WHEEL AND DELIVERY DEVICE

41

36. STEERING WHEEL AND DELIVERY DEVICE No. Part code Part description Qty. No. Part code Part description Qty.

3404037-15 Tube 1

29 Q2360425 Cross slot flat round head combination screw 1

3404038-15 Universal joint fork 1

33 3403051-Q447 Steering column lower cover 1

3404054-15 Blank cover 1 34 3403049-15 Dustproof cover 1

15 3404046-15 Boot 1

35 3403062-240 Right steering column cover 1

16 3404047-15 Dust seal ring 1

36 3403061-240 Left steering column cover 1

17 3404048-15 Universal joint fork 1 18 CQ35120 Nut 1 19 Q40120 Flat washer 1 20 Q40420 Spring washer 1

21 3404053-15 Seal cover 1

22 3402010-240A Steering wheel assy (horn button is not included) 1

23 3721015B1-240 Horn button assy 1 24 3402021-15 Elastic pin 1 25 Q1601040 Bolt 2 26 Q1460820 Combined bolt 4



42

FIG.36 STEERING WHEEL AND DELIVERY DEVICE

43

37. POWER REDIRECTOR AND STEERING PIPELINE


-1 3408010-348

Power redirector oil reservoirassy.

13 3403016-362 Redirector bracket

-2 3408016-5P

Power redirector oil reservoir bracket

-14 CQ1512040T Bolt

-3 CQ1500816 Bolt Q40320 Elastic washer Q40308 Elastic washer

-15 3400920-362 Redirector and steering

arm assy.

-4 3406440A382 Oil return tube assy.

3411010-50A Power redirector -5 3406010-Q634 Oil inlet tube assy.

3003041-362 Steering arm

-6 T67420376 Belt -16 3407020-Q101 Power steering pump assy. -7 3406030-362 High pressure hose assy

-17 CQ67527 Worm delivery type hose

clamp

-8 3406022-91 Hollow bolt -18 CQ67535 Worm delivery type hose clamp -9 3406322A8E Combined seal ring -10 3406021-91 Hollow bolt

-11 3406321A8E Combined seal ring

-12 CQ1501655 Bolt

44

FIG.37 POWER REDIRECTOR AND STEERING PIPELINE

45

38. AIR BRAKE SYSTEM AND PIPELINE

No. Part code Part description Qty. No. Part code Part description Qty. 1

Air supply system

1

2 Front shaft brake system 1

3 Rear axle brake system 1

46

FIG.38 AIR BRAKE SYSTEM AND PIPELINE

47

39. AIR SUPPLY SYSTEM


1 3506205-Q655 Front air pipe assy. 1 13 Q40108 Washer 1

2 Q40308 Elastic washer 4 14 3506203-D465 Air hose clip 5

3 CQ34008 Hex nut 4 15 CQ1501230 Hex head bolt 2

4 CQ1500830 Hex head bolt 4 16 3506100-Q691 Air delivery hose assy. 1

5 3506207-4E - Bush, air hose 4 17 3506200-Q691 Air delivery hose assy. 1

6 3506206-05 - Hose clip, air hose 24 18 3506300-Q691 Air delivery hose assy. 1

7 3506123-Q205AH - Bracket, front air hose assy. 24 19 3506260-Q107 Air delivery hose assy. 1

8 3506010-Q377 Air delivery hose assy. 2 20 3513800-Q620AW Air supplu unit assy. 1

9 Q80314 Straight vent connector 3 21 3506210-Q691 -

Air hose, air compressor to air dryer 1

10 Q40312 Elastic washer 5 22 3506030-242 Air delivery hose 2

11 CQ34012 Hex nut 5 23 3506209-1H Bent pipe connector 2

12 3506423-05 Single pipe clip 4 24 CQ35320 Hex flat nut 2

48

FIG.39 AIR SUPPLY SYSTEM

49

40. FRONT AXLE BRAKE SYSTEM


25 3523010-20A Exhaust brake valve assy. 1

38 3518020-X303AW Relay valve and pipe connector assy

1

26 QF1A0502380B Penumatic brake nylon pipe assy. 1

39 CQ1501240 Hex head bolt 4

27 QF1D1401150 Pneumatic brake metal pipe assy. 1

40 3530010-Q403

Diaphragm brake air chamber and pipe connector assy.

