DW90A (Yuchai Fast Transmission Hande Axle) OM 202201000-En

202201000
DW90A OFF-HIGHWAY
WIDE-BODY DUMP TRUCK
Yuchai Engine / FAST Transmission/ Hande Axle
Operation and Maintenance

Manual
1
January 13, 2022 Contents
DW90A
Contents
Foreword 8.Brake System ............................................... 98
9.Operation Instructions of Rollback Cab Lifting

I. Safety Instructions System .......................................................... 111
1.Safety Precautions ..........................................4 10.Vehicle Axle and Tyre Systems ................ 117
2.Instructions to Drivers .....................................5 11.Maintenance and Service of Suspension Sys-

tem................................................................. 129
3.Restrictions on Service Environment of Vehicle
...........................................................................6 12.Dump Body Lifting System ....................... 143
4.Safe Operation ................................................7 13.Electrical System ...................................... 170
5.Safety Signs ..................................................11 14.Air Conditioning System ........................... 179
II. Product Overview IV. Schedule

1.Outline Drawing of the Vehicle .....................19 1.Tightening Torque of Bolts and Nuts at Import-
ant Parts ........................................................ 183
2.Vehicle Parameters.......................................20
2.Oil Filling Part, Grade and Capacity ........... 184
3.Main Components .........................................21
3. Number and Consumption of Working Medium
4.Main Purpose and Service Environment Re- for Each Assembly......................................... 187
quirements .......................................................23
Index
III. Use of Vehicle
Hydraulic Schematic Diagram ....................... 195
1.Preparation for Driving ..................................24
Schematic Diagram of Electrical System ....... 196
2.Cab ...............................................................29
Schematic Diagram of Brake System ............ 197
3.Electrical Layout of Instrument Panel ...........44
4.Maintenance of Engine and Its Auxiliary System

.........................................................................56
5.Transmission.................................................69
6.Clutch and Its Control Parts ..........................77
7.Steering System............................................87
2
Contents January 13, 2022
DW90A
3
January 13, 2022 Foreword
DW90A
Foreword
Dear customers, welcome to use our DW90A series wide-body dump truck.
This Manual is hereby prepared to help you properly operate the vehicle. It details technical parameters
and structural performance of the wide-body dump truck and its assemblies, sets forth operation and
maintenance requirements, gives a list of analysis of common faults and corresponding troubleshooting
methods, and briefly introduces basic removal, installation and commissioning methods. This Manual is
a practical technical document for drivers and maintenance personnel of the wide-body dump truck. To
observe operation and maintenance requirements specified herein is an important condition for
operating the vehicle properly.
Dear customers, your familiarity with the wide-body dump truck and the degree of your maintenance
determine the economic benefits of the wide-body dump truck. For the purposes of better use of the
vehicle and prevention of accidents, we kindly ask you to carefully read this Manual and operation
instructions of engine, and strictly abide by the requirements and regulations specified herein.
For the operation and maintenance of engine from Xi’an Cummins Engine Co., Ltd., Fast transmission
and Hande axle, please refer to corresponding accompanying data.
In case of any quality problems in the normal use of the product during the warranty period, please feel
free to contact our After-sales Service Center for warm and thoughtful services.
This Manual shall be kept in a safe and clean place allowing convenient read and use by operators.
Make sure that this Manual is in good condition. The vehicle shall always be accompanied by this
Manual when being resold or leased.
Please do not use the vehicle for any other purposes except those described in this Manual. If you want
to refit the vehicle or equip the vehicle with other special equipment to meet your special requirements,
please contact your dealer for confirmation; otherwise, you will be liable for all consequences caused by
unauthorized modification.
Liugong will provide users with full "three guarantees" if they operate and maintain the vehicle according
to instructions in this Manual. However, in case of any misuse or intentional operation of the vehicle for
any other purposes except those specified by the manufacturer, the "three guarantees" will become
invalid and on-site maintenance may be rejected. Only trained or experienced personnel are allowed to
operate the vehicle and only professionals to inspect and maintain the vehicle.
Product model, code of product series, code of engine series and code of main components shall be
correctly recorded, since these codes are the important basis for reporting to the judiciary authorities for
tracing in case of stealing. In addition, your dealer also needs these codes to provide you with status of
relevant machines or ordering of parts. If this manual is attached in the machine, you are required to
record these correct codes in a safety place beyond the machine.
Liugong reserves the rights to modify and revise this Manual without prior notice. We appreciate your
understanding! In case that any data, illustrations and text in this Manual are inconsistent with the actual
product, the actual product shall prevail.
Guangxi LiuGong Machinery Co., Ltd.
Liugong (Changzhou) Mining Machinery Co., Ltd.
4
I. Safety Instructions January 13, 2022
1. Safety Precautions DW90A
I. Safety Instructions
1.Safety Precautions
This section covers safety precautions and warnings for the wide-body dump truck. Before operation,
maintenance and repair of the vehicle, please carefully read and understand this Manual in detail, strictly
abide by all safety precautions and warnings, and carefully maintain the vehicle, to reduce faults, prolong
the service life of the vehicle, and avoid vehicle accidents and personal injuries.
Most accidents related to product operation, maintenance and repair are caused by ignorance of basic
safety rules or maintenance rules and measures. Your familiarity with all relevant rules before operation
of the vehicle can help you avoid the occurrence of an accident.
As it is impossible for Liugong to predict all potential accident hazards that may occur during operation
and maintenance, safety measures in this chapter are incomplete. If you take actions that are not
proposed or allowed herein during operation or maintenance, please make sure that you and others can
implement these actions safely. If you are not sure about some safety measures, please contact the
After-sales Service Center of Guangxi LiuGong Machinery Co., Ltd. or your dealer.
Do not lengthen, widen or heighten the dump body or lengthen the wheel base without authorization.
Any changes to the vehicle must be subject to Liugong's approval; otherwise, Liugong will not bear any
responsibility. Please refer to the Quality Assurance Manual for the handling of quality problems.
5
January 13, 2022 I. Safety Instructions
DW90A 2. Instructions to Drivers
2.Instructions to Drivers due to falling during running of the vehicle.

Observe the Surrounding Environment before
Driving
Only personnel with driving license or equivalent
driving skills can operate the vehicle.
Do not operate the vehicle if you feel unwell, take
drugs that can cause sleep, or drink alcohol, as
operation in such a case will affect your
judgment and may lead to an accident.
No Drunk Driving
P1T000003
37
Check for any Objects on the Platform before
Driving
P1T000001
37
When working with another operator or with
traffic police on the work site, make sure that all
the staff can understand all your hand signals.
Operation based on Staff's Hand Signals P1T000004
37
P1T000002
37
Before getting on the vehicle, check the vehicle
for any abnormalities such as oil leakage, water
leakage, air leakage and looseness of bolts, and
eliminate such abnormalities (if any) to avoid the
occurrence of faults or even serious accidents.
Check whether there are people, animals or
obstacles around or below the vehicle to avoid
causing harm to other people/objects.
Do not place any inflammables on the
supercharger, exhaust pipe, muffler, radiator or
preheating pipe of the dump body to avoid a fire.
Make sure that articles (if any) are securely
placed on the working platform to avoid damage
6
3. Restrictions on Service Environment of Vehicle DW90A
3.Restrictions on Service According to the technical parameters in

"product information", please do not overload.
Environment of Vehicle The maximum slope shall be 20% and the
minimum turning radius shall not be more than
During operation, investigation on topography, 11 m at rated load. Please drive the vehicle on
landform and geology of work site shall be the roads satisfying relevant conditions and keep
conducted. The vehicle shall, where possible, a safe distance. The vehicle shall run at a low
not run on roads near cliff edges, soft roads or speed on an icy or muddy road, as tires are easy
uneven roads. Attention shall be paid to weather to skid, easily causing the vehicle out of control.
changes. Appropriate fuel oil, engine oil and Pay Attention to Road Slope Change
lubricating oil shall be used based on the change
of ambient temperature.
Do not Run in a Dangerous Area Where Possible
P1T000007
37
Pay Attention to Icy Pavement
P1T000005
37
Operate the Vehicle based on Environmental
Changes
P1T000008
37
P1T000006
37
7
DW90A 4. Safe Operation
4.Safe Operation In case of poor road conditions and unstable

materials, the vehicle shall be operated and
driven with care to avoid instability of loaded
Sudden braking, rushing, sudden steering at materials and the whole vehicle.
high speeds and zigzag driving are prohibited in
the course of normal driving. When the vehicle is running, the dump body
must be lowered to the lowest position,
During cross running or change of driving particularly when passing by HV lines, bridges
direction on a ramp, please take care as the and other buildings as well as narrow roads, to
center of gravity of the vehicle will change in this prevent product and personal accidents.
case. During driving on a ramp under full load,
sudden braking is not allowed. Do not release Loaders, excavators or electric shovels shall be
the clutch or take a sharp turn when going kept as low as possible at the time of loading.
downhill. This is because that the service life of the bottom
plate of the dump body depends on the impact
High-speed driving, sharp turn or sudden braking degree of loading to a great extent.
on slippery roads (icy or smooth roads) shall be
avoided. Auxiliary devices such as retarder and The bucket shall align with the dump body at the
exhaust brake (if any) shall first be used for time of loading to prevent damage to the frame of
braking where possible, and a "stab braking" the dump body caused by electric shovel.
mode shall be used to prevent wheel lock. No Driving before the Dump Body Completely
Falls Onto The Truck Frame
The clutch must be released for gear shifting;
otherwise, parts in the transmission will be easily
damaged!
No Sudden Braking or Sudden Steering at High
Speeds
P1T000011
37
Aligning the Bucket with the Dump Body Where
Possible
P1T000009
37
Pay Attention to Rollover on Road
P1T000012
37
P1T000010
37
8
4. Safe Operation DW90A
When the vehicle dumps materials, its center of Clean the Vehicle before Leaving
gravity will change continuously, and the ground
conditions will affect the stability of the vehicle. In
this case, it is dangerous to perform operation on
soft roads or operation if there are materials
sticking to the dump body.
During unloading of the dump body, it is strictly
prohibited from knocking the bottom plate of the
dump body back and forth.
During unloading of the dump body, the P1T000014
exposure time of the lifting cylinder to the air 37
shall not exceed 30 min. Do Not Leave the Cab or Knock the Dump Body
during Dumping
After unloading, it is strictly prohibited from

driving the vehicle before the dump body
completely falls onto the truck frame.
At the time of stopping the vehicle, the dump

body must be kept at the lowest position and the
lifting lever in the middle position, with the power
take-off disconnected, the parking brake pulled P1T000015
up, the engine shut down and the key removed. 37
It is better to park the vehicle on a horizontal Please Keep Clear of the Vehicle during
ground with the transmission lever at the neutral Dumping
position. Tires shall be wedged to park the
vehicle on a slope if required. The transmission
lever shall be pulled to the R position to park the
vehicle on a downhill slope and to the first gear
position to park the vehicle on an uphill slope.
The vehicle shall be cleaned before leaving.
Confirm that the Vehicle is Still before Leaving
P1T000016
37
During inspection and maintenance, the vehicle
must be securely fixed to avoid accidents.
P1T000013
37
9
DW90A 4. Safe Operation
No open flame is allowed during inspection at

dark places. Pay Attention to Personal Protection during
Fix the Vehicle Properly during Inspection and Welding near Tires
Maintenance
P1T000019
37
P1T000017
37 Inspection of Tire from the Side
No Open Flame during Inspection at Dark Places
P1T000020
37
P1T000018
37 When the dump body is lifted for maintenance of
During welding repair of the vehicle, the main components under the dump body, the dump
power switch shall be turned off. body support rod must be lowered to the position
allowing safe support. After maintenance, the
Special attention shall be paid to possible support rod must be restored to its original
explosion of tires during welding near the tires. position.
Inspection of tires shall be conducted from the
sides instead of the forward and backward
rotation direction of tires.
Maintenance or replacement of tires shall be
conducted by specialized maintenance
personnel as this operation may cause hazards.
Inspection of batteries and other electrical
systems shall be conducted with care.
10
4. Safe Operation DW90A
Asbestos Danger
Breathing asbestos dust can be hazardous to

your health. Equipment and replacement parts
shipped from Liugong have no asbestos in them.
Liugong recommends the use of genuine factory
spare parts only. Observe the following rules if
you are handling any spare parts that contain
asbestos or asbestos fibers:
● Never use compressed air to clean up
asbestos. Use a wet method in order to clean
up asbestos materials. Water the area down
to clear asbestos dust.
● A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
can also be used.
● Do not grind materials that contain asbestos.
● Operate the machine on the windward side of
the asbestos as far as possible.
● Obey environmental regulations for the
disposal of asbestos.
● Shower after contact with asbestos.
Wear an approved respirator if there is no other
way to control the dust.
11
DW90A 5. Safety Signs
5.Safety Signs
5.1Positions of Safety Signs
There are some safety signs on the vehicle. This section covers the pasting positions of these safety
signs and potential hazards indicated by these safety signs. Please take some time to get familiar with
these safety signs.
Positions of Safety Signs on DW90A (48Y1499 Sign Group)
12 13 14 15 35 27
20 21
23 24 25 26
33
17 P1TM00075
12. Caution sign 21. Safety sign 27. Sign

13. Safety sign 23. Sign 30. Refueling safety sign
14. Anti-winding sign 24. Sign 33. Sign indicating protection against
15. Sign 25. Safety sign hydraulic oil scald
17. Caution sign 26. Sign for caution before operation 35. Safety sign
20. Safety sign
12
5. Safety Signs DW90A
Positions of Safety Signs on DW90A (48Y1499 Sign Group)

3 8 9 10
P1TM00077 P1TM00076
3. Safety sign 9. Sign

8. Sign 10. Sign
5.2Description of Signs
3.Safety sign
Hot pressure liquid. As a result of high-boiling, coolant will
become hot or generate steam, burning the hands of
operating personnel at the time of opening the tank cover.
The sign is used to remind operating personnel of stopping
the engine first to allow the radiator to cool down, and then
slowly unscrewing the cover to release pressure.
74A3180
8.Sign
Position indication of fire extinguisher.
74A2875
13
9.Sign
Always lock adjusting lever after adjustment of steering
console.
74A3393
10.Sign
1. When the body is lifting , the vehicle must be parked on
a flat road, make sure the vehicle in the neutral and the
parking brake is working.
2. While the vehicle is in motion , make sure the lifting
handle is in the neutral position and lifting operation is
forbade.
3. While the body is falling, be sure that the lifting handle
can be put into the neutral position after it is held in
descending position for 15 seconds after the body is in
place.
4. When the vehicle is in the lifting state, the safety pole
must be put up before inspection and maintenance
under the body.
79A5598
12.Caution sign
Whenever mounting or dismounting machine, face
machine and maintain 3 points of contact.
Never jump from machine. Ensure steps are clean.
74A4508
14
13.Safety sign
An engine fan blade may cut fingers, so a safe distance
shall be kept or the engine shall be shut down during
maintenance.
74A3161
14.Anti-winding sign
ENTANGLEMENT HAZARD
Keep clear or stop engine before servicing.
74A3171
15.Sign
A safe distance shall be kept as the wheel may squeeze
the body during steering.
79A0145
15
17.Caution sign
Before starting the vehicle,please ensure that the stop
valve is in open state to avoid damage to the pump.
79A6629
20.Safety sign
Fumes given off by batteries are combustible.
Keep flame and sparks away, do not store tools or metal
objects near batteries.
Risk of explosion if metal objects cause a short circuit.
Sulphuric acid contained in batteries is poisonous, do not
allow acid to contact skin, clothing or your eyes.
If you spill acid on yourself, immediately:
●Flush your skin with water
●Apply a neutralizing agent such as lime
●Flush eyes with water for 10-15 minutes Immediately
seek medical attention.
74A3188
21.Safety sign
HP pipelines shall be subject to pressure relief before
maintenance to avoid personal injury caused by HP liquid.
74A3170
16
23.Sign
Avoid damaging electronic components when welding:
●Place machine on level ground and engage parking
brake.
●Shut off engine and turn off battery main switch.
●Remove electrical connectors from transmission, engine
control units and instrument panel plug.
74A2840
24.Sign
Do not clean inside of cab with water under pressure, or
electrical component damage will occur.
Prevent loss of electrical power, and turn off battery main
switch when machine is shut down or being parked
overnight.
74A3235
25.Sign for caution before operation

Please read the operation instructions carefully before
operating the vehicle.
74A3080
17
26.Safety sign
Drivers must wear seat belts when driving.
74A4317
27.Sign
Personnel behind the vehicle are in danger of squeezing
when the vehicle moves backward.
74A7707
30.Refueling safety sign

FUEL TANK
For fuel tank filling or fuel system maintenance, smoking is
prohibited, with spark and open flames being kept away.
Fuel filling must be implemented with engine off and in the
open air.
74A3081
33.Sign indicating protection against hydraulic oil scald

HYDRAULIC TANK
Relieve tank pressure. With engine off, remove cap slowly
to prevent burns from hot oil.
74A3093
18
35.Caution sign
Personnel are in danger of crush when maintaning
carriage.
79A6628
19
January 13, 2022 II. Product Overview
DW90A 1. Outline Drawing of the Vehicle
II. Product Overview
1.Outline Drawing of the Vehicle

Rollback Cab (Right-hand Drive)
P1TM00074
Fixed Cab
P1TM00083
20
II. Product Overview January 13, 2022
2. Vehicle Parameters DW90A
2.Vehicle Parameters
The specific parameters shall be subject to the parameters on the certification and
nameplate. The parameters provide below are for common models:
Item Parameter
Product model DW90A
Gross vehicle weight (kg) 90000
Curb weight (kg) 31000
Payload mass (kg) 59000
Rectangular
30/36
bucket 1
Container volume paperback/ stack (m3) Rectangular
32/38
bucket 2
Tail bucket 30/35
Rollback Cab 9075 × 3450 × 4385
Overall dimensions (L×W×H) (mm)
Fixed Cab 9170 × 3450 × 4385
Wheel base (mm) 3800+1550
Front 2765
Tread (mm)
Rear 2500
Front overhang (mm) 1760
Rear overhang (mm) 2060
Approach angle (°) 32
Departure angle (°) 43
Maximum speed (km/h) ≥ 36
Maximum gradeability (%) ≥ 35
Maximum tractive force (kN) ≥ 420
Minimum turning diameter (m) ≤ 22
Minimum ground clearance (mm) ≥ 372
Axle load (t) 20/35/35
Engine model Yuchai YC6K480-GT30
Engine power (kW) Yuchai 353
430 diaphragm spring clutch, pneumatic control
Clutch model
and power-assistance
7th gear 7DS220 mechanical transmission
Transmission model 8th gear 8DS240 mechanical transmission
Automatic 4800 ORS
Hydraulic retarder Optional FH400B
7th gear 7 forward, 1 reverse
Gear 8th gear 8 forward, 1 reverse
Automatic 7 forward, 1 reverse
21
DW90A 3. Main Components
3.Main Components
(1) Frame
Integrated Flexible Frame
P1T000043
(2) Engine, transmission and drive axle

Yuchai engine YC6K480-GT30
P1TP00060
1. Here is the engine number.

22
II. Product Overview January 13, 2022
3. Main Components DW90A
Transmission
1
P1TT00044
1. Here is the transmission number.
Reinforced Integrated Frame for Mining Area
Front axle
P1T000046
1. Here is the front axle number.
Intermediate axle
P1T000047
1. Here is the intermediate axle number.

23
DW90A 4. Main Purpose and Service Environment Requirements
Rear axle
P1T000048
1. Here is the rear axle number.
4.Main Purpose and Service Environment Requirements
The vehicle is applicable to the transportation of surface soil stripped from open-pit coal mines, large
sand and gravel mines, small and medium-sized non-ferrous metal mines, cement mines, gem mines
and other earthworks and loose materials.
Although the vehicle is an off-road vehicle, the slope of road shall not be greater than 20% and the
turning radius shall be greater than 11 m. In cold season, the vehicle shall be filled with corresponding oil
as required.
24
III. Use of Vehicle January 13, 2022
1. Preparation for Driving DW90A
III. Use of Vehicle
1.Preparation for Driving
Keep the vehicle in good condition. Do not drive the vehicle with faults.
1.1Preparations
Preparations before driving mainly includes: start and stop of the engine and routine inspection before
driving.
1) Turn on the main power switch to power on the vehicle;
2) Check the operating conditions of the whole circuit system. After the key switch is turned on (the key
switch is at the "ON" position), all instruments are in normal indication.
3) Inspection of oil and fluids of the vehicle
a. Inspection of engine oil: Park the vehicle on a flat ground and then pull out the oil dipstick before
starting. The upper end of the oil stain shall lie between MAX and MIN. If it is higher than MAX,
drain oil; otherwise, inject oil. If the engine has been started, this inspection shall be conducted 15
min after the stop of the engine.
b. Inspection of coolant: Start the engine and switch on the air heater to run for 2 min. At this
moment, the engine water temperature shall be 50±5°C and the coolant level shall vary between
MAX and MIN. If the level is lower than MIN, it needs to inject coolant.
Coolant shall be injected when the engine is idling after pressure relief through the pressure relief valve.
It is strictly prohibited from injecting coolant when the engine is at high temperature.
c. Fuel inspection: Observe the fuel indicator light on the instrument when the engine is started, and
inject a proper amount of fuel based on the performance and operating requirements of the
engine. Fuel must be injected if the fuel level is lower than 1/8.
d. Brake fluid inspection: Conduct inspection after air is exhausted from the clutch system to ensure
the brake fluid level between MAX and MIN.
e. Windshield washer fluid inspection: Visually observe the windshield washer fluid level which shall
vary between MAX and MIN. If the level is lower than MIN, it needs to inject windshield washer
fluid.
25
January 13, 2022 III. Use of Vehicle
DW90A 1. Preparation for Driving
f. Hydraulic oil inspection: Park the vehicle on a flat ground, lift the dump body 5 times consecutively
and then shut down the engine. After 15 min, check the oil dipstick of the hydraulic oil tank to
ensure the oil level between MAX and MIN. If the level is lower than MIN, it needs to inject
hydraulic oil. Do not inject hydraulic oil of different brands!
4) Check for water in the brake air reservoir. When the vehicle is stationary, pull down or push up the
exhaust valve to remove water from the air reservoir. If there is any oil-water mixture is discharged,
it indicates that the desiccator has failed and shall be replaced immediately.
5) Check the tire pressure. In case of insufficient air pressure, inflate tires with special tools.
6) Leakage inspection: After the vehicle is started, check for any leakage of lubricating oil, coolant and
air lines.
7) Air intake system of engine
a. Check the prefilter for any blockage by foreign matters.
b. Check for any breakage of the pipeline between the supercharger inlet and the air filter outlet, and
if any, replace the pipeline in time.
c. Before the vehicle starts to run, check for any people or other obstacles around the vehicle.
1.2Start of Engine
Turn the key switch to the "ON" position to start the engine.
Do not turn off the key switch while the vehicle is running!
1) Starting process: Push the transmission shift lever to the neutral position, press the clutch pedal,
and then turn the key switch to "START" to start the engine.
If the start of the engine fails, push the key back to "ACC" for restarting. If the engine still cannot
be started within 5~10 sec, wait for 1 min and then repeat the above operation. If the start of the
engine fails 3 times consecutively, stop starting, find out and repair faults before start. After start,
idle the engine for a few minutes, and then slowly increase the speed to 1,000~1,2000 r/min for
running with partial load. Full-load running of the engine is allowed only when the water
temperature is higher than 60°C and the engine oil temperature higher than 50°C!
2) Inspection of engine oil pressure after start

After the engine is started, observe the pressure value indicated by the pressure gauge. The engine oil
pressure indicator light shall be off.
Do not allow the engine to run at high speed in a cold state. Instead, idle it for 2~3 min first. If the
engine oil pressure gauge has no indication, shut down the engine immediately for inspection.
26
3) Shutdown of engine
After the vehicle is parked, shut down the engine and turn off the main power switch.
After heavy-load operation, the engine shall be shut down after idling for 2~3 min.
1.3Start and Shift
Users shall operate the vehicle in strict accordance with the instructions and bear all
consequences arising from violations of regulations!
27
DW90A 1. Preparation for Driving
1.3.1Start
In case that there is a low air pressure alarm or the alarm buzzer sounds after the engine is started, the
whole vehicle cannot be started. The handbrake can be released to start the vehicle only when the air
pressure reaches 0.55 Mpa and all alarm lights and buzzers are off.
All DWA90 series vehicles must be started at 1st gear!
1.3.2Shift
Refer to "5.4 Control and Precautions for Transmission" on page 74 for operation details.
1.3.3Differential Lock
Refer to "10.2.2 Use of Inter-axle Differential Lock" on page 118" for operation details.
1.3.4Lifting and Falling of Dump Body
Refer to "12.3. Lifting Steps" on page 155" for operation details.
1.3.5Use in Low-temperature Environment
a. Engine cooling system

Refer to "4.6.2 Filling of Coolant" on page 64" for operation details.
b. Battery
Refer to "13.2 Battery" on page 170" for operation details.
c. Starting system
At low temperature, the engine shall be started by means of auxiliary starting device.
d. Stop
During stop in cold weather, the vehicle shall be unloaded first and then run at idle speed for 2~3 min,
and finally be stopped after the water temperature and oil temperature drop. It should be noted that
coolant containing antifreeze additive shall not be drained after stop of the vehicle. If there is no
antifreeze additive in antifreeze, drain valves or water plugs of engine oil cooler cover, radiator and water
inlet pipe on the body must be opened.
28
1.4Run-in of New Vehicle
1 The running-in mileage of a new vehicle shall be 1,000~2,000 km.

During the running-in period, the vehicle shall be loaded as per 70% of the volume of the dump
2
body.
Do not slam on the accelerator during the running-in period of new vehicle. Meanwhile, the
3 stroke of the accelerator pedal shall be strictly controlled to prevent the engine from running at
Run-in of new high speed.
vehicle During running on an uphill slope, it is necessary to shift to a low gear in time and the engine
4
shall not run at very low speed.
During running, timely shifting and smooth engagement of clutch are required to avoid sudden
5
acceleration and emergency braking.
Regularly check the engine, clutch and transmission for overtemperature or noise and other
6
abnormalities. In case of any abnormalities, find out the causes in time and eliminate the faults.
1 Clean the engine air filter element.
Clean the engine lubrication system and replace the lubricating oil and the filter elements of fine
2
and coarse filters.
3 Check and tighten the bolts of cylinder head and intake and exhaust pipes.
4 Check and adjust the tightness of fan and generator belts.
5 Re-tighten the connecting bolts of the engine and transmission.
6 Tighten the flange bolts of drive shaft.
7 Check and adjust the free stroke of clutch pedal.
Maintenance 8 Remove water and dirt accumulated in the air reservoir.
after running-in
Check the sealing conditions of brake lines and their connections, and where necessary, adjust
9
and tighten them; eliminate air leakage of brake lines.
Check and adjust the technical conditions of front axle steering mechanism;
Check and adjust steering tie rods and drag links to eliminate possible gaps between the rods/
10
links;
Tighten relevant bolts and nuts of the steering mechanism.
Check and tighten all bolts and nuts of the suspension system, particularly U-bolts and nuts of
11
the front and rear suspensions and connecting bolts and nuts of the thrust bar.
Check whether the connectors of battery and other electrical circuits are firmly connected and
12
whether all lights and meters operate normally.
29
DW90A 2. Cab
2.Cab
2.1Operation of Door
Do not drive the vehicle with the doors not closed!
2.1.1Opening/Closing of Doors from Outside
Opening of door: If the door is unlocked, pull the handle outwards to open the door; if it is locked, insert
the key and turn 180° clockwise, and then pull the handle outwards to open the door.
Closing of door: Directly push the door to engage with the cab tightly.
Locking of door: After closing the door, insert the key and turn 180° counterclockwise, and pull out the
key. Alternatively, before closing the door, insert the key and turn 180°, and then close the door. After the
door is locked, the door cannot be opened by directly pulling the exterior handle of the door.
2.1.2Opening/Closing of Doors from Inside
Opening of door: Pull the interior release handle inside the cab and then push it outwards to open the
door.
Closing of door: Pull the interior handrail to pull the door inwards to close the door.
Door Lock (Rollback Cab)
4
P1TC00007
1. Door lock and key 3. Interior handrail

2. Exterior handle 4. Interior handle
30
2. Cab DW90A
Door Lock (Fixed Cab)
4
1
P1TC00105
1. Door lock and key 3. Interior handrail

2. Exterior handle 4. Interior handle
31
DW90A 2. Cab
2.2Access Door
2.2.1 Access Door of Rollback Cab
Access Door Lock
1 P1TC00008
1. Access door lock
Opening of access door: An access door lock is installed under left and right side of the front LOGO on
the cab, and the access door can be opened by turning 90°C anticlockwise and pulling the door lock
handle outwards.
Closing of access door: Press down the access door and turn it 90°C clockwise to lock it..
Do not close the access door with too much force. Make sure that personnel are far away from
the moving range of the access door to prevent from being pinched by the access door.
32
2. Cab DW90A
2.2.2 Access Door of Fixed Cab
1
P1TC00107
1. Access door lock 2. Grab handle
Opening of access door: Turn the access door lock to 90°, and pull the grab handle outward to open the
access door.
Closing of access door: Pull the access door down, close the access door with appropriate force, and
turn the access door lock to the level.
33
DW90A 2. Cab
2.2.3 Engine Hood Access Door of Fixed Cab
P1TC00106
1. Pull-locks 2. Valve support 3. Hood access door
Opening of hood access door: Mount the platform, open the two pull-locks on the side of the platform,
and lift the hood access door upward to the maximum stroke of the fixed valve support of the hood
access door.
Closing of hood access door: Operate in the reverse of opening the hood access door.
Do not close the access door with too much force. Make sure that personnel are far away from
the moving range of the access door to prevent from being pinched by the access door
34
2. Cab DW90A
2.3Left and Right Rearview Mirrors
Rearview Mirror (Rollback cab)
P1TC00010
Rearview Mirror (Fixed cab)
P1TC00108
Press the rearview mirrors for adjustment up and down, left and right. When adjusting the main rearview
mirror of door and platform, open the rearview mirror protective cover, loosen four bolts to adjust the
angle, and then tighten the bolts in place.
When adjusting the rearview mirror at the door side, ensure that the distance between the upper and
lower mirrors is 40±5 mm, and the lower mirror is 100 mm above the bend of the bracket. Press the
rearview mirrors for fine adjustment up and down, left and right.
Do not adjust the viewing angle by adjusting the rearview mirrors with hands. If adjustment is
required, loosen fastening bolts of the rearview mirrors for adjustment and then tighten the bolts.
Make sure that all fastening bolts are securely fastened without looseness. Alternatively, the
angle of mirror glass can also be adjusted for adjustment of viewing angle.
35
DW90A 2. Cab
2.4Seat and Seat Belt
The seat of the vehicle can be adjusted back and forth, up and down, and the backrest angle can also be
adjusted, with the adjustment method as shown in Fig. The seat belt is integrated on the cab.
Driver's Seat
6
3
4
P1T000053
1. Headrest 3. Forward/backward height 5. Damper locking handle

2. Backrest angle adjustment handle adjustment handle of seat 6. Forward/backward adjustment
4. Stiffness adjustment handle handle
(1) Headrest height adjustment

Adjustment method:
a. Pull the adjustment button and press down the headrest to the required position, and then release
the button;
b. Pull the headrest upwards to the required position.
Adjustment range: 3 adjustment positions, 25 mm at each position, totaling 75 mm in adjustable range.
(2) Elevation adjustment of backrest
Adjustment method: Pull the backrest adjustment handle upwards to turn the backrest to the required
angle and then release the handle.
Adjustment range:
36
2. Cab DW90A
a. 0~80° backwards relative to the vertical line;

b. 41° forwards relative to the vertical line.
(3) Height adjustment of front and rear ends
Adjustment method: Pull the height adjustment handle downwards, and then apply appropriate force to
the upper or lower surface of the front (rear) end of the seat cushion to lift down or up the front (rear) end
of the seat cushion to the required position, and then release the handle.
Adjustment range: 60 mm for the height of the front end and 60 mm for the height of the rear end, and
±12° for the inclination of the seat cushion through adjustment of both front and rear ends.
(4) Stiffness adjustment
Adjustment method: Rotate the hand wheel to adjust the preset force to the required value based on
road conditions and driver's weight. Do not turn the red pointer to the range of less than 40 and greater
than 130.
Adjustment range: 40~130 KG
(5) Damper locking
Adjustment method:
a. When the handle is vertical, there is hydraulic damping action on the seat.
b. Turn the handle counterclockwise and apply appropriate force to the seat downwards. The seat is
fixed when the handle is locked.
c. In case that the damper spring fails, it needs to lift up the seat. In this case, operate as per b to
realize two-position locking of the seat height.
(6) Forward/backward position adjustment (optional)
Adjustment method: Pull the handle upwards to move the seat forwards (backwards) to the required
position, and then release the handle.
Adjustment range: 0~±100 mm (10mm×20)
(7) Fastening of seat belt: Pull the seat belt buckle latch, wrap the seat belt around the shoulder, and
then insert the buckle latch into the buckle until a sound of engagement is heard.
(8) Unfastening of seat belt: Press the red button on the seat belt buckle in the direction of arrow and
press the buckle latch to automatically restore the seat belt to its original position.
37
DW90A 2. Cab
Driver's Seat Belt (Rollback cab)
P1TC00009
Driver's Seat Belt (Fixed cab)
P1TC00104
1. Safety belt
Please fasten your seat belt before driving! Check the status and function of the seat belt every
day.
38
2. Cab DW90A
2.5Steering Wheel and Steering Column
The steering wheel can be adjusted up and down, front and back, with the range of 2.5°for forward/
backward adjustment and 25 mm for upward/downward adjustment.
Use of handle: When a driver sits on the seat, pull the handle counterclockwise to adjust the angle or
length of the steering column to the position convenient for the driver to operate the steering wheel, and
then pull the handle clockwise (i.e. in the opposite direction) to lock the steering column.
Schematic Diagram for Adjustment of Steering Column
P1T000055
1. Steering column adjustment handle

39
DW90A 2. Cab
2.6Internal Devices in Cab
Internal Layout Plan of Rollback Cab
1
2
3 P1TC00102
P1TC00101
40
2. Cab DW90A
6 8 9 10
11 P1TC00013
P1TC00014
12 13 P1TC00012
41
DW90A 2. Cab
P1T0000058
14
1. Front passenger's seat armrest 6. Safety hammer 11. Fire extinguisher

2. Storage compartment 7. Top box 12. Glove box
3. Brake handle 8. Sun visor 13. Fuse box
4. Brake pedal 9. Sun visor reset rope 14. Windshield washer fluid filler
5. Accelerator pedal 10. Cup holder
(1) Front passenger's seat armrest: a person on the front passenger's seat can hold the armrest to
ensure the stability of the body.
(2) Storage compartment: place mobile phone and other common things.
(3) Brake handle: on the left of the steer wheel. It is used after the vehicle stops to prevent slipping. Push
the handle forward to travel the vehicle, push the handle backward to park the vehicle.
(4) Brake pedal: the first one on the right of the steering gear, which is pressed when needs to reduce
the speed of vehicle or stop the vehicle.
(5) Accelerator pedal: the second one on the right of the steering gear, which is used when the vehicle
needs to accelerate or increase the engine rpm during driving.
(6) Safety hammer: on the beam column inside the right window of the cab. It is used to break the glass
in emergency access to the right glass passage.
(7) Top box: on the top left side of the cab.
(8) Sun visor: directly in front of the cab. It can be pulled down to any position as required.
(9) Sun visor reset rope: at the side of sun visor. The sun visor returns to the top end by pulling the reset
rope.
(10)Cup holder: for placing bottles or cups.
(11)Fire extinguisher: at the left rear of the cab. It is used in case of emergency, see fire extinguisher
instructions for use method.
(12)Glove box: under the recliner and close to the fuse box.
(13)Fuse box: under the recliner.
(14)Windshield washer fluid filler: on the fender under the door. Unscrew the black knob, and then pull
out the white hose to inject windshield washer fluid.
42
2. Cab DW90A
Internal Layout Plan of fixed Cab
1
4
2
3
P1TC00109 P1TC00110
7 10 11
P1TC00112
12 12
13 14 15 P1TC00111
43
DW90A 2. Cab
1. Coat hook 6. String bag 11. Windshield washer fluid kettle