2

28 QF1A1201150G Penumatic brake nylon pipe assy. 1

41 3506328-D96F -

Bracket, tighten rearaxle tri-vent pipe connector

1

29 QF1A0807180R Penumatic brake nylon pipe assy. 1

42 3506020-Q6V Air delivery hose assy. 2

30 QF1C0807360EW Penumatic brake nylon pipe assy. 1

43 3506440-Q101 Air delivery hose assy. 1

31 QF1A1201650G Penumatic brake nylon pipe assy. 1

44 3506430-Q101 Air delivery hose assy. 1

32 3506427-Q402 Block 5 45 3506420-Q101 Air delivery hose assy. 1

33 3724115-Q8E Plastic belt assy. 15 46 3506410-Q101 Air delivery hose assy. 1

34 3523010-D603A Pleastic belt 1 47 QF1C0807360EW

Penumatic brake nylon pipe assy. 1

35 3516010-D569E Fast relief valve and pipe connector assy. 1

48 QF1A0807180R Penumatic brake nylon pipe assy. 1

36 3506010-Q126A Hexical protect sleeve assy. 1 49 3506418-Q126A Bent pipe connector 2

37 3518010-X303AW Relay valve and pipe connector assy 1 50 3506020-Q801 Air delivery hose assy. 1

50

FIG.40-1 FRONT AXLE BRAKE SYSTEM

51

FIG.40-2 FRONT AXLE BRAKE SYSTEM

52

41. ELECTRICAL

No. Part code Part description Qty. No. Part code Part description Qty. -1 3732015-362 Fog lamp l.h. assy 1 16 Connector 3 3732020-362 Fog lamp r.h. assy 1 17 3724045-Q691 Frame wiring harness

assy 1

2 3711015-D900 Headlamp l.h. assy 1 18 7901035-50 Speaker assy 2 3711020-D900 Headlamp r.h. assy 1 19 3714030-240 Driver reading lamp assy 2 3 20 7911010-D897 Radio cassette assy 1 4 3721010/20-116 / High /low horn button assy 2 21 3802020-8E

Electronic speedometer sensor

1

5 3720010-Q109 Brake lamp switch assy 1 22 3724050-Q262 Room lamp wiring harness assy

1

6 3704010-D816 Starter switch assy 1 7 3724010C395 Cab wiring harness assy 1 23 3808020-18D Sensor, water temperature

gauge 1

8 3818060-50 Door warning switch assy 1 24 Alternator assy 1 9 3735010-Q710 Combined switch 1 25 Starter assy 1 11 3801010-362 Instrument panel assy 1 26 Air heater 1 27 3810020-18D Sensor, oil pressure gauge 1

13 3725020/30-240 / Cigar lighter insert end and socket assy

1 28 3708020-50A Starter relay assy 1

14 3722010-398Q

Fuse box and relay assy 1 29 3818050-8E Air pressure warning switch

2

15 Washer connecting wire 1 30 3806040-Q235 Sensor, oil meter 1

53

FIG.41 ELECTRICAL

54

41. ELECTRICAL No. Part code Part description Qty. No. Part code Part description Qty. 31 3729050-116

Reverse buzzer assy 1

32 3724185-Q211 -

Wire assy,starter to battery main switch

1

33 3716015-Q325 Combination tail lamp l.h. assy

1

34 3716020-Q325 Combination tail lamp r.h. assy

1

35 3818050-8E Air brake warning switch assy

1

36 3720010-Q109 Brake lamp switch assy

1

37 Reverse lamp switch assy

1

38 3818040-271 Cab tumbler switch assy

1

39 3708020-50A Starting preaheatuing relay assy 1 40 3703010-174 Battery assy 2 41 Connecting wire of heater motor 1 42 3724175-Q191