2. Rear seats 7. Container lifting handle 12. Air conditioning outlet
3. Rear grab handle 8. Hand brake handle 13. Clutch pedal
4. Safety hammer 9. Gear shift handle 14. Brake pedal
5. Fire extinguisher 10. Cup holder 15. Accelerator pedal
(1) Coat hook: on the rear upper part of the seat, and it is used to hang the clothes.
(2) Rear seats: for temporary use.
(3) Rear grab handle: hold it by hand to stabilize the body while temporary riding.
(4) Safety hammer: it is on the column between the two glasses on the right. It is used to break the glass
in emergency access to the right glass passage.
(5) Fire extinguisher: at the left rear of the cab. It is used in case of emergency, see fire extinguisher
instructions for use method.
(6) String bag: on the left side of the seat, light weight files can be stored.
(7) Container lifting handle: on the right side of the seat and near the glass, it is permanently in the
middle free position. Pull up the handle locking mechanism, push it forward to lift the container, push
it backward to lower the container.
(8) Hand brake handle: on the rear right of the seat. It is used after the vehicle stops to prevent slipping.
Push the handle forward to travel the vehicle, push the handle backward to park the vehicle.
(9) Gear shift handle: on the right front of the seat. When shifting, mirror shift according to the gear shift
operation instructions.
(10)Cup holder: under the right glass, and can hold water cups or beverage bottles with a diameter of
less than 60mm.
(11)Windshield washer fluid kettle: on the rear right of the seat. Open the cap above the windshield
washer fluid kettle to fill the windshield washer fluid. Be careful not to fill it up to prevent overflow.
(12)Air conditioning outlet: on the instrument panel and evaporation box, it can be closed and opened,
and the air outlet direction and volume can be adjusted.
(13)Clutch pedal: on the left side of the steering column, it is used during gear shifting and operated
according to the gear shift operation instructions.
(14)Brake pedal: the first one on the right of the steering gear, which is pressed when needs to reduce
the speed of vehicle or stop the vehicle.
(15)Accelerator pedal: the second one on the right of the steering gear, which is used when the vehicle
needs to accelerate or increase the engine rpm during driving.
44
3. Electrical Layout of Instrument Panel DW90A
3.Electrical Layout of Instrument Panel

Layout Plan of Instrument Panel
1 2 3 4 5 6 1
7 8
P1TE00008
1. A/C air outlet 3. Rocker switch 5. Multi-function 7. Cigarette lighter

2. A/C control panel 4. Parking brake handle combination handle 8. Start switch
6. Combination instrument
45
DW90A 3. Electrical Layout of Instrument Panel
3.1Main Functions of Instrument Panel and Indicator Lights
Layout Plan of Meters
1 2 3 4 5
6 7 8 9 10 11 12
P1TE00007
1. Tachometer 4. Rear axle brake air 7. Fuel gauge 10. Button II

2. Front axle brake air pressure gauge 8. Button I 11. Voltmeter
pressure gauge 5. Speedometer 9. LCD 12. Engine oil pressure
3. Signal light area 6. Coolant temperature gauge
gauge
3.1.1Engine Tachometer (No. 1 in Fig.)
It indicates the engine speed, through which a driver can check the current engine speed, and then
make corresponding adjustment to ensure reasonable use of the engine.
3.1.2Front Axle Brake Air Pressure Gauge (No. 2 in Fig.)
It indicates the air pressure of the front axle brake circuit system in the vehicle running process. The
normal range is 0.6-1.0 MPa. If the pressure is lower than 0.6 MPa, the indicator light will give an alarm
and the "STOP" indicator light will be on accompanied by buzzer alarm. Treatment measures: Inflate or
check the air lines.
46
3.1.3Rear Axle Brake Air Pressure Gauge (No. 4 in Fig.)
It indicates the air pressure of the rear axle brake circuit system in the vehicle running process. The
normal range is 0.6-1.0 MPa. If the pressure is lower than 0.6 MPa, the indicator light will give an alarm
and the "STOP" indicator light will be on accompanied by buzzer alarm. Treatment measures: Inflate or
check the air lines.
3.1.4Speedometer (No. 5 in Fig.)
It indicates current running speed of the wide-body vehicle. The normal range is 0-45 km/h, and the
speed greater than 45 km/h is considered abnormal.
Treatment measures: Reduce the load.
3.1.5Engine Coolant Temperature Gauge (No. 6 in Fig.)
It indicates the temperature of engine coolant. Under normal running conditions, the pointer shall be at
the middle position, i.e. the normal operating coolant temperature of engine is 80~90°C. During running
at high speeds in high-temperature areas or on steep slopes, the pointer will move to the red sector. In
case of too high engine coolant temperature, the coolant temperature alarm light will be on. In this case,
the vehicle shall be stopped immediately and the engine shall run at low idle speed, allowing coolant to
return to normal temperature.
47
3.1.6Signal Light Assembly (No. 3 in Fig.)

Illustration Diagram of Signal Lights
Left-turn Water-in-oil Right-turn

No driving
indicator light indicator light indicator light
Engine
Exhaust
Lifting coolant
brake Fog light
indicator light temperature
indicator light
alarm
Low engine
Charging Front dome
High beam oil pressure
failure alarm light
alarm
Running
Intake Rear dome Clearance
indication of
heating light light
backup light
Rear work Brake

Engine fault Rear light
light indicator light
Inter-axle
Engine Low engine differential
Fuel level
shutdown coolant level lock indicator
light
Air filter Energy Low air
Engine
clogging saving pressure
preparation
alarm indicator light alarm
3.1.7Fuel Gauge (No. 7 in Fig.)
It indicates the amount of fuel in the fuel tank when the vehicle is powered on. The pointer will change
slightly when the vehicle is accelerating or running uphill/downhill. If the indication range of the pointer is
less than or equal to 10%, the low fuel alarm light will be on and indicating that it needs to inject fuel.
3.1.8Button I (No. 8 in Fig.)
Short press of button I can realize page turning of LCD and long press of button I for more than 2s can
reset subtotal mileage and subtotal working time of engine.
3.1.9LCD (No. 9 in Fig.)
It displays data such as engine fault code, accumulated mileage, accumulated working time of engine,
subtotal mileage, subtotal working time of engine, time and date.
3.1.10Button II (No. 10 in Fig.)
The time and date displayed on the LCD can be adjusted through the button.
48
3.1.11Voltmeter (No. 11 in Fig.)
It indicates current voltage of the vehicle to monitor the battery status.
3.1.12Engine Oil Pressure Gauge (No. 12 in Fig.)
It indicates current engine oil pressure.
3.2Introduction to Main Functions of Electrical Components and

Switches
3.2.1Start Switch (Fig.)
After the key is inserted into the start switch, there are four selection positions, as shown in Fig.
Their functions are respectively as follows:
OFF: power-off. At the position, the key can be pulled out.
ON: power-on. The key must be kept at this position when the engine is running.
START: Start the engine.
Start Switch
ON
START
OFF
KEY
P1T000065
49
3.2.2Radio-cassette Player
Radio-cassette Player Panel
1 2 3 4
P1TE00009
1. Volume button/POWER 2. Function key area 3. LCD 4. USB/SD card interface
Press the power switch (No. 1) to power on the radio-cassette player. U flash disk and SD card can be
inserted into the USB/SD card interface (No. 4), and MP3 or radio can be played through "MODE" key in
the function key area (No. 2). A driver can view current mode through LCD (No. 3).
By operating keys in the function key area (No. 2), the following functions can be realized: volume
adjustment, radio frequency modulation, and MPS playing mode switching.
3.2.3Retarder Position Selector Switch and Indicator Light
(1) Position selector switch

Retarder position selector switch
P1TT00053
Select the brake position of hydraulic retarder based on different operating conditions.
50
Turn the handle to 1st/2nd/3rd/4th position to select the retarding position. When the retarder is working,
the corresponding position light on the instrument will be on. The higher the position is, the more obvious
the retarding effect is.
0 Retarder off
1 Constant speed gear
2 The 1st brake position
3 The 2nd brake position
4 The 3rd brake position
5 The 4th brake position
P1TE00002
A) Retarder controller indicator light (on the B) Retarder position selector switch
instrument)
The 1st position is the constant speed gear

1) Adjust the travel speed (generally greater than 30km/h), engine rpm (greater than 1500r/min).
2) Enable constant speed function at desire speed. The retarder ensures the constant speed of the
truck within the maximum brake torque range. If already in the constant speed gear, but need to
reset the constant speed downhill, shift the gear back to “0” position and then to the “1st” position. If
the constant speed function is enabled and the travel speed increases, the service brake auxiliary
retarder is required to adjust the travel speed. If the handle is not in the constant speed gear, the
automatic adjusting function is closed immediately. When using constant speed gear, if the retarder
has high temperature protection (the working indicator light flashes), the retarder will automatically
lower the torque or exit. If need to realize the constant speed again, manually shift to constant speed
gear after the working indicator light stops flashing.
3) Exit the constant speed. Brake gear is used in 2-5 brake position, at this time, the engine rpm is
greater than 1500r/min. When the brake gear increases from gear 2 to gear 5, the brake torque is
also increases in turn, and select a reasonable brake gear base on the weight of truck or the brake
distant. Shift the retarder gear switch step by step (do not shift the gear in jump style) to obtain
proper brake torque. In order to reduce the actual brake torque, shift the handle switch from high
gear to low gear over multiple steps. After braking, turn the retarder handle back to “0” position.
Disconnect the main switch immediately when the following situations occur:
1. When parking the truck, the retarder indicator is aways on.
2. When the brake pedal is not depressed, the manual switch is in O position, and there is drag
brake feeling or the indicator light is always on.
51
(2) Retarder indicator light
(Retarder control indicator light off

symbol, accroding to ca manufacturer)
Power on text
When retarder is in the off state, it
flashes 3 times and goes out
Keep lighting up
“constant speed gear”
Keep lighting up
brake gear is 1st~4th
Retarder control indicator light

flashes:
Temperature limit P1TE00003
3.2.4Multi-function Combination Switch
The combination switch integrates the functions of turn signal light, light control, emergency flasher
(emergency light), windshield wiper and windshield washer. Please be familiar with the switch and keep
in mind. These functions can be realized through rotation, forward/backward adjustment, upward/
downward adjustment, and pressing.
The whole combination switch is shown in Fig.
Combination Switch
P1T000069
1) Turn signal control lever

The turn signal control lever (No. 1 in Fig.) is located on the combination switch handle.
52
The right-turn indicator light will flash if the control lever on the combination switch handle is pushed
forwards.
The left-turn indicator light will flash if the control lever on the combination switch handle is pulled back.
Turn signal control lever
P1T000070
2) Dimmer switch and high beam switch

The dimmer switch and high beam switch are located on the turn signal control lever.
When overtaking, lift the turn signal control lever upwards from the high beam position, and then the high
beams of the headlights will be on, and flash when the control lever is lifted up to down to remind the
drivers of vehicles ahead. In the normal running process of the vehicle, the headlights will be on when
the high beam switch is turned on, regardless of the conditions of other lights.
Move the left handle control lever of the combination switch up and down to realize dimming.
3) Wiper switch
Turn the rear end of the control lever on the combination switch handle to allow the operation of the
wiper (as shown in Fig.).
The wiper has three speed positions with corresponding marks on the control lever as follows:
O Stop of wiper
┛ Intermittent wiping
Ⅰ Low-speed wiping
Ⅱ High-speed wiping
4) Control of windscreen sprinkler
Press the button at the end of the combination switch handle, the sprinkler starts to work, with water drop
sprayed from the nozzle and the wiper starting to wipe the windshield until the button is released.
In sunny days, the wiper must be used together with the scrubber as it will scratch the glass if it
is used alone. In cold weather, the wiper shall be prevented from being frozen on glass.
53
3.2.5Rocker Switch
Introduction to Functions of Rocker Switch
Position light switch

The position light switch has three
positions: Front fog light switch
0: off; Press the switch, and then the front
1: The position light is on; fog light will be on.
2: The headlights are on. To light on the front fog light, the
If the switch is at "1" position, i.e. the position light shall be turned on first.
position lamp is on, all switch
backlights will be on.
P1T000071 P1T000072
Hazard warning light switch

Press the switch, and then all turn Horn switch
lights of the vehicle will flash at a The switch can be used to switch the
certain frequency. The switch is used air and electric horns.
for hazard alarm.
P1T000073 P1TE00004
Engine brake switch Cab front work light switch

Press the switch to turn on the Press the switch to turn on the cab
engine brake. front work light.
P1T000075 P1T000077
54
Introduction to Functions of Rocker Switch
Rear light (waist light) switch

Turn on the switch, and then the work
Cab rear work light switch
light on the front wheel fender will be
Press the switch to turn on the cab
on. In case of insufficient light, turn
rear work light.
on the light to facilitate observation of
wheel rims.
P1TE00005 P1T000079
Rotating warning light switch

Inter-axle differential lock switch
Press the switch, and then the
Press the switch to turn on the inter-
rotating warning light on the top of
axle differential lock.
the cab will be on.
P1T000081 P1T000082
Energy saving switch

Booster switch
Press the switch, and then the
Press the switch to switch on the
engine power will drop to 70%. It is
pressurizer and introduce fresh air to
recommended that this function be
the cab.
activated in no-load state.
P1T000083 P1T000084
55
3.2.6Cigarette Lighter
Press the cigarette lighter. When the temperature rises to a certain value, the cigarette lighter will pop up
and can be taken out.
The power supply of cigarette lighter is +24V. In case of emergency, the cigarette lighter can be pulled
out and other specific plugs can be inserted for power supply (for example, mobile phone charging).
Cigarette lighter
P1T000085
3.2.7Dome Light
The dome light is located in the middle of the top of the cab. It is equipped with a switch which can be
pressed to light on the dome light. The dome light power supply is not controlled by the key switch, so
the dome light can still be on without turning on the key switch.
Dome Light
P1T000086
56
4. Maintenance of Engine and Its Auxiliary System DW90A
4.Maintenance of Engine and Its Auxiliary System
4.1Operation and Maintenance of Engine
YC6K480 engine is adopted and refer to the Operation Manual for details.
4.2Replacement of Engine Oil, Filter and Prefilter
During the service of vehicles, engine oil, filter and prefilter are required to be replaced regularly
according to the length of service period, to ensure the engine can run stably.
1) Replacement of engine oil
Replacement interval: Replace the engine oil in strict accordance with the interval specified in
"Mandatory Maintenance Details about DW90A Mining Dump Truck" when the trucks are still in the
mandatory maintenance time limit (mileage). See the replacement interval specified in Operation and
Maintenance Manual of YC6K480 Engine if the trucks are beyond the mandatory maintenance time limit
(mileage).
a. Open the drain plug to drain oil (The drain plug is on the bottom of engine oil pan, namely, No. 1 in
the figure below).
When draining oil, pay attention to checking whether the engine oil color is normal and whether the
engine oil is free of foreign matters. Find out and eliminate any faults and hidden troubles in time.
b. After the oil is drained out, remove the foreign matters on the drain plug and then tighten the plug.
c. Replace the old engine oil filter element with a new one. Fill new engine oil into the engine till the
oil level reaches the upper limit of dipstick. To prevent the engine from starting without being
lubricated, turn the key switch to the start position (gear 4) when the HP oil pump does not supply
oil, idle the engine for a while, and start the engine to run at a low speed after the engine is
lubricated. Check whether the engine oil filter leaks oil.
Position of Drain Plug
P1TP00062
1
1. Drain plug
57
DW90A 4. Maintenance of Engine and Its Auxiliary System
Position of Engine Oil Dipstick
P1T000088
1. Engine Oil Dipstick
2) Replacement of engine oil filter

Replacement interval: The engine oil filter (see Fig. for its position) needs to be replaced when the
engine oil is replaced. Make a replacement in strict accordance with the interval specified in "Mandatory
Maintenance Details about DW90A Mining Dump Truck" when the trucks are still in the mandatory
maintenance time limit (mileage).
Engine oil filter
1
P1TP00061
1. Engine oil filter

58
Replacement of engine oil filter
Screw-in by +3/4
P1T000090
4.2.2Replacement Method
During replacement, remove the filter with a special filter spanner. During installation of new filter, wipe
up the junction surface, fully fill the filter with clean filtration medium, lubricate the rubber seal ring with a
small amount of clean filtration medium, install the filter manually, and screw the filter in by 3/4 rounds
(see P1T000090) after the seal surface is combined with the junction surface. Start the engine and check
whether the seal surface leaks oil. In case of oil leakage, further tighten the filter till the oil leakage stops.
3) Replacement of fuel filter
The replacement interval and method are the same as those of "fuel filter".
Fuel filter
P1TP00063
1. Fuel filter
59
Fuel prefilter
P1TP00063
1. Fuel prefilter
4) Replace fuel pre-filter

It is installed on the right side of vehicle (as shown in Fig.). Both replacement interval and method are the
same as those mentioned in "Replacement of engine oil filter".
4.3Daily Maintenance and Precautions
1) Check the coolant level, engine oil level and fuel level.
2) Check whether the relevant parts are sufficiently applied with lubricating grease.
3) Check whether there is any leakage of oil, water and gas.
4) Check the external adapting pieces and accessories for their connecting and tightening status.
5) Check whether the fan belt is too tight or too loose.
6) Check the diesel oil engine for its oil and water temperatures.
7) Check whether the exhaust temperature, color, sound and vibration are normal and whether the
speed is stable or not.
Refer to the Operation Manual for engine for details.
60
4.4Maintenance
Both inspection and maintenance shall be carried out for the engines in strict accordance with the
"Routine Inspection and Maintenance Interval Mileage". For detailed steps, see "Section 6 - Technical
Specification for Maintenance" mentioned in Operation and Maintenance Manual.
4.5Operation Specification for In-cylinder Braking of the Engine
4.5.1 What is engine overspeed
The engine overspeed refers to the speed of the engine exceeding the maximum allowable operating
speed of the engine during the operation of the vehicle. It is required that the maximum speed of
YC6K480 engine shall not exceed 2100 rpm.
4.5.2 What are the reasons for engine overspeed
The engine overspeed can be divided into two types: active overspeed and passive overspeed.
Since the electronic control technology has already been widely used for engines, that is, the fuel supply
is controlled by ECU, which fundamentally guarantees that the engine overspeed will not be caused
during combustion work and the engine overspeed will not occur due to the engine itself.
The passive engine overspeed is caused by reversed towing of the engine by the vehicle's transmission
system due to cut-in during gear shifting or shifting to a wrong gear when the vehicle is running, resulting
in the engine speed exceeding the limit. At this time, the engine has stopped fuel supply and work, and is
rotating passively due to the reversed towing.
4.5.3 What faults or failures may be caused by engine overspeed
The engine overspeed may cause movement disorder of the engine valve mechanism, and the valve
may hit the piston, causing valve breakage, piston fracture or even cracking of the cylinder block. It may
also cause the tightening bolts of the gear system driving the valve mechanism to loose or break, or
faults such as the displacement of the interference-based press-fitted gears. Such faults are not covered
by the engine warranty and need self-paying repair.
4.5.4 Instructions for preventing overspeed:
When the vehicle is running, if the engine speed exceeds1900 r/min, the driver shall hit the brake to slow
down the vehicle and shift gears in time to prevent overspeed. If the speed exceeds 2300 r/min, the
instrument buzzer will give an audio alarm at a frequency of 1 Hz.
61
4.5.5 Instructions for brake use:
The working principle of engine brake:

When the vehicle brake switch is turned on, the engine will stop injecting fuel into the cylinder during
compression braking. In this case, the engine serves only as a compressor that absorbs power, and the
engine brake system will open the exhaust valve before the end of the compression stroke to prevent
combustion in the cylinder. The compressed air will be discharged through the exhaust system, and the
compression energy will no longer drive the engine to run through the power stroke, which increases the
engine's braking power and provides additional braking force of 326 horsepower for the vehicle. It shall
be turned on before going downhill and the appropriate gear shall be selected and applied in cooperation
with the brake.
Service conditions for engine brake:
1. Turn on the engine brake switch on the right side of the steering wheel
Engine brake switch
P1T000075
2. The engine speed is higher than 1000 rpm.