Wire assy,battery main switch to battery

1

43 Air horn button assy 0 44 Horn shift switch assy 0 45 Center solenoid valve assy with

union joint assy 0

46 Reverse lamp switch

1

48 3721120-398 Horn shift button assy

1

55

FIG.41 ELECTRICAL

56

42. BATTERY

No. Part code Part description Qty. No. Part code Part description Qty. -1 3703010-174 Battery assy,with electrolytic 2 3703020-174 Battery assy,without electrolytic 2

2 3724200-240 Ground wire assy 1 3 3724175-Q191

Wire assy,battery main switch to battery

1

4 3703205-Q101 Battery protection cover 1 5 3724180B1-Q101

Wire assy,connecting battery 1

6 3703015C1-Q101 Battery fix frame assembly 1 7 3703180B1-Q101 Press plate assembly 1 CQ1500820 Bolt, to fix battery 4 CQ34008 Nut 4 Q40308 Spring washer 4 3703025C1-Q101 Front plate assembly 1 3703030-D78 Front lock buckle assembly 2 3703035C1-Q101 Rear plate assembly 1 3703040-02 Rear lock buckle assembly 2 3703044C1-Q101 Bottom board battery fix frame 1

57

FIG.42 BATTERY

58

43. IGNITION SWITCH

No. Part code Part description Qty. No. Part code Part description Qty. - 3704010-D816 Ignition switch assy 1 1 Switch main body 1 2

2 and 4 holes connector 2

3 Key 3 4 Electric harness protection

sleeve 1

5 Tighten bolt 1

7 3704012-50 Harness protection bracket 1

59

FIG.43 IGNITION SWITCH

60

44. COMBINED SWITCH

No. Part code Part description Qty. No. Part code Part description Qty. - 3735010-Q710 Combination switch assy 1 1 Lamp switch 1

3 Self-tapping screw 7 4 Wiper switch 1 5 Main body of combination switch

1

61

FIG.44 COMBINED SWITCH

62

45. HEADLAMP

No. Part code Part description Qty. No. Part code Part description Qty. - 3711015-D900 Head light, lh 1

3711020-D900 Head light, rh 1

1 H1 24V70W 24V70W halogen bulb 4

2 H3 24V70W 24V70W bulb 2

3 R5W 24V5W 24V5Wtiny lamp 2

4 Mirror 2

5 P21W 24V21W 24V21W turning lamp 2

6 174264-2 Insert 2

63

FIG.45 HEADLAMP

64

46. DRIVER READING LAMP

No. Part code Part description Qty. No. Part code Part description Qty. - 3714030-240 Drivers reading light assy 1 1 Drivers reading light switch 2

2 C5W Drivers reading light bulb 2

3 DJ7031Y-3-10 Connector 2

65

FIG.46 DRIVER READING LAMP

66

47. COMBINED REAR LAMP

No. Part code Part description Qty. No. Part code Part description Qty. - 3716015-Q325 Combination tail light

l.h.assy 1

3716020-Q325 Combination tail light

r.h.assy 1

1 R10W 24V. R10W-

24VR10W, for rear side indicator

2

2 P21W 24V 21W

24V 21W bulb,for turn light 2

3 P21W 24V. 21W

24V 21W bulb,for brake lamp

2

4 Reflector 2

5 R5W 24V 5W

24V 5W bulb,for tail light 2

6 P21W 24V. 21W

24V21W bulb,for fog lamp 2

7 P21 24V. 21W

24V. 21W bulb,for brake lamp

2

8 R10W 24V. 10W-+

24V 10W bulb,for side marker lamp and side reflector

2

9 P5W 24V. 5W -

24V 5W bulb,for licence lamp

2

10 174264-2 Plugging connector 2

67

FIG.47 COMBINED REAR LAMP

68

48. FUSE BOX WITH RELAY

No. Part code Part description Qty. No. Part code Part description Qty. - 3722100A395Q

Fuse box assy and relay 1

1 3722010-398Q Fuse box assy 1 2 3711070-240

Relay assy,for wiper 2

3

4 3711030-240 . .