3. The opening degree of the accelerator pedal is 0.
4. The clutch pedal is in the released state.
Out-of-service conditions for engine brake:
1. Turn off the engine brake switch on the right side of the steering wheel.
2. Depress the accelerator or clutch pedal.
62
1.Generally, the engine overspeed is caused due to the dragging by the whole vehicle when a too
low gear is selected by the driver during downhill driving. Since the vehicle speed is directly
related to the vehicle's transmission ratio and the rear axle speed ratio, in theory, when the
current vehicle speed exceeds the maximum speed limit of the current gear, the engine is likely
to overspeed.
2.The lower the gear is, the higher the vehicle speed will be, and the easier the engine overspeed
will become.
3.Engine brake is an auxiliary braking tool, which could not completely replace the parking brake.
It shall be turned on before going downhill and the appropriate gear shall be selected and applied
in cooperation with the brake.
Under no circumstances should an engine overspeed alarm appear. Generally, the engine brake
shall be turned on before running downhill to ensure that the engine overspeed will not occur.
Once the engine overspeed occurs, very serious consequences may be caused by even a very
short period of overspeed. Engine faults caused by the engine overspeed are not covered by the
engine warranty and need self-paying repair.
63
4.6Cooling System
4.6.1Structure
"Fig. Cooling System" shows the structure of cooling system, while "Fig. Expansion Tank" shows the
structure of expansion tank.
Cooling system
P1T00057
1. Expansion tank 2. Exhaust pipeline 3. Water pipe 4. Intercooler 5. Water radiator
Expansion tank
P1T00056
6. Safety exhaust port 7. Filler

64
4.6.2Filling of Coolant
The coolant is filled through the expansion tank filler. The auxiliary water tank is engraved with two scale
Min and Max. Additional coolant needs to be filled if the level is below the Min scale, and coolant should
not exceed Max scale.
The coolant used in the cooling system shall meet the requirements of engine. Soft water or softened
water shall be used in the preparation of coolant. Otherwise, the heat dissipation effect will be affected
due to precipitates and scales.
The following methods are provided for softening the hard water:
1. Boil the hard water.
2. Add 0.5~1.5g of sodium carbonate (Na2CO3) into each liter of water.
3. Add 0.5~0.8g of sodium hydroxide (NaOH) into each liter of water.
The antifreeze can be JFL-318 [0°C ~ -10°C] or JFL-338 [-10°C ~ -26°C], or it can be made as per the
mix ratio and method of self-made antifreeze.
Mix ratio of self-made antifreeze
Ultimate Glycerinum - Water Ethanediol - Water
Temperature (°C)
of Antifreeze Glycerinum Specific Gravity, Ethanediol Specific Gravity,
Freezing Point Weight, % D Weight, % D
-10 32 1.0780 28.4 1.0340
-20 51 1.1290 38.5 1.0506
-30 64 1.1647 47.8 1.0627
-40 75 1.1894 54.7 1.0713
The antifreeze made of "ethyl alcohol - water" should not be used for the engine.
Seawater shall never be used to directly cool down the engine.
The antifreeze can be added as per the service requirements of engine, or it can be made
according to the formula recommended herein (Table 3-4.1 Mix Ratio of Self-made Antifreeze).
When the antifreeze is used, its freezing point shall be 5°C less than the lowest temperature of
the service area.
Unless otherwise described, the water tanks of vehicles manufactured by Guangxi LiuGong
Machinery Co., Ltd. are filled with engine antifreeze at -35°C when they leave factory. The users
need to replace the antifreeze with suitable one based on the local air temperature.
65
The engine antifreeze needs to be replaced once every two years, or its freezing point needs to be
checked. In case of unsatisfactory freezing point, the satisfactory antifreeze shall be used instead in
time. During the replacement of antifreeze, the antifreeze applicable to aluminum water tank and radiator
shall be selected as per the manual; otherwise, we will not undertake any responsibilities or losses due
to corrosion of water tank and radiator and other quality issues incurred therefrom!
4.7Maintenance of Air Intake System
4.7.1Structure of Air Intake System with Desert-type Filter
"Fig. Structure of Air Intake System with Desert-type Filter" shows the structure of air intake system.
Structure of Air Intake System with Desert-type Filter
P1T000096
1. Cyclone prefilter 2. Air filter (desert-type) 3. Bracket 4. Drain outlet
According to the operating conditions and service environment, the air intake system is of the three-
stage air filtration mode. The prefilter is of a maintenance-free fan bearing, while the air filter is of a paper
filter.
1) Maintenance instruction
a. Clean and clear the main filter element after 250h of operation.
b. Gently knock the end of main filter element to shake off the accumulated dust.
c. Purge the main filter element from its interior to exterior with dry compressed air at a pressure not
more than 0.5Mpa, to remove the accumulated dust inside the main filter element.
66
Never clean the main filter element with oil or water!

2) The main filter element shall be replaced in case of the following conditions are met:
a. The outer filter element has been damaged.
b. The outer filter element has been cleaned and cleared for more than 5 times.
c. The safety filter element is forbidden to be used after cleaning and clearing, and it shall be
replaced simultaneously with the main filter element.
4.7.2Structure of Air Intake System with Oil-bath Air Filter
"Fig. Structure of Air Intake System with Oil-bath Air Filter" shows the structure of air intake system.
Structure of Air Intake System with Oil-bath Air Filter
1
3
2 5
P1T000097
1. Bracket 3. Prefilter 5. Filter assembly 7. Main filter element

2. Oil level 4. Connecting hose 6. Oil pan 8. Oil filter element
1) Maintenance instruction
a. Clean and clear the main filter element after 250h of operation.
b. Gently knock the end of main filter element to shake off the accumulated dust.
67
c. Purge the main filter element from its interior to exterior with dry compressed air at a pressure not
more than 0.5Mpa, to remove the accumulated dust inside the main filter element.
d. The oil filter element shall be cleaned and cleared and the engine oil shall be replaced after 300h
of operation.
Never clean the main filter element with oil or water!
2) The main filter element shall be replaced in case of the following conditions are met:
a. The outer filter element has been damaged.
b. The outer filter element has been cleaned and cleared for more than 5 times.
c. The safety filter element is forbidden to be used after cleaning and clearing, and it shall be
replaced simultaneously with the main filter element.
3) The engine oil shall be replaced in case of the following conditions are met:
a. The oil filter element needs to be cleaned and cleared and the engine oil needs to be replaced, if
the engine oil cannot flow easily when the oil pan is shaken.
b. The engine oil needs to be replaced if the engine is not used for more than one year.
Precautions
a. If the blocking alarm indicator of air filter turns on, or if the engine emits black smoke or it is lack of
power, an inspection must be timely carried out for the following two factors: (1) Check whether the
filter element is blocked; (2) check whether the bellows connected to the pressure inlet of engine is
deformed.
b. For the oil-batch air filter, its oil viscosity is consistent with that of engine used at the same time.
c. The engine oil status must be checked every day if the engine is used in a poor environment.
d. Please use the air filter products accredited by us to prolong the service life of engine.
68
4.8Maintenance of Fuel System
Fuel Strainer--Clean
Do not allow foreign material to enter the fluid circulation system when checking the fluid level,
adding fluid, changing fluid or replacing the fluid filter.
1. Stop the engine.
2. Carefully clean the dust and dirt around the fuel tank filler cap. Remove the fuel filler cap of the fuel
tank. Check the gaskets for damage. Replace the gaskets if damaged.
3. Remove the fuel strainer and check for damage. Replace the fuel strainer if damaged.
4. Wash the fuel filler and fuel strainer with clean and nonflammable detergent. Dry the fuel filler and
fuel strainer using compressed air or allow to air dry.
5. Install the fuel strainer and filler cap.
Water and Impurity--Remove
The fuel pump and fuel injection nozzle are precision devices, if fuel is mixed with water or impurity, the
fuel pump and fuel injection nozzle can't work properly and quickly worn. Measures should be taken to
remove water and impurity in fuel.
1. If the condition is permitted, fuel should be deposited for 24 hours before it is filled to the tank.
2. Before filling, screw out the drain plug at the bottom of the fuel tank to drain out water and impurity
deposited in the tank once every week.
3. After completing daily work, add fuel and remove the humid air in the fuel tank.
4. After replenishing the fuel tank every time, wait for 5 ~ 10 minutes before starting the engine so that
water and impurity have sunk to the bottom of the tank.
5. After completing daily work, loosen the water drain plugs of fuel water separator to drain out water
and impurity.
Add the fuel in time. Any residual fuel at the bottom of the fuel tank that contains water and
impurity will affect the normal running of the engine. Drain and clean fuel tank before adding.
69
DW90A 5. Transmission
5.Transmission
The DW90A wide-body dump truck is mainly equipped with Fast 8-gear mechanical transmission and 7-
gear mechanical transmission as optional equipment. In addition, FC AT automatic transmission may
also be adopted as required by the user.
The mechanical transmission is also designed with double middle shaft and without the auxiliary
transmission. The shift sleeve rather than synchronizer is used for gear shifting. The first gear features a
high speed ratio and strong gradeability. The arrangement of gear positions is rational, the difference
between speed ratios is small, the gear position is clear, and the gear shifting is flexible. Double levers
and a flexible shaft are used for manipulation so the gears can be engaged conveniently and easily.
Adopt a structure with a large center distance and features a long service life, applicable to the mines
operating condition.
5.1.Structure of Transmission
5.1.1Double Middle Shaft
Equipped with two structurally identical middle shafts, with a spacing of 1800. After the power is input
through the input shaft, it is respectively sent to these two middle shafts, and then two component forces
gather together on the main shaft for output. The structure is as shown in the figure.
Schematic Diagram of the Twin-Layshaft Configuration of 8-Speed Transmission
P1T000098
70
5. Transmission DW90A
Schematic Diagram of the Power Transmission of 8-Speed Transmission
P1TT00047
Schematic Diagram of the Twin-Layshaft Configuration of 7-Speed Transmission
P1TT00048
71
Schematic Diagram of the Power Transmission of 7-Speed Transmission
P1TT00049
With the double middle shaft structure, all gears on the main shaft are simultaneously engaged into the
gears on these two middle shafts. Various main shaft gears move on the main shaft, so the main primary
shafts only subject to torque, free of bending moment, thus improving the stress status of main shaft and
bearing. In theory, each middle shaft only transmits 1/2 of torque so the double middle shaft structure
can reduce the center distance of transmission, the width of gears, the axial dimension, and the weight,
thus featuring high reliability and durability.
5.1.2"Gear Matching" and Its Procedure
In the event of the double middle shaft structure, "gear matching" must be performed to ensure correct
engagement between middle shaft gears and main shaft gears.
The "gear matching" means: During the assembling of transmission, the marked gear teeth on the drive
gears of two middle shafts are respectively inserted into the grooves of two groups of marked gear teeth
on the input shaft (primary shaft) gears (each group includes two adjacent teeth), as shown in the figure.
The "gear matching" of auxiliary transmission is also performed as per the above method. Usually, the
pair of gears at the rear position is used for "gear matching".
"Gear matching" procedure:
(1) Mark any two adjacent gear teeth on the primary shaft gear. Then, mark the corresponding two
adjacent gear teeth opposite to the above two gear teeth. Ensure that the quantity of teeth between
two groups of marks shall be the same.
(2) Mark the tooth on the drive gear of each middle shaft towards the gear keyway to facilitate
identification.
(3) During assembling, respectively engage the marked teeth on the drive gear of two middle shafts into
the marked gear tooth grooves on both sides of the primary shaft gear.
72
Schematic Diagram of Gear Matching
1 3 2
P1T000099
1. Drive gear of left middle shaft 2. Drive gear of right middle shaft 3. Input shaft gear
5.1.3Shift Mechanism
The main transmission is not installed with a synchronizer, and the gear shifting is realized by moving the
gear sleeve. The secondary shaft sliding sleeve is installed on the secondary shaft via an involute spline.
When the sliding sleeve is moved, the soldered teeth (outer spline) of sliding sleeve are engaged into the
inner spline of secondary shaft gear, to transmit the power.
5.2Control Structure
The mechanical transmission is of the double-lever long-distance control (as shown in Fig.). T The
neutral position of the transmission is at the gears 4 and 5. The control lever is moved front and back as
well as left and right by the lever head. The gear selection and shifting flexible shafts are respectively
used to drive and rotate the rocker arm to the corresponding positions, thus realizing the gear shifting.
Schematic Diagram of Gear Shifting Mechanism (7-gear)
1
2
3 驾驶室操纵杆位置
Positions of control lever in cab
5
P1TT00046
1. Lever head 3. Gum cover 5. Bracket

2. Control lever 4. Flexible shaft
73
Schematic Diagram of Gear Shifting Mechanism (8-gear)
5
P1TT00001
1. Lever head 3. Gum cover 5. Bracket