Relay assy,for fog lamp, horn, brake lamp

7

. . Tail lamp, high and low beam

3722011-50 (5A) Slice fuse(5A) 9 3722012-50 (10A) Slice fuse(10A) 11 3722013-50 (15A) Slice fuse(15A) 4

69

FIG.48 FUSE BOX

Fuse box assy.

70

49. CONTROL BOX BOTTOM PANEL WITH CONTROL

No. Part code Part description Qty. No. Part code Part description Qty. - 3722060-Q49

1

Control box bottom panel with controller

1

1 3741060-240 Interval wiper control assy 1

2

Steering assist lighting control assy

1

3 3726030-367 Flasher assy 1

4 3818080-240 Coolant level control assy

1

5 3720030-240 Brake lamp wire control assy

1

6 3750030-240 Preheating control assy

1

7 3722016-367 Control box bottom panel

1

8 CQ2724813 Cross recess pan head self-tapping screw

10

9 Q40105 Washer 10

71

FIG.49 CONTROL BOX BOTTOM PANEL AND CONTROL

72

50. NAMEPLATE


- 3722014-362Y Nameplate, fuse

box 1

73

FIG.50 NAMEPLATE

74

51. CIGAR LIGHTER

No. Part code Part description Qty. No. Part code Part description Qty. -1 3725010-240 Cigar lighter plug

assy 1

3 3725020-240 Cigar lighter socket

assy 1

4 Housing, cigar

lighter socket 1

75

FIG.51 CIGAR LIGHTER

76

52. FOG LAMP

No. Part code Part description Qty. No. Part code Part description Qty.-1 3732015-362 Fog lamp l.h. assy

1

3732020-362 Fog lamp r.h. assy 1

2 H3 Bulb

2

3 Lamp base 2

4 DJ70217-6.3-10 Insert

2

77

FIG.52 FOG LAMP

78

53. DASHBOARD

No. Part code Part description Qty. No. Part code Part description Qty.- 3801010-362 Instrument panel

assy 1

1 Engine tachometer 1

2 Air-pressure gauge 1

3 Speedometer 1

79

H

FIG.53 DASHBOAD

80

54. SIDE TURNING LAMP

No. Part code Part description Qty. No. Part code Part description Qty. - 3726030A109 Side turning light 2

81

FIG.54 SIDE TURNING LAMP

Applied to 357 972 752

82

55. FUNCTION SWITCH

No. Part code Part description Qty. No. Part code Part description Qty.- 3735020B385 Function switch assy

1

1 3721120-398 Horn shift switch 1 2 3726050-398 Hazard warning switch

1

3 3732060-395 Front fog switch 1 4 3732070-398 Rear fog light switch

1

5 AJK-05 Side panel 2 6 AJK-06 Cover plate

9

7 3735022-398 1 Bottom board 1 2

8 3735023-398 2 Bottom board 2 3

83

FIG.55 FUNCITION SWITCH

84

56.FUEL SENSOR

No. Part code Part description Qty. No. Part code Part description Qty. - 3806040-Q235 Fuel sensor assy 1 1 Insert 1 2 Movable float 1

85

1

2

FIG.56 FUEL SENSOR

86

57. AIR PRESSURE GAUGE NYLON PIPE

No. Part code Part description Qty. No. Part code Part description Qty. - 3816030-240

Air pipe assy,air pressure gauge(red)

1

3816040-240

Air pipe assy,air pressure gauge(black)

1

1 3816033-50 Sleeve 2

87

1

FIG.57 AIR PRESSURE GAUGE NYLON PIPE

88

58. POWER RESOURCE DISTRIBUTOR BOX AND ATTACHED EQUIPMENTS

No. Part code Part description Qty

Documents

Manual de partes de Camion FAW CA1161