2. Control lever 4. Flexible shaft
5.3Installation of Flexible Shaft
(Refer to Fig..)
Requirements are as follows:
a. When the flexible shaft is installed on the vehicle, its bending radius shall not be less than 300mm
and its service temperature range shall be -40 ~ +100°C.
b. The connection between flexible shaft and gear shifting/selection rocker arms shall meet the
following requirements:
(1) The angle between flexible shaft and rocker arm shall be 90° as far as possible.
(2) For the flexible shaft, its guided sleeve and jacket connector must be on the same straight line with
the push-pull rod in terms of spatial position.
c. The gear selection flexible shaft and the gear shifting flexible shaft are respectively installed on the
controller.
d. Put the control lever to the neutral position, and then check whether the dimension of transmission
end flexible shaft meets the requirement. If not, adjust the connecting length between flexible shaft
ball joint and pull rod thread, to change the installation dimension of flexible shaft.
e. Perform both gear shifting and selection upon installation, to ensure that the lever can be pushed
into each gear position. In case of any difficulties in gear selection, check and adjust the
installation dimension of gear selection/shifting flexible shafts as per the above text
74
5.4Control and Precautions for Transmission
(1) Before a vehicle starts to run, its parking brake shall be released. For a vehicle with energy storage
air break breaking, after the brake valve of vehicle is enabled, the vehicle cannot start to run with its
lever in the correct gear position unless the air pressure increases to the value large enough to
release the brake.
(2) Start in gear 1 or gear 2 according to the road conditions.
(3) During gear shifting, the clutch shall be thoroughly separated, the shift lever shall be pushed in place,
and the shift sleeve shall be fully engaged.
(4) If the lever needs to be pushed into the reverse gear, the vehicle shall be stopped before gear
shifting, to avoid the damage to parts inside the transmission. When the lever is pushed into the
reverse gear, a relatively strong gear selection force is required to overcome the resistance from the
reverse gear lock.
(5) When the lever is pushed from the low gear position area to the high one (vice versa), the lever shall
be upshifted gear by gear; otherwise, the service life of auxiliary transmission synchronizer will be
affected.
(6) When the vehicle runs downhill, the gear shifting between high and low gear position areas shall be
avoided as much as possible.
(7) When the vehicle is parked, the shift lever shall be put in the neutral gear.
(8) During running, in case of any abnormal sounds from the transmission, unsmooth operation and
other abnormal phenomena, the driver shall immediately stop the vehicle for inspection and not drive
the vehicle again until all faults are eliminated.
(9) An inspection shall be frequently carried out for the breather plug. If the plug is blocked with mud, the
mud shall be removed when founded.
(10)Operation of dragged vehicle
When the transmission is working, both its shaft and gears rotate quickly, sufficiently lubricating the
transmission. However, when the vehicle is dragged with its rear wheels on the ground and its power
train system connected, the middle shaft gear and the main shaft gear of the main transmission will not
rotate, but the main shaft will rotate at a high speed, driven by the rear wheels. As a result, the
transmission will be severely damaged due to lack of lubricating.
To prevent this phenomenon, attention shall be paid to the following points:
Never allow a vehicle to slide with its lever in the neutral gear when it is shut down.
Never press the clutch pedal to allow a vehicle to slide with its lever in the neutral gear.
When a vehicle needs to be dragged, the half shaft can be taken out, or the drive shaft can be released,
or the drive wheels can be above the ground.
75
5.5Maintenance of Transmission
Correct and rational use and regular maintenance of transmission are very important to ensure safe and
reliable vehicle running and prolong the service life of transmission. Please follow the use requirements
given below.
5.5.1.Designation of Lubricant
The transmission must be filled with the gear oil with its property at least at the 85W/90 GL-5 level.
5.5.2.Correct Oil Level
It needs to ensure that the oil level is flush with the lower edge of filler. The conical oil filler hole on the
side of oil pan can be used to check the oil level. Oil filling can be stopped when oil overflows from the
filler hole. The oil level shall be at least 5mm below the lower edge of oil level observation hole. An
excess oil amount will give rise to temperature rise and oil leakage of transmission. An extremely small
amount of oil will give rise to poor lubricating of components, and even burnout of transmission.
5.5.3.Working Temperature
The highest temperature of the transmission in continuous operation shall not exceed 120°C. In case of
exceeding this limit value, the lubricant will be disintegrated, thus reducing the service life of
transmission. When the transmission starts below -40°C, its rubber seals such as oil seal will be
damaged, and leakage will occur.
The working temperature of transmission will exceed 120°C in the event of any one of the following
cases:
(1) The transmission continuously works at a traveling speed < 32Km/h.
(2) The engine speed is high.
(3) High ambient temperature;
(4) The transmission is surrounded by eddy current.
(5) The exhaust system is too close to the transmission.
(6) The transmission runs at a large power and overspeed.
76
5.5.4.Working Slant Angle
The lubricating may be insufficient when the working slant angle of transmission exceeds 12°. The
working slant angle is equal to the installation angle of transmission on chassis plus the upper slope
angle. If the slant angle exceeds 12°, the transmission shall be installed with a lubrication pump or
cooling device, to ensure a proper lubricating effect.
5.5.5.Lubricant Replacement Interval
During replacement of lubricant for transmission, the old lubricant in transmission shall be drained out.
To avoid chemical reactions between the lubricants of different models, the model of new lubricant shall
be the same as that of old one.
For a new transmission, its lubricant must be replaced when the vehicle mileage reaches
2,000~3,000km.
Both lubricant level and leakage shall be checked for every 10,000km, and the lubricant shall be
supplemented when needed at any time. During the inspection of lubricant level, the vehicle shall be
parked on a level road. Considering the volume expansion of hot lubricant, to avoid inaccurate
measurement, an inspection shall not be carried out for a vehicle just stopping running. The inspection
shall be carried out when the lubricant level is stable and the vehicle is slightly cooled down.
For every 20,000km, check the air filter for its screen, clean the screen and filter inner wall with soap
water, and dry them with compressed air.
Replace the lubricant for every 20,000km.
●Please designate the procedures specific for controlling the transmission to avoid personal
injury or equipment failure.
●Before starting the vehicle, the driver shall sit on the driver seat, push the shift lever to the
neutral gear, and release the manual brake.
●If the driver needs to leave the cab before the vehicle starts to run or when the engine is running,
the driver shall put the shift lever to the neutral gear and tightly lock the wheels via the manual
brake.
●When the driver parks the vehicle or leaves the cab, the driver shall put the shift lever in the
neutral gear and push the brake handle in place.
●Do not release the manual brake or conduct the gear shifting before the vehicle air pressure
rises to the correct value.
●Do not drive the vehicle downhill with the shift lever in the neutral gear.
●When a vehicle needs to be dragged, the half shaft can be taken out, or the drive shaft can be
released, or the drive wheels can be above the ground.
77
DW90A 6. Clutch and Its Control Parts
6.Clutch and Its Control Parts
6.1Overview of Clutch Control System
The clutch system is mainly used to interrupt or transmit the engine power, thus enabling the gear
shifting of transmission.
Principle of Pull-type Clutch Controller
8
7
3 1
6 5 2
4
P1T000103
1. Clutch pedal 3. Clutch control line 5. Clutch boost cylinder 7. Clutch release bearing
2. Clutch master cylinder 4. Air reservoir 6. Release fork 8. Clutch Assembly
The clutch control system is of a hydraulic control and pneumatic booster structure (as shown in Fig.).
When the clutch pedal is pressed, the master cylinder pushes the brake fluid into the hydraulic control
chamber of booster cylinder installed on the bottom of transmission. On one hand, the brake fluid applies
the working pressure to the piston. On the other hand, it also applies the control pressure to regulate the
air inlet valve in the booster cylinder air chamber. When compressed air flows into the booster cylinder
air chamber, a pneumatic boosting force is generated and pushes the piston together with the brake fluid
so that the booster cylinder push rod moves forwards. With the lever effect, the release rocker arm and
the release fork push the release bearing backwards (as shown in Fig.). As a result, the pressing force
between friction disc and flywheel exerted by pressure plate disappears, and the friction disc and
flywheel are separated.
When the pedal is released, the clutch master cylinder gets back to its original position and the oil
pressure disappears. Under the effect of diaphragm spring, the clutch pressure plate, release bearing,
release fork, and clutch booster push rod all get back to their original positions.
78
6. Clutch and Its Control Parts DW90A
Schematic Diagram of Clutch Pressure Plate
P1T000104
1. Diaphragm spring 2. Clutch pressure plate
The clutch master cylinder, oil can and other similar components are all arranged on the front wall of cab
( as shown in Fig. P1T000105). The clutch master cylinder is connected to the booster cylinder installed
on the bottom of transmission through a HP hose. The oil can is directly installed on the clutch master
cylinder so that both assembling and brake fluid filling are more convenient and faster.
Clutch master cylinder
3
P1T000105
1. Clutch cylinder oil can 2. Clutch master cylinder 3. Cab
Working parameters of clutch system:
Working media: brake fluid and air

Maximum working pressure of oil: 12MPa Maximum pressure of compressed air: 1MPa
Brake fluid used for master cylinder: conforming DOT3
Working temperature: -40 ~ +80°C
standard
Pedal travel: maximum ≤ 45mm Pedal force: ≤ 190N with pneumatic boosting force
79
6.2Installation of Clutch
1) Installation of clutch: Install both driven disc assembly and friction disc on the mandrel (positioning
tool used to install clutch driven disc), and align them to the flywheel center hole. Fit two stud bolts of
flywheel into any two holes on the clutch pressure plate. Respectively install other 10 hexagon
stubs, and tighten them diagonally.
2) Connection of pull-type clutch: After the above steps are completed for the pull-type clutch, (1) take
out four clamp springs from the pressure plate assembly to close the flexible lock ring on the clutch
pressure plate assembly (as shown in View A of Fig.); (2) install the release bearing on the
transmission spline shaft and then install the release fork; (3) install the transmission onto the engine
flywheel housing, and apply a backward tensile force to the release fork at the booster cylinder
installation position (connect a soft cable to the upper end of release fork to pull backward); after a
sound of "bang" is heard, the clutch cover assembly and the release bearing are fitted in place (the
flexible lock ring is fixed onto the release bearing); then, install the booster cylinder.
Structure of Clutch
1 2 3
P1T000106
1. Clutch disc assembly 3. Stud 5. Release bearing

2. Clutch driven disc assembly 4. Washer 6. Diaphragm spring
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6.3Installation Requirements for Clutch Control System
Layout of Clutch Control System
2
3 1
5
6
7 P1T000107
1. Clutch pedal 4. Clutch cylinder oil can 7. Clutch boost cylinder

2. Stopper bolt 5. Clutch master cylinder
3. Clutch master cylinder push rod 6. Oil pipe
Refer to Fig. for adjustment, and determine the reference structure as per the actual assembling
structure.
6.3.1Inspection and Adjustment for Clearance between Master Cylinder Push Rod
and Piston
Inspection and adjustment for clearance between master cylinder push rod and piston: When adjusting,
gently push the pedal with a hand to feel that the clutch master cylinder push rod contacts the piston;
then, adjust the height of stopper bolt to ensure a clearance of 0.5mm-1mm between push rod and pis-
ton (slightly shake as shown in Fig.); finally, tighten the nut. The clearance between push rod and piston
should not exceed 1mm; otherwise, the effective stroke of clutch master cylinder will be reduced. The
installation deflection angle shall not exceed 3° (as shown in Fig.); otherwise, the upper end face of
clutch master cylinder will be subject to eccentric wear and oil leakage.
81
Schematic Diagram for Clearance of Push Rod
P1T000108
Schematic Diagram for Installation Deflection Angle
P1T000109
6.3.2Adjustment of Lower Stopper Bolt
Press the clutch till the working stroke of clutch master cylinder reaches 25mm. Then, adjust the lower
stopper bolt (see No. 2 in Fig. P1T000107) till the bolt head contacts the clutch pedal and restricts the
clutch pedal from moving downwards continuously. Finally, tighten the lower stopper bolt.
6.3.3Inspection and Adjustment of Clearance at Release Bearing
This vehicle is equipped with a pull-type clutch so such adjustment is unnecessary.

82
6.3.4Installation Requirements for Clutch Booster Cylinder
For the clutch booster, its port 11 is connected to the air inlet line while its port 14 is connected to the oil
inlet line. When the booster is installed, the arrow on the front end face shall be upwards. (Refer to Fig..)
Schematic Diagram for Installation of Clutch Booster Cylinder
P1T000110
After the clutch booster push rod is connected to the fork rocker arm, the angle of push rod cannot be
more than 3°; otherwise, the service life of booster will be reduced and even oil or air leakage may be
caused directly. (Refer to Fig.)
Installation Angle of Clutch Booster
P1T000111
83
6.4Precautions for Use and Maintenance of Clutch Control System
6.4.1Air in Hydraulic system
If air exists in the clutch hydraulic system, the effective stroke of booster cylinder push rod will be
reduced, the separation of clutch will be incomplete, and the shift lever will be difficult to be pushed to the
corresponding gears. During assembling or removal of oil pipes, loosen the bleed screw of booster
cylinder (Fig. P1T000112); add the brake fluid of specified designation from the oil can; press the clutch
pedal and simultaneously supplement the brake fluid till the fluid overflows from the exhaust valve;
tighten the bleed screw, and then quickly press the clutch pedal for several times and then press and
hold the clutch pedal; loosen the bleed screw of booster cylinder till no air leaks; tighten the exhaust
valve and repeat the above steps for 2~3 times. In this way, the air in the hydraulic system will be
thoroughly discharged.
Position of Bleed Screw
P1T000112
During exhaust, tighten the exhaust valve or union nut before releasing the pedal, to avoid suction of air.
When the pedal is released, it shall get back to the maximum height so that the brake fluid in oil can will
be supplemented to the total cylinder hydraulic chamber.
6.4.2In the first maintenance of a new vehicle, the clearance shall be readjusted once. In each Level-II
maintenance, namely, vehicle mileage reaching 12,000km every time, the clearance shall be checked
and adjusted once. In each Level-I maintenance, namely, vehicle mileage reaching 4,000km every time,
the clearance shall be checked once.
6.4.3The DOT3 brake fluid is used as the working medium of the hydraulic system. During removal and
installation of oil pipes, a threaded sealant can be used to seal the union nut and connector.
6.4.4During replacement of brake fluid, the residual fluid left in the hydraulic system shall be drained out
thoroughly and then the brake fluid of the specified designation and batch shall be filled uniformly.
6.4.5The brake fluid is corrosive, so it needs to prevent the brake fluid from splashing on the human
body or paint surface during exhaust.
6.4.6The brake fluid selected must conform to HZY3, HZY4, DOT3, DOT4 and similar standards. It is
forbidden to use mineral oil or other poor quality brake fluid.
84
6.4.7The booster selected must be as long as the push rod, to avoid burnout of clutch disc or oil leakage
of booster.
6.4.8During maintenance, the professional technicians of repair factory shall be employed to remove,
disassemble, clean, adjust and replace all damaged seals and relevant components. These parts and
components must be cleaned with ethyl alcohol and then dried with compressed air, to avoid invasion of
external dust or foreign matters. During replacement of new seals, the seal lubricating grease must be
applied and it is forbidden to perform the assembling by force.
6.5Common Faults and Troubleshooting
6.5.1Incomplete Separation of Clutch or Spongy Brake Pedal
When the clutch is pressed, the clutch cannot separate completely, the lever cannot be
Fault pushed into a gear, abnormal sounds can be heard when the lever is pushed into a
gear, or a spongy brake pedal is felt.
(1) The clearance of master cylinder push rod is too large.
(2) The clearance of fork rocker arm is too large.
(3) Air exists in the braking line.
Main causes (4) The oil pipe expands and the stroke is reduced.
(5) The booster leaks air or oil.
(6) The master cylinder leaks inside so a pressure cannot be provided.
(7) The clutch pressure plate spring is soft.
Solutions:
1Measure the movement distance of clutch booster push rod or the swing distance of
rocker arm.
If the swing distance is more than 25mm (20mm for most vehicle models; please refer
to the vehicles of the same model), the fault cause is that the clutch pressure plate
spring is soft and the replacement of clutch pressure plate can eliminate this fault.
2.1If a connector leaks oil, the connector can be tightened with a spanner or it can be
replaced.
Steps
2.2If an oil pipe, booster or master cylinder leaks oil, a new one shall be used instead of
1Check the clutch booster
the old one.
push rod for its stroke.
2.3If an oil pipe expands, it shall be replaced.
2Check the booster, oil pipe
3Check and adjust the push rod clearance, and gently shake the push rod with hands to
and connector, and master
solve the problem.
cylinder for oil leakage. Check
4.1Eliminate the faults as per 6.4.1.
the oil pipe for expansion.
4.2Fill oil from the oil pump through the bleed screw, or use a shampoo bottle with a
3Check the clearance of
pump head to instead of the oil pump.
master cylinder push rod.
5.1Remove the clutch booster air inlet line or thoroughly remove the air sources of the
4Discharge the air in the
vehicle. Then, press the clutch pedal. If the pedal can be pressed to the metal (i.e.
system line.
master cylinder subject to internal leakage), replace the master cylinder (provided that
5Check the clutch master
the oil pipe does not expand).
cylinder for internal leakage.
5.2Remove the clutch master cylinder oil outlet line. Seal the clutch master cylinder oil
outlet with a plug. Then, press the clutch pedal. If the pedal can be pressed to the metal
(i.e. master cylinder subject to internal leakage), replace the master cylinder. (In this
process, the operator needs to ensure that no air exists in the master cylinder after the
plug is installed, to avoid incorrect judgment.)
5.3Press the clutch pedal, push the lever to gear 1, and then hold the pedal. If the
vehicle starts to run in 15~20s,
the master cylinder is subject to internal leakage and it shall be replaced.
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6.5.2Heavy Clutch Pedal
When the clutch pedal is pressed, the pedal force is strong and sometimes the pedal
Fault
even cannot be pressed down.
(1)The air line leaks air or the air pressure is low.
(2)The clutch pedal mechanism is deformed, stuck or jammed.
Main causes (3)The clutch release fork and the release bearing are stuck tightly.
(4)The clutch booster piston is stuck.
(5)The clutch master cylinder piston is stuck.
Solutions:
1.1Check whether the air pressure (more than 0.7MPa in general) in the air reservoir is
low.
1.2Check the air line and the clutch booster for air leakage. Tighten the connector or
replace the corresponding components subject to air leakage.
1.3Check the air line for throttling, which slows down the air flowing into the salve
cylinder.
Steps 2Check the clutch pedal mechanism for deformation. Check the pedal for smooth
1Check the gas line and air movement. Replace the corresponding components in case of any problems.
pressure. 3Remove the pin shaft from the clutch booster push rod fork. Manually push the fork
2Check the clutch pedal rocker arm to ensure whether the rocker arm can rotate or not. In case of any
mechanism. stagnation, apply the lubricating grease to the moving parts of both rocker arm and
3Check the clutch fork and bearing, or check the fitting surface between rocker arm and bearing for abrasion.
the release bearing. 4Loosen the bleed screw, press the pedal, and tighten the screw after releasing the
4Check the clutch booster. pedal. If the pedal force is not strong, remove the clutch booster air inlet line, oil inlet
5Check the clutch master line and fork rocker arm. Manually pull (or push in case of push rod with ball head
cylinder. structure) the booster push rod. If the booster piston does not return to its original
position or it cannot be pulled back, a new component shall be used instead of the old
one.
5If the booster mentioned in 4 is normal, remove the master cylinder oil outlet line, and
then press the clutch pedal. If the pedal force is strong or the pedal is stuck, a new
component shall be used instead of the old one (the guarantee service does not include
a heavy or stuck clutch pedal caused by the expansion of seal ring due to incorrect
brake fluid). If the pedal force is not strong, the oil pipe may be subject to throttling.
6.5.3Stuck Clutch
When a vehicle starts to run, the driver feels that the clutch is stuck and the vehicle is
Fault
subject to shaking or play.
(1)The clutch pressure plate or friction disc is uneven.
(2)The clutch pedal mechanism is deformed, stuck or jammed.
Main causes (3)The clutch release fork and the release bearing are stuck tightly.
(4)The clutch booster piston is stuck.
(5)The clutch master cylinder piston is stuck.
Solutions:
1Do not start the engine, slowly press and release the clutch pedal, hear whether the
Steps
exhaust sounds of booster are continuous or not. If the sounds are continuous, the fault
1Confirm the fault.
that may be caused by uneven clutch pressure plate or friction disc.
2Check the clutch control
Replace the clutch pressure plate or friction disc.
system.
2If the exhaust sounds are discontinuous, conduct the troubleshooting as per 3 and 6
specified in "Heavy Clutch".
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6.5.4Burnout of Clutch Friction Disc
The booster push rod is stuck or cannot return to its original position. The clutch cannot
Fault
be engaged. The friction disc is burnt out.
(1)The clearance of master cylinder push rod does not reach 0.5~1mm (the push rod
cannot be shaken).
Main causes (2)The rocker arm does not have a clearance. Therefore, the clutch is in the semi-
clutched state, thus causing burnout of friction disc.
(3)The booster push rod with a ball head structure is too long.
Steps
Solutions
Check the clearance of
Check and adjust the push rod clearance, and gently shake the push rod with hands to
master cylinder push rod and
solve the problem.
that of rocker arm.
6.5.5Booster Subject to Air Leakage with Clutch Pedal not Pressed
Fault The booster leaks air when the clutch pedal is not pressed.
(1)The line leaks air.
Main causes (2)The assembling or repair site is not clean, so impurities get stuck at the booster valve
and the valve cannot be closed.
Solutions
Steps
1Repair the air pressure line.
Check the booster positions
2Feel whether there is any air flow comes from the exhaust outlet with hands. If
subject to air leakage.
possible, remove the exhaust outlet bolt for repair.
6.5.6Other Faults
Fault Main causes Solutions

The assembling or repair site is not clean, so
impurities get stuck at the master cylinder oil Clean the hydraulic line and master
Oil pressure system incapable
inlet valve, the valve cannot be closed, and cylinder with industrial alcohol or brake
of pressure establishment
the oil pressure system fails in pressure fluid.
establishment.
After all of the above factors are eliminated,
Booster subject to air leakage Replace the booster if repair is
the operator can still hear the sound of air
with clutch pedal pressed impossible.
leakage or feel the air flow with hands.
(1)Repair the oil pressure line or remove,
(1)The incorrect brake fluid (forged and fake
Master cylinder not returning disassemble and clean the line and
commodities or unspecified synthetic brake
to its original position, getting assembly. Replace the seals.
fluid) is added so the seals fail early.
stuck, or returning to its (3)The product guarantee service does
(3)The incorrect mechanical oil is added, so
original position very slowly not include the seals damaged due to
the seals expand and lose effectiveness.
incorrect brake fluid or mechanical oil.
87
DW90A 7. Steering System
7.Steering System
7.1Structure and Principle of Steering System
(1) Structure of Steering System

Structure of Steering System
1 4
3
P1TH00025
1. Steering gear 3. Steering cylinder 5. Hydraulic oil tank

2. Priority valve 4. Gear pump
88
7. Steering System DW90A
(2) Principle:
Schematic Diagram of Steering System
P1T000114
1. Steering cylinder 2. Steering gear 3. Priority valve 4. Hydraulic Pump
Working process: a. The hydraulic oil reaches the port P of priority valve from the oil pump. The oil
reaches the port CF at first, and then reaches port P of steering gear, and finally flows through the one-
way valve. When the steering gear valve element is in the middle position, the hydraulic oil cannot pass.
In this case, the oil pressure in the priority valve control oil line will increase. The oil in the left control line
of priority valve passes through three orifices and then flows back to the oil tank. The right control line is
static so the oil pressure in the right line is more than that in the left line. The priority valve element
moves towards the left side and the hydraulic oil from oil pump will flow to the port EF, thus supplying oil
to the equipment. B. When the steering wheel is turned right, the hydraulic oil passes through the port
CF, priority valve P and one-way valve in turns. The steering gear is in the right position, and the
hydraulic oil will flow into the oil cylinder through the oil line, thus forcing the tires to change their
direction.
89
7.2.Structure and Principle of Main Components
(1) Structure and components of steering cylinder

Structure of Steering Cylinder
10 9 13 8 7 6 12 11 3 4 3 2 1 17 16 14 15 18 19 20
21 22
Rod head
P1T000115
S/N Name Specification S/N Name Specification

1 Cylinder tube 12 Retainer - O-ring T3
assembly
2 ROD AS 13 O-ring 70x2.65
3 Cylinder head 14 Piston
4 Sleeve 40x50x15 15 Seal - piston SRP 70x55x7.3
5 Round wire snap ring D46.8x1.5 16 O-ring 39.4x3.1
- for holes
6 Seal - for buffering 40x55.5x6.3 17 Retainer - O-ring T3 40.2x45x1.25
7 Seal - piston 40x50x6 18 Support ring 70x65x10
8 Retainer - U-ring 40x50x3 19 Steel ball D4
9 Steel - dustproof 40x52x7/10 20 Screw - for tightening inner M6x8L
hexagon concave end
10 Round wire snap ring D55.3x1.5 21 Retainer D47x8.5L
- for holes
11 O-ring 64.4x3.1 22 Knuckle bearing GE30ES
90
(2) Structure and components of Priority valve

Structure of Priority Valve
1 2 3 4 5 6 7 8
9 10 11
P1T000116
1. Plug 4. Throttle plug 7. O-ring 10. O-ring

2. O-ring 5. Spool 8. Plug 11. Spring
3. Valve body 6. Throttle plug 9. Plug
(3) Structure and components of steering gear

Structure of Steering Gear
31 30 29 28 27 26 25 24 16
23
11 10 13 10 14 15
10 12
2 3 4 6 7 8 9
1 5
20 19 18 17
32
35 30 29 34 33
P1T000117
1. Dust ring 9. Valve body 18. Spring 28 Valve element

2. Front cover 10. O-ring 19. Stop pin 29. Spring
3. O-ring 12. Baffle plate 20. Steel ball 30. O-ring
4. Shaft seal 13. Stator and rotor pair 23. One-way Valve 31. Plug
5. O-ring 14. Rear cover 24. Plug 32. Valve base
6. Retainer 15. Bolt 25. O-ring 33. Steel ball
7. Plane bearing 16. Pin 26. Pipe plug 34. Ball seat
8. Slip ring 17. Leaf spring 27. Valve base 35. Plug
91
7.3Steering Control
The steering control of this vehicle features full hydraulic steering. A driver can control the vehicle to run
along a straight line or make a turn with the steering wheel.
(1) Middle position: When the vehicle runs along a straight line, the driver does not need to apply a
steering force to the steering wheel and the wheel will not rotate.
(2) Steering process: When the vehicle needs to make a turn, the driver will turn the steering wheel. In
this case, the hydraulic oil will push the oil cylinder to realize the steering. Specifically, if the driver
turns the steering wheel to the left side, the vehicle will turn left; if the driver turns the steering wheel
to the right side, the vehicle will turn right.
(3) Straightening of steering wheel: After the steering control is finished, the driver needs to straighten
the steering wheel. In this case, the hydraulic oil will push the oil cylinder to realize this purpose. The
vehicle wheels will get back to be along a straight line till the vehicle itself runs straightly.
(4) Flow amplification effect: It refers to the characteristic that the steering effective displacement is
equal to the measured displacement (400ml/r) in case of the steering at a low speed (5RPM) and the
equivalent displacement (640ml/r) in case of the steering at a high speed (5-60RPM). The
advantages are as follows: If the steering wheel is slowly turned when the vehicle is running, the
direction correction will not be too much; when the running direction of vehicle needs to be changed
quickly, the driver can increase the input speed of steering wheel to increase the steering flow, thus
realizing the fast steering.
7.4Precautions
1. The steering gear oil cylinder works depending on the hydraulic oil supplied from the steering oil
pump driven by the engine. The vehicle shall not slide when the engine is shut down; otherwise, the
steering force will disappear and accidents may occur.
2. The vehicle shall be stopped immediately when the steering system fails due to oil pump or oil line.
92
7.5Maintenance
(1) Adjustment of Steering System

Positioning Bolt of Front Axle
P1T000118
1. Steering wheel 3. Hydraulic oil tank 5. Steering cylinder

2. Steering gear 4. Hydraulic Pump
Normally, the front axle is positioned via an adjusting screw and a block. It does not need any adjustment
in general unless the screw becomes loose. The adjustment method is as follows:
a) Fully tighten the positioning bolt that has been loose.
b) Fully turn the steering wheel towards the direction of bolt to be adjusted. Mark the oil cylinder in
this direction. Slowly turn the steering wheel till the oil cylinder extends by 20mm. Screw out the
positioning bolt till it contacts the block.
c) Adjust the other positioning bolt using the same method.
(2) Maintenance of steering system
a) Regularly replace the old hydraulic oil with suitable new one based on the ambient temperature.
In general, HM-46# hydraulic oil is suitable and HV-46# hydraulic oil is applicable to low
temperature and high altitude environment.
b) Fill of hydraulic oil tank: For the first filling of hydraulic oil, fill the oil till the oil level reaches the
middle position of dipstick. After the engine is started for running, supplement the oil till the oil
level reaches the middle position again. Meanwhile, check the hydraulic oil level before startup
every day, to ensure that the hydraulic oil level is in the middle of dipstick, as shown in Fig. . (In
case of filling or replacement of oil, avoid water flowing into the oil tank. Especially in rainy days,
fill oil indoors or at the place with rain shelter.)
c) Regularly (20h weekly) apply the lubricant to the oil cylinder support (pin shaft at the link joint), as
shown in Fig..
93
Indication of Hydraulic Oil Level
Refueling position
P1TM00082
Pin Shaft Points to Be Lubricated
P1T000120
94
Common Faults and Troubleshooting for Steering Gear and Priority Valve
Diagnosis of Common Faults of Steering System
Fault Cause Troubleshooting method
The junction surface between Check and clean the junction
The junction surface is polluted.
components leaks oil. surface.
The front cover of steering
Oil leakage The shaft seal ring is damaged. Replace the seal ring.
gear leaks oil.
The tightening torque of bolt
The valve bolt (plug) leaks oil. Tighten the bolts(plug).
(plug) is insufficient.
The steering wheel is heavy
Check the oil pump and the oil
when it is turned fast and light The oil supplied is insufficient.
supply line.
when it is turned slowly.
The oil cylinder creeps, the oil Discharge the air in the system.
contains bubble, irregular Air exists in the steering system. Check the oil pump inlet for air
sounds are heard. leakage.
Check whether a steel ball is
The steering is hard, and the The manual steering one-way provided. Check whether the
steering cylinder fails to work. valve fails. steel ball is cushioned by
Hard steering pollutants.
The FK overload valve leaks and Check the oil cylinder for internal
The oil cylinder does not
the oil cylinder is subject to leakage. Replace the FK
work.
internal leakage. combination valve.
The FK safety valve leaks or the
The steering is easy at no Replace the FK combination
safety valve spring does not
load and hard at heavy load. valve.
work.
The viscosity of hydraulic oil is
Hard steering
too high.
The steering wheel fails to
The leaf spring fails. Replace the leaf spring.
return to the middle position.
The pressure runout The pin is bent or broken, and the
increases significantly, and pin groove of couple axle is Replace the pin or couple axle.
even the steering fails. ruptured.
When the steering wheel is The couple axle is incorrectly
Steering turned, it immediately turns to installed at the position of rotor,
malfunction Make a reassembling.
the reverse direction or while the rotor is at the position of
swings left and right. couple axle.
A running vehicle deviates
from the driving direction, and The two-way overload valve is
it does not make corrections cushioned by pollutants or the Check the overload valve.
when the steering wheel is spring fails.
turned.
95
Common Faults and Troubleshooting for Steering Gear and Priority Valve
Diagnosis of Common Faults of Steering System
The steering column and the
The pressure drop in the
valve element are not installed
The steering middle position increases.
concentrically. The steering
wheel cannot When the steering wheel
column tightly jacks the valve Carry out the troubleshooting as
get back to the stops rotating, the steering
element in the axial direction. The per the actual situations.
middle position gear does not unload (the
steering resistance of steering
automatically. vehicle deviates from the
column is too strong so the lead
driving direction).
spring is broken.
Steering wheel
The steering wheel cannot be
incapable of
turned to the extreme Appropriately increase the safety
being turned to The safety valve pressure is low.
position, and the steering is valve pressure.
the extreme
hard.
position
After the steering oil cylinder
is turned to its extreme
position, the steering wheel The overload valve pressure is Appropriately increase the
No end point
can be easily turned when a low. overload valve pressure.
force is applied (no sense of
end point).
In case of power steering, the
oil cylinder piston reaches its
extreme position but the
The radial or axial clearance of The radial or axial clearance of
No manual driver cannot obviously feel
the stator and rotor pairs is too the stator and rotor pairs is too
steering the end point. In case of
large. large.
manual steering, the steering
wheel can rotate but the oil
cylinder keeps still.
96
Common Faults and Troubleshooting for Oil Cylinder

Diagnosis of Common Faults of Steering Cylinder
Remove the scratches with oil
The sliding surface of piston rod stone and polish the sliding
Piston rod has scratches and rust. surface. If oil still leaks, replace
all piston rods.
The electroplated layer falls off. Seal
Pollutants get stuck on the seal, Remove the pollutants and
thus abrading the seal. replace the seal.
The seal is burnt out due to air Replace the seal and exhaust the
compression. oil cylinder.
The piston rod Replace the seal, check the
leaks oil (the Seal - piston rod hydraulic oil for its quality, check
piston rod The seal is subject to aging. the causes of abnormal high
surface is temperature, and replace the
accumulated hydraulic oil when necessary.
with oil drops). The seal is deformed and
squeezed out.
Replace the seal and check the
The seal is deformed and
Seal - for buffering causes of abnormal high
squeezed out.
pressure.
The dust ring is polluted. Remove the pollutants.
Steel - dustproof
The dust ring lip is damaged. Replace the seal.
The abrasion exceeds the
Sleeve allowable limit or there are some Replace the lining.
scratches.
The junction Remove the pollutants, replace
The O-ring is polluted or
surface O-ring the O-ring, and check the fitting
damaged during assembling.
between surface.
cylinder head
and tube leaks Cylinder head threads The cylinder head is loose. Retighten the cylinder head.
oil.
Remove the scratches by
The inner wall is subject to
Cylinder tube polishing. Replace the cylinder
scratches or deformation.
tube if it is impossible to repair.
The bending of piston rod
Piston rod Replace the piston rod.
exceeds the allowable limit.
The oil cylinder
The seal inside cylinder head is Check and remove the pollutants.
extends and Cylinder head
polluted. Check the lining.
contracts not
smoothly. The inner hole is deformed, the
Replace the cylinder tube
Cylinder tube piston has pits, and the cylinder
assembly and the piston.
tube has scratches.
97
Common Faults and Troubleshooting for Oil Cylinder

Diagnosis of Common Faults of Steering Cylinder
Replace the seal and check
Piston seal It is abraded. whether the piston and the
cylinder tube inner wall fail or not.
The piston rod
extends or Replace the cylinder tube
contracts Cylinder tube The inner wall is damaged. assembly. Attempt to repair if the
automatically scratches are not severe.
and does not Retighten the nut. Check the
work at a Piston nut It is loose. setscrew and threads for
certain working damage.
speed.
Check whether the control valve
The valve is subject to internal
Control valve is polluted or damaged. Replace
leakage.
the valve if damaged.
The impact is
strong when Replace the pin shaft and bearing
the oil cylinder Pin shaft and bearing bushing It is excessively abraded. bushing. Apply the lubricant to
extends or ensure full lubrication.
contracts.
Abnormal noise The lubrication is insufficient or
can be heard the type of lubricant is incorrect. Replace the pin shaft and bearing
when the oil Pin shaft and bearing bushing bushing as needed. Apply the
cylinder is It is excessively abraded. lubricant to ensure full lubrication.
working.
98
8. Brake System DW90A
8.Brake System
8.1Operation Instructions and Principles of Brake System
The brake system of the wide-body dump truck is a double-circuit pneumatic brake system consisting of
a service brake (foot brake), a parking brake (hand brake) and a secondary brake (engine in-cylinder
brake or exhaust brake).
(1) Service brake
Service brake is a pedal-operated double-circuit pneumatic brake whose maximum working pressure is
1 MPa. The first loop acts on the first axle wheels while the second one on the intermediate/rear axle
wheels. Once the pressure of one air reservoir of the two loops drops to below 0.55 MPa, the vehicle
shall be stopped immediately to find out the causes of pressure drop. Several times of braking in a short
time may also result in pressure drop to below 0.55 MPa.
(2) Parking brake
Parking brake is an energy storage spring brake, which acts on the intermediate and rear axles through
the spring energy storage chamber on the axles. When the driver stops the vehicle, switch the hand
brake switch to the parking position to make the vehicle stay put. Only after the hand brake is released,
loop pressures of brake systems 21 and 22 are higher than 0.6 MPa (low pressure alarm light out), the
hand brake indicator light is out and the compressed gas pushes the spring back into position can the
brake be released. Hand brake can also serve as emergency brake. If the foot brake happens to fail in
case of emergency during driving, the vehicle can be braked by use of hand brake. When the service
brake is damaged and the vehicle needs dragging, the hand brake can be used as service brake to drag
the vehicle.
(3) Secondary brake
Two secondary brakes including engine in-cylinder brake and exhaust brake are provided for the vehicle.
The engine in-cylinder brake needs no manual operation because the vehicle can automatically
recognize the need to use this function and can actuate this function to realize secondary braking where
needed.
During driving down a long slope in mountainous areas, the butterfly valve on the exhaust pipe will be
closed under the action of the solenoid valve and cylinder, thus realizing engine exhaust braking. The
use of exhaust brake can reduce the use of main brakes, and the wear of tyres and wheel brakes, thus
extending their service lives.
Note that when using the engine exhaust brake: the transmission shall not be in neutral and the
clutch pedal shall not be stepped. When the engine speed is lower than 1,100 r/min, the exhaust
brake will not work. The lower the position, the better the exhaust braking effect.
99
DW90A 8. Brake System
Structural Layout of Brake System
4 2
3 P1TB00015
1. Differential relay valve 2. Relay valve 3. Desiccator+ four-circuit 4. Air kettle

protection valve
Once the engine is started, the air compressor (also called inflating pump) begins to work. The high-
temperature air from the air compressor is cooled through the first air tube, and then flows to the
desiccator to remove moisture before going to the four-circuit protection valve. When the pressure
reaches the specified cracking pressure of the four-circuit protection valve, the air flows to all air
reservoirs, from there to relay valves and finally to the brake chamber to realize braking.
Schematic of brake system
P1T000122
100
8.2Description of Main Important Components
8.2.1Desiccator
The desiccator not only has the function of unloading valve but also can dry the air from the air
compressor to a certain extent with a return connection as the intermediate connection. To be specific,
when the desiccator is used as an unloading valve, the vapor and oil gas in the desiccator will be
broughtto the atmosphere by the air in the air reservoir, thus realizing regeneration of desiccator. Refer
to Fig..
Profile and Working Principles of Desiccator
1
7
2
6
5
4
P1T000123
1. When air flows through the particle 4. Condensate water appears as the 7. Drying cylinder
drying cylinder, its moisture is temperature drops, and the
absorbed and stay at the upper condensate water flows to the
layer of the cylinder. outlet valve through the channel.
2. Air compressor 5. Four-circuit protection valve
3. Channel 6. Open the check valve.
8.2.2Four-circuit Protection Valve
The four-circuit protection valve is used in multi-circuit pneumatic brake system. When one of the circuits
fails, certain safe brake air pressure can still be ensured for other circuits. The four air outlets are
independent from each other and can be used to control the rear axle, front axle, parking and secondary
circuits. The cracking pressure of the first and second circuits can be the same as or different from that of
the third and fourth circuits, but not less than the later. It can be adjusted by use of a pressure adjusting
spring.
The four output ports of the product are labeled as “21”, “22”, “23” and “24”. During installation,
corresponding tubes shall be connected according to the numerical labels (port 21 to rear axle brake
circuit; port 22 to front axle brake circuit; port 23 to secondary air circuit; port 24 left as it is). Do not make
any mistakes during installation. Otherwise, the brake system will malfunction.
101
Profile of Four-circuit Protection Valve
P1T000124
8.2.3Master Brake Valve (Also Called “Foot Brake”)
During working as shown in Fig., the upper circuit outputs brake signal pressure to the relay valve to
open it, and make the compressed air in the (intermediate) rear axle brake air reservoir flow via the relay
valve to the (intermediate) rear brake chamber, putting the (intermediate) rear brake camshaft in rotation,
stretching leading and trailing shoes of the drum brake and thus realizing braking of the (intermediate)
rear axle wheels. The lower circuit outputs brake signal pressure to the relay valve to open it, and make
the compressed air in the front axle brake air reservoir flow via the relay valve to the front brake sub-
chambers on the left and right, putting the front brake camshaft in rotation, stretching leading and trailing
shoes of the drum brake and thus realizing braking of the front wheels..
Braking of Master Brake Valve
P1T000125
1. The service brake pedal is pressed. 3. The push rod moves downwards under the effect of
2. Roller roller.
4. Open the valves in the chambers 11 and 12, and
simultaneously close the exhaust valves.
102
Releasing of Master Brake Valve
P1T000126
1. Release the service brake and the pedal. 2. Close the valves in the chambers 11 and 12, and
simultaneously open the exhaust valves to control the
return air to be exhausted through the exhaust valve.
8.2.4Hand Brake
Function: It can realize follow-up control of the vehicle and combination vehicle emergency brake and
parking brake, and its inspection function is used to check the slope parking ability of the vehicle when
the tractor is in parking brake state. The vehicle can be automatically returned to the driving position by
controlling the handle between the driving and parking positions and can be locked in the parking
position.
Structural Diagram of Hand Brake
P1T000127
1. The lever is at the rightmost position. In this case, the 2. When the lever 1 is turned by a=42.5°, the lever is right
vehicle brake is completely released. at the thrust position. In this case, the vehicle is
completely braked, and the residual air in the control
port is exhausted from Port 3.
103
8.2.5Relay Valve
Working principles: Generally, the air inlet is connected to the air reservoir while air outlet the brake
chamber. When the brake pedal is stepped on, the output pressure of the brake valve is input as control
pressure of the relay valve under which, the intake valve is pushed open. Then the compressed air flows
directly from the air reservoir to the brake chamber via the air inlet, without passing through the brake
valve, which greatly shortens the inflating path of the brake chamber and accelerates its inflation.
Working Principles of Relay Valve
Step on the pedal

Input brake signal 3
Pneumatic, relay
valve
Open
4
P1T000128
1. Master valve 2. Air reservoir 3. Relay valve 4. Brake chamber
For braking, the compressed air from the brake valve enters chamber A from port 4, moving the piston 7
downward to close the exhaust valve 6. Then the intake valve 5 is opened and the compressed air will
flow from port 1 to the brake chamber via port 2. In a balanced state, the intake and exhaust valves will
automatically close.
104
8.2.6Differential Relay Valve
The differential relay valve is used to prevent overlapping of forces in the combined spring brake cylinder
and brake chamber (spring brake chamber) when the service and parking brake systems are used at the
same time, thus avoiding quick inflation and exhaust of the spring brake cylinder caused by overloading
of mechanical driving elements.
Working Principles of Differential Relay Valve
With no brake
1 signal pressur
Piston 1
Piston 2
4
To spring chamber
Spring cavity
P1T000129
1. Hand brake valve 2. Air reservoir 3. Differential relay 4. Master valve 5. Brake chamber
valve
Port 1 to air reservoir; port 2 to brake chamber; port 41 to port 2 of brake valve; port 42 to port 2 of brake
valve; port 3 to the atmosphere
105
8.2.7Brake Chamber
The front, intermediate and rear brake chambers of the vehicle are all of a combined type acting on the
front, intermediate and rear service brakes and realizing parking and emergency brake. The diaphragm
spring brake chamber is used to provide wheel braking force. The diaphragm chamber in the combined
spring brake chamber is used for service braking, and the spring cavity is used for parking braking and
emergency braking. The two cavities are totally independent.
Structural Diagram of Brake Chamber
P1T000130
1. Service brake port 2. Parking brake port
During service braking, the compressed air from operation of foot brake valve enters cavity A through
port 11, acts on the diaphragm d and pushes the return spring c of tray a; the spring c then pushes out
the push rod b, and the force applied on the diaphragm d acts on the brake arm through the push rod b,
generating braking torque on wheels.
During parking braking and emergency braking, operate the hand brake valve to release, in whole or in
part the compressed air in the cavity B via port 12, and the spring f releases its energy in whole or in part
accordingly, applying braking torque on wheels through piston e, diaphragm d, tray a, push rod b and
brake arm. Unscrew the release bolt g to release the parking brake. It’s a manual way to release the
brake in case of no compressed air.
106
8.2.8Air Reservoir
Air reservoir
P1T000131
Functions of air reservoir:

a. Energy storage
Air supply is required almost everywhere on the wide-body dump truck from sirens to brakes. Without an
air reservoir, it is far from enough to rely on air supply of the air compressor alone. In this case, the air
pumped by the air compressor needs to be stored in the air reservoir.
b. Filtration
We all know that air contains a large amount of dust and water molecules as well as engine oil pumped
in due to fault of the air compressor. Once entering the vehicle air circuits, they tend to damage vehicle
parts and components with time passing by, posing certain hazard to driving safety. The air pumped by
the air compressor will be detained temporarily in the air reservoir. As the water molecules, dust and
engine oil in the air are relatively heavier than the air, they will fall to the bottom of the air reservoir, thus
giving the air reservoir the role of a filter.
c. Pressure stabilization
When the air is pumped in the vehicle by the air compressor, upward and downward movement of the air
compressor piston result in extremely unstable compressed air in the vehicle air circuits. The air
reservoir, like a water reservoir, detains the unstable air there before letting it out through the outlet as
stable compressed air.
d. Cooling
After air is absorbed in the air compressor from the outside world, its volume will become small and
meanwhile its temperature will rise to a certain extent. A higher temperature means a relatively small
density, and thus a reduced volume of air stored. Moreover, the moisture in the air is hard to settle due to
a higher temperature. Therefore, the air must be cooled before entering the vehicle air circuits.
Generally, the following parts are installed on the air reservoir: quick-inflating connector, water discharge
valve, safety valve and air pressure sensor.
107
8.3Precautions
(1) Power steering systems (clutch booster and gear shifting valve of auxiliary transmission) can be
operated after the brake lamp goes out. However, the vehicle is not yet fully ready for driving before
the air reservoir pressure reaches 0.7 MPa. Only after the air reservoir pressure reaches 0.7 MPa
can the brake reach specified braking performance.
When the vehicle is stopped, the hand brake must be pulled!
(2) Before the engine is started, the hand brake valve handle must be placed in the braking position.
Otherwise, when the brake system pressure rises, the original parking brake effect will be eliminated.
Never start the vehicle before the signal lamp goes out!
(3) To reduce brake failure and reduction of braking force caused by too hot brake shoes during
continuous stepping on the brake, it is suggested that exhaust brake should be used down a long
slope and a proper position be selected according to the gradient and length of the slope.
(4) The engine brake cannot be used as emergency brake in place of the service brake, or used as the
parking brake.
(5) The exhaust brake begins to work only when the engine speed is higher than 1,000 rpm. The high-
efficiency speed range of the exhaust brake is 1,600~22,000 r/min. To improve brake efficiency, a
proper transmission position shall be selected for use of the engine brake. Generally, the position for
going up a slope shall be selected for braking down the slope.
(6) For driving on snowy or wet pavements, emergency brake shall be used only when necessary. When
emergency brake is used, pay attention not to lock the wheels for fear of accidents caused by side
slip. Engine brake shall not be used on snowy pavements and shall be used with caution on wet
pavement.
108
8.4Maintenance
1. Check the airtightness of the brake system.

(1) Airtightness of air circuit system: Start the compressor and stop it when the stored air pressure
reaches the maximum working pressure. Observe the duplex pressure gauge. The pressure drop
shall not exceed 0.01 Mpa within 10 min. If not, it means poor airtightness and inspection shall be
carried out.
(2) Airtightness of brake system: Shut down the motor and step on the brake pedal for 3 min. If the
pressure indicated by the white pointer of the pressure gauge remains unchanged, it means the
airtightness is reliable.
2. Maintenance
(1) The brake line airtightness shall be regularly checked to ensure that it is in good condition. Once any
bending, scratching or squashing is found, timely replacement is required.
(2) Replacement of desiccator: During the use of the air desiccator, the brake air reservoir shall be
regularly checked for ponding. If water is released from the air reservoir once the pull ring of water
discharge valve is pulled, then desiccant shall be replaced immediately. If the drying cylinder is of a
non-removable structure, then the whole drying cylinder shall be replaced. Under worse use
conditions with too much dust and foreign matters, the period of replacement shall be shorter.
Normally, the air reservoir is discharged once every month. In case water is discharged, replacement
is required.
109
8.5Diagnosis and Removal of Common Faults of Brake System
(1) Common Faults and Fault Removal of Brake System
S/N Fault Fault Diagnosis Fault Removal

The rated pressure of the pressure- Re-adjust the bolts of air
System pressure too high
1 regulating valve of air desiccator is not desiccator for pressure
or too low
properly adjusted. regulating.
Slow or no inflation of a.The brake pipeline leaks; a.Repair the leaking pipeline;
2
system b.The air compressor fails; b.Replace the air compressor;
3 Water in brake pipeline Dying cylinder of desiccator not working Replace the desiccator.
a.Shut down the engine. Check
for leakage and repair it.
b.Place the hand brake valve in
the parking position. If the air
a.The pipeline cracks;
pressure does not fall, it means
Low air pressure during b.The diaphragm cavity of the spring
4 diaphragm cavity of the spring
driving brake chamber leaks air.
brake chamber leaks air. Foreign
c.The relay valve leaks air.
matters shall be cleared and
diaphragm Y-ring replaced.
c.Repair the relay valve or
replace it.
(2) Common Faults and Fault Diagnosis of Braking Components

With the following causes: a. Engine oil
is mixed in the air compressor resulting
in failure of the molecular sieve; b.A
temperature of more than 65 °C results
in obvious degradation of drying
function; c.Water condensation in the air
reservoir is considered as failure of the
No drying function Replace the desiccator.
desiccator.
3With the following causes: a.The
pressure release cavity is filled with
foreign matters; b.The pressure release
Air valve is damaged due to expansion; c.
desiccator The pressure-regulating valve is
damaged.
O-ring leaks due to permanent
Clean the pressure release cavity
Leakage around retainer deformation caused by temperature,
and replace the O-ring.
pressure, oil stain and other factors.
With the following causes: a.The
Clear the pressure release cavity
pressure release cavity is filled with
to remove foreign matters and
foreign matters; b.The pressure release
Leakage at exhaust port replace the pressure release
valve is damaged due to expansion; c.
valve and pressure-regulating
The pressure-regulating valve is
valve.
damaged.
110

The four-circuit protection valve
shall be disassembled. If it is
Failure in inflation of one The valve of one circuit of the four-circuit
caused by a blocked valve, the
circuit of the four-circuit protection valve is blocked and cannot
fault can be removed by clearing
protection valve be opened.
the blockage and reassembling
the valve.
Four-circuit Leakage of four-circuit
protection The diaphragm and the valve body are Replace the diaphragm and the
assembly and degradation
valve cracked. valve body.
of braking performance
The pressure-regulating spring stiffness
Cracking and protection Replace the pressure-regulating
attenuates and the spring seat is
pressure drop spring and spring seat.
cracked.
Cracking pressure rise The valve is blocked and the valve return Replace the valve and valve
and impossible to adjust spring is broken. spring.
a.The intake valve and seals in the upper
or lower cavity of the master brake valve
The master brake valve
are damaged due to poor sealing of
leaks when the brake Replace damaged parts.
rubber seal ring.
pedal is not stepped on.
b.Leakage may also be caused by
Master mixing of air in relay valve ports 1 and 4.
brake valve
The pipe layout is improper or the design Rearrange pipes or re-design the
Nodding or drifting during
braking forces of front and rear axles are braking forces of front and rear
braking
too large. axles.
Rubber spring load is low or pipe flow is Replace the rubber spring or
Weak braking
small. rearrange pipes.
a.The diaphragm is broken or aged.
Leakage of service brake a.Replace the diaphragm.
b.Tightening force of the clamp is
diaphragm chamber b.Tighten the clamp.
insufficient.
a.The Y-shaped sealing ring of the large
cylinder in the spring cavity fails or has
foreign matters, and the breathing tube
in the spring cavity leaks. a.Replace the Y-shaped sealing
b.The sealing ring at the junction of the ring or clear the foreign matters.
spring cavity large cylinder and the ring b.Replace the sealing ring or
Brake Leakage of spring cavity
flange fails or has foreign matters, and clear foreign matters, and tighten
chamber in service
the connecting bolts are loose. the connecting bolts.
c.The sealing ring between the guide c.Replace the sealing ring or
cylinder and the connecting push plate clear the foreign matters.
fails or has foreign matters, resulting in
leakage at lock screws in the spring
cavity.
Insufficient parking a.Large spring load attenuates or
a.Replace the large spring.
braking force or parking breaks.
b.Readjust the length of push rod.
failure b.Position of clevis is adjusted improper.
111
DW90A 9.Operation Instructions of Rollback Cab Lifting System
9.Operation Instructions of Rollback Cab Lifting System
No personnel or other living beings are allowed in or under the cab, or 2 m in front of the cab
during cab rollback.Cab rollback is not allowed on a ramp. No personnel is allowed in the cab
when the cab is in rollback state.
9.1Principles of Cab Rollback Mechanism
(1) System Layout

Cab Lifting System Layout
3
1
2
4
5
7
P1T000132
1. Electric pump 3. Lifting cylinder 5. Hand pump 7. Connected to power

2. Motor connector 4. Hand-operated rocker 6. Controller supply
arm
(2) System schematic

Schematic Diagram of Cab Lifting System
P1T000133
112
9.Operation Instructions of Rollback Cab Lifting System DW90A
9.2Instructions for Cab Rollback
During cab fixation with mechanical locks, before lifting, the mechanical locks on both sides at
the rear of the cab must be manually opened; after cab dropping, manually lock the mechanical
locks on both sides before driving.
No personnel or other living beings are allowed in or under the cab, or 2 m in front of the cab
during cab rollback.Cab rollback is not allowed on a ramp. No personnel is allowed in the cab
when the cab is in rollback state.
Schematic Diagram of Mechanical Lock in the Cab
1 P1T000202
9.2.1Mechanical Lock in the Cab
(1) Cab lifting mode: Pull the reversing lever of the hand pump to the lifting position as shown in Fig. 1. In
this case, the manual or electric mode can be selected. When the manual mode is selected, insert
the manual rocker in the rocker insertion hole of the hand pump as shown in Fig. Shake the rocker up
and down and the cab can be rolled back. Alternatively, the electric mode can be selected by
manually pressing the controller button as shown in Fig. At this time, the electric pump is started and
the cab is lifted up.
Cab rollback is not allowed on a ramp. The cab shall be thoroughly rolled back each time before
repair or maintenance is carried out. No personnel is allowed in the cab when the cab is in
rollback state.
113
(2) Operation instructions for cab dropping mode: Pull the reversing lever of the hand pump back to the
dropped position as shown in Fig. 2. At this time, operation procedures are the same as those for the
lifting mode. The rocker can be used to shake the hand pump up and down to control cab dropping or
the controller button can be pressed for controlling as shown in Fig.
Operation Instructions for Cab Lifting
P1T000134
Cab Lifting Pump (Hand Pump)
1 2
P1T000135
1. Hand pump 2. Electric pump control button

114
9.3Operation Precautions
(1) Maintenance operation may begin after the cab is rolled back by the oil pump to the top dead center
and it is confirmed that the cylinder limit lock hook has fallen into the limit slot and that the pump
reversing lever is in the lifting position. The vehicle may not be driven before the oil pump rolls back
the cab to the bottom dead center and lock it there.
(2) The motor being too hot may get it burned. Therefore, when the electric pump has been used
continuously for 3-5 times, the thermal protection function of the motor will be automatically actuated,
thus shutting down the motor. Please note that this is not fault and re-start the motor again after it is
cooled.
(3) When the cab rollback mechanism is used, the vehicle shall be stopped on a level ground. Please
start the parking controller, switch to the neutral position and fix objects in the cab.
(4) Do not begin maintenance before the cab is rolled back to the top or pawl of the limit lock hook of the
cab rollback cylinder enters the limit slot. Where the cab cannot be dropped or can only be dropped
slowly after being kept in a rollback state for a long time, as the oil cylinder limit pawl is locked, the oil
pump handle needs to be switched to the “lifting” position and pressed several times to release the
pawl from the pawl slot; then the oil pump handle needs to be switched to the “dropped” position and
pressed several times to drop the cab. Dropping the cab by forceful pressing will result in damage of
the limit mechanism or breakage of the piston rod and other dangers.
9.4Maintenance
(1) During vehicle assembling, after the oil cylinder and oil pump are installed in place and before oil
pipes and the lifting controller are connected, please make sure to fill 10# aviation hydraulic oil (for
ground use) in the oil tank. Before doing so, the oil shall be filtered through a 200-mesh or above
stainless steel filter screen. Directly rotating the rocker or starting the lifting controller before oil is
filled in the tank will result in entry of air into the electric pump, thus leading to slow rollback, lifting
and dropping of the cab. After the oil pump pipes are connected, rotate the oil pump rocker to when
oil flows out from corresponding oil pipe (to release the air in the oil pipe) and then connect the oil
pipe to corresponding oil cylinder pipe joint according to the schematic diagram.
(2) The intake and exhaust plugs on the oil tank can automatically intake and vent air, and discharge
excess oil. Therefore, oil discharge from the intake and exhaust plugs does not mean oil leakage.
(3) When the cab rollback mechanism is used in general environmental conditions, the cab shall be
rolled back at least once every week; when it is used in severe working conditions, the cab shall be
rolled back at least once every day. In severe working conditions, the electric pump assembly, hand
pump assembly and oil cylinder assembly surface, especially greasy dirt at the O-rings of intake and
exhaust plugs must be cleaned every day to ensure that the intake and exhaust plugs of the oil pump
assembly are unblocked.
(4) The system hydraulic oil shall be replaced once every 6 months or every 30,000 km and 10# aviation
hydraulic oil (for ground use) is required.
(5) Please be careful and do not damage the oil pipes and wires of the cab rollback system when
repairing the engine.
115
For use in general environmental conditions: The cab shall be rolled back at least once every
week and the hydraulic oil replaced once every half a year.
For use in an environment with serious pollution: The cab shall be rolled back once every day
and the hydraulic oil replaced once every three months.
Oil filling and exhausting are only allowed during cab rollback and dropping.
Fault Fault cause Solutions

The oil pump The reversing lever is not in the position for Switch the reversing lever to the position for cab
(especially the electric cab lifting. lifting.
pump) works normally
but there is no cab Vent holes of intake and exhaust plugs on Clear the vent holes of the intake and exhaust
lifting. the oil tank are blocked by dirt. plugs.
Check whether the vehicle power supply is

The power supply is not connected.
connected and whether the vehicle is in neutral.
Vent holes of intake and exhaust plugs on Clear the vent holes of the intake and exhaust
Operate the lifting the oil tank are blocked by dirt. plugs.
controller and no action The connector pin becomes loose resulting Re-fix the connector pin and avoid false
is observed; the electric in poor contact. connection.
pump is not operating The vehicle fusible line circuit is open and Please replace the vehicle fusible line and the
either. the connector fuse is melt. connector fuse.
Check the connector interfaces and re-connect
Connectors are reversely connected. them according to the marks on the cab lifting
controller.
The lifting controller Check whether the vehicle is in neutral and
relay is actuated and The main circuit is not connected. whether the engine fusible line is installed or
clopping and the damaged.
electric pump motor
does not work. The motor is damaged. Replace the electric pump sub-assembly.
The reversing handle is

in the “cab dropped”
position; the electric Re-connect the oil pipes according to the
Pipes are connected reversely.
pump supplies oil; the schematic diagram.
cab can be lifted but
cannot be dropped.
The electric pump stops
Check whether the vehicle power supply is
when the cab is lifted The electric pump control circuit is open.
connected.
half way.
116
Fault Fault cause Solutions

Drop the cab to its original position; remove the
The electric/hand pump intake and exhaust plugs on the oil tank; place a
begins to work when filter screen at the oil filler of the oil tank and fill
the cab is lifted half way The oil in the oil tank is not enough. oil until the oil level is flush with the plunger
and cannot be lifted any piston upper surface (here the rocker shall be
further. put in the lower position). Refer to the oil filling
diagram.
The interior of the hydraulic system is
The cab slides contaminated. The steel ball of the pilot Clean the oil tank, oil pipes and oil circuit
continuously. operated check valve of the oil cylinder fails system and replace the hydraulic oil.
to seal the opening.
Vent holes of intake and exhaust plugs on Clear the vent holes of the intake and exhaust
the oil tank are blocked by foreign matters. plugs.
Remove the nuts of pipe joint of oil cylinder A
The hydraulic oil is contaminated. The and discharge oil out by hand pump; or remove
During normal
screw holes of the oil pump system or oil the screws of pipe joint of oil cylinder A and the
operation of the oil
cylinder pipe connections and the connecting oil pipes; clean and purge with gas
pump, the cab rollback,
connecting oil pipes are blocked by foreign the screw holes of pipe joints and connecting oil
lifting or dropping
matters. pipes to remove the foreign matters in there.
speed drops or the cab
Replace the hydraulic oil if necessary.
cannot be lifted or
dropped. Switch the oil pump handle to the “lifting”
The oil cylinder limit pawl is locked after the
position and press it several times to release the
cab is kept in a rollback state for a long
oil cylinder limit pawl from the pawl slot; then
time (for the dropping fault of oil cylinder
switch the oil pump handle to the “dropped”
N008 or oil cylinder with limit pawl).
position and press it to drop the cab.
During cab dropping,
bubbling and oil
leakage are observed
at the intake and Check the oil quantity after exhausting of the
exhaust plugs; oil system and fill oil until the oil level is flush with
There is too much hydraulic oil in the oil
leakage is also found the plunger piston upper surface (here the
tank.
on the connection rocker shall be put in the lower position). Refer
surface of the oil pump to the oil filling diagram.
and oil tank; there is
even explosion of oil
tank.
The cab cannot be The oil is dirty. Clean the system and replace the hydraulic oil.
dropped in position. Use hydraulic lock bolt. Try hard to pull the cab in position.
Intake and exhaust Automatic oil discharge by intake and exhaust
Normal phenomenon
plugs of oil tank leak oil. plugs
117
DW90A 10. Vehicle Axle and Tyre Systems
10.Vehicle Axle and Tyre Systems
10.1Use and Maintenance of Vehicle Axles

Profile of Vehicle Axles
P1T000137
1. Front axle assembly 2. Intermediate axle 3. Rear axle

118
10. Vehicle Axle and Tyre Systems DW90A
10.1Overview of Vehicle Axles
The front axle of the DW90A non-road wide-body dump truck is a steering axle with a straight beam
structure, and the intermediate and rear axles are two-stage reduction drive axles. As the main
components of the vehicle, axles are mainly used to bear various forces from the pavements and vehicle
frame. The drive axles are used to increase the torque and drive the whole vehicle. Drive axles have a
casting housing and are equipped with inter-wheel and -axle differentials as well as inter-axle differential
locks.
10.2 Use of Vehicle Axles
Whether the parts and components of the vehicle axles can work normally depends in a large degree
whether they are reasonably used, maintained and repaired. To help you reasonably and fully use and
carefully maintain and repair the product so as to keep it in good condition and expand its service life,
some basics are provided for your reference:
10.2.1Connection of Rim To Axle
The rim nut specification is M 24×1.5 and its tightening torque is 780-880 N.m. The rim nuts must be
tightened in pairs and symmetrically. During normal use, the nuts shall be frequently checked for
looseness, and shall be timely tightened when found loose.
Notes:
a. Avoid damaging wheel bolt threads. No paint, lubricating grease or other dirt is allowed to stick on
the fitting surface of the brake drum and the rim, or the wheel nut pressing surface.
b. Apply some lubricating grease, engine oil or other anti-jamming agents on the wheel bolt and nut
threads before installation.
c. Re-tighten the wheel nuts after a 50 km drive every time the wheels are re-assembled.
10.2.2Use of Inter-axle Differential Lock
The inter-axle differential lock is a mechanism used to ensure synchronous running of the two drive
wheels so that although one drive shaft slips when the vehicle is running on complicated pavements, the
other one can still provide drive force. When the vehicle is driving on good pavements, the inter-axle
differential lock shall be disconnected.
To use the inter-axle differential lock for driving on muddy or poor pavements, step on the clutch when
the vehicle is stopped and then press the rocker switch of the inter-axle differential lock on the
instrument panel of the cab; meanwhile set the transmission in low-speed position and engage the
clutch.
The differential lock must be used when the vehicle is stopped, and must never be used when the
vehicle is driving normally or taking turns! When the vehicle is driving out of muddy pavements,
the inter-axle differential lock switch shall be immediately disconnected to avoid damage to the
differential.
119
Notes:
The clutch must be disengaged before the inter-axle differential lock is engaged. To engage the inter-
axle differential lock, use the rocker switch when the vehicle is stopped and the indicator light shall go on
when the differential lock is engaged.
a. To pass in poor road conditions, the inter-axle differential lock shall be disengaged. If the indicator
light remains on after that, stop the vehicle and find out the causes and continue driving only after
it is confirmed that the inter-axle differential lock has been disengaged.
b. To ensure the vehicle has good passing capacity, inter-axle differential lock engagement shall be
regularly checked. To be specific, carry out level-II maintenance and overall inspection for a drive
of 10,000 km each time.
10.2.3Use and Maintenance
a. Wash away oil stain, dirt and dust regularly. In particular, keep the breather plugs unblocked.
Check tightening of all parts, especially the main reducer, hub brake and rim bolts and timely
tighten them when they are found loose.
b. Regularly check leakage of all parts and timely repair and eliminate the fault. Check the lubricating
oil level of the main reducer and the hub assembly and fill in oil timely to reach the required oil
level, thus ensuring normal operation.
c. The clearance between the friction plate and the brake drum inner round surface is generally 0.7-
1.2 mm and can be adjusted by use of the adjustment mechanism on the brake arm.
d. No oil stain or foreign matters are allowed on the brake friction surface so as to ensure normal
braking.
10.2.4Provisions for Maintenance of Front Axle
Maintenance Maintenance
Maintenance Contents Remarks
Item Mileage
Before driving the vehicle, check whether connecting bolts and
nuts of all external parts of the wheel axle become loose.
Check whether there is oil leakage of the wheel axle before
Routine driving the vehicle.
/
maintenance Before driving the vehicle, check braking performance and
return of the brake.
Fill lubricating grease from the lubricating grease nozzle of the
wheel axle.
Check and adjust the brake clearance which shall be 0.7-1.2
mm.
First 5,000 km or within one Check whether connecting bolts and nuts of external members
maintenance month of the axle become loose, and tighten them if they do.
wheel axle.
120
Item Mileage
Replace hub lithium-based grease and the filling quantity shall
be 2/3 of the cavity capacity.
Once for every Check and adjust the brake clearance which shall be 0.7-1.2
increase of 20,000 km mm.
Regular
or once every year
maintenance Check whether connecting bolts and nuts of external members
after the first
maintenance of the axle become loose, and tighten them if they do.
wheel axle.
10.2.5Provisions for Maintenance of Intermediate and Rear Axles
Item Mileage
Before driving the vehicle, check whether connecting bolts and
nuts of all external parts of the wheel axle become loose.
Check whether there is oil leakage of the wheel axle before
Routine driving the vehicle.
/
maintenance Before driving the vehicle, check braking performance and
return of the brake.
wheel axle.
Replace lubricating oil of drive axle.
Check and adjust the brake clearance
First Check whether connecting bolts and nuts of external members
5000KM
maintenance of the axle become loose, and tighten them if they do.
wheel axle.
Replace lubricating oil of drive axle.
Once for every Clean and unblock vent holes.

increase of 10,000 km Apply lubricating grease at the brake shoe pin and check to
or once every year ensure that the thickness of the brake friction plate is not less
Regular
after the first than 8 mm.
maintenance
maintenance, Check whether connecting bolts and nuts of external members
whichever comes of the axle become loose, and tighten them if they do.
earlier;
wheel axle.
121
10.2.6Models and Filling Quantities of Recommended Lubricating Oil and Grease
Type of Remark
Lubricating Part Lubricant Type of Lubricant Quantity
Axle s
2# lithium-based
Lubricating Fill to 2/3 of the
Hub inner cavity grease or HP-R
grease cavity capacity
Front axle lubricating grease
Lubricating 2# lithium-based
Lubricating grease nozzle Fill up
grease grease
Main reducer 28L
First rear
axle Single
Hub reducer Select lubricating oil as 6.3L
side
Gear oil per different seasons
Main reducer and regions (remarks) 18L
Drive axle Second
rear axle Single
Hub reducer 6.3L
side
Lubricating 2# lithium-based
Lubricating grease nozzle Fill up
grease grease
Notes:
Regions with temperature above -12°C: 85W/90 GL-5 gear oil for heavy duty vehicles;
Regions with temperature above -26°C: 80W/90 GL-5 gear oil for heavy duty vehicles;
Regions with temperature above -40°C: 75W/90 gear oil for heavy duty vehicles (severe cold regions);
10.3Precautions for Repair of Wheel Axles
10.3.1To disassemble the main reducer, check contact and engagement between bevel gears by
coloring. Adjustment of engagement marks of driving and driven bevel gears: Apply “Sudan red” (colored
paint) on the surface of driven bevel gear and turn the driven bevel gear to check the engagement mark.
Required engagement mark: Convex side: The mark shall be in the center along the tooth width, slightly
tilting to the small end along the tooth length, but shall not go beyond the small end and the tooth crest.
Concave side: The mark shall be in the center along the tooth width, slightly tilting to the large end along
the tooth length, but shall not go beyond the large end and tooth crest.
In case of improper engagement mark, change it by changing the adjusting shim between the driving
bevel gear bearing block and the main reducer housing.
122
Engagement of Main Reducer Gears
1 2
P1T000139
1. Convex side of driven bevel gear 2. Concave side of driven bevel gear
Instructions for Adjustment of Driving and Driven Gears

Tooth surface of driven gear
Adjustment method
Convex side Concave side
Move the driving bevel gear towards the

driven bevel gear. If the backlash is too
small, move away the driven gear.
Move the driving bevel gear away from the

driven bevel gear. If the backlash is too large,
move the driven gear close.
Move the driven bevel gear away from the

driving bevel gear. If the backlash is too
large, move the driving gear close.
Move the driven bevel gear towards the

driving bevel gear. If the backlash is too
small, move away the driving gear.
123
10.3.2 Removal of Brake Drum:
Remove three sunk screws with a cross screwdriver and then use the fastening screw to push the brake
drum out of the jackscrew hole ?.
Instructions for Removal of Brake Drum
P1T000141
10.3.3Removal of Hub Reducer:
1. Turn the oil drain hole downward straight. Remove the drain plug with a wrench to drain out the hub
lubricating oil as shown in Fig.
Location of Hub Oil Drain Hole
P1T000142
1. Oil drain hole

124
2. Remove the 10 hub fastening screws with a socket wrench, and remove the hub end cap. Remove
the hub clamp spring and the thrust washer of the sun gear with clamp pliers. Take out the sun gear,
and pull out the half shaft as shown in Fig.
Removal of Sun Gear
P1T000143
3. Remove connecting bolts of the hub reducer with a cross screwdriver.

4. Diagonally push out the hub reducer at the jackscrew hole with fastening screws, and remove the
hub reducer assembly.
Remove the 5 hub reducer connecting bolts with a socket wrench; knock out the 5 planetary shafts
evenly distributed on the hub reducer with a copper rod, and take out the planet carrier.
5. Remove the washer (1), planet gear (2), needle bearing (3), washer (1) and thrust washer (4)
successively. Turn the planet carrier for 180°, and knock down the gear shaft with a copper rod,
ensuring that the mating surface is not damaged. Refer to Fig..
Removal of Planet Gear
2 3
P1T000144
125
10.3.4To replace rolling needle in the hub reducer planet gear, all rolling needles shall be grouped for
configuration. The inner diameter deviation of the same group shall not be greater than 0.005 mm;
cylindricity of the rolling needle shall be 0.003 mm; the radial clearance between the rolling needle,
planet gear inner hole and planet gear shaft is 015-0.030 mm.
10.3.5After maintenance or replacement of half shaft of the hub reducer, ensure that the clearance
between the post and the stop block is adjusted to be 1-2 mm after assembling.
10.3.6During repair, clean with solvent the part originally applied with sealant. After drying, apply a 1
mm-thick sealant on the part. Clean the threads as well and after they are dried, apply locking sealant on
the thread ends and then tighten them according to required tightening torques.
10.3.7All seals once removed must be replaced and not be reused.
10.3.8 Friction plate of brake: The friction plate shall be replaced if it is less than 8 mm according to
visual inspection through the sightglass to prevent damaged rivets from affecting the brake performance.
10.4 Wheel Replacement
10.4.1When a wheel is replaced, avoid damaging threads of the wheel bolts.

10.4.2 No paint, lubricating grease or other dirt is allowed to stick on the fitting surface of the brake drum
and the rim, or the wheel nut pressing surface.
10.4.3Apply some lubricating grease, engine oil or other anti-jamming agents on the wheel bolt and nut
threads before installation.
10.4.4Put on the wheels and tighten the rim nuts symmetrically and evenly in groups in suspension; then
put down the wheels and tighten the nuts with a torque of 780-880 N.m.
10.4.5Re-tighten the wheel nuts after a 50 km drive every time the wheels are re-assembled.
10.4.6To replace an inner tube, install all part assemblies as shown in the Fig.
Assembling of Wheel and Rim
3
2
4 5
1 6
P1T000145
1. Rim body 3. Flange 5. Lock ring

2. Flange 4. Bead base 6. O-ring
126
10.5Tyre Pressure and Bearing Capacity
Before a new vehicle is delivered out of factory, the front tyre pressure is about 0.85 MPa. After the
vehicle arrives in the mine area and before its use, the user must re-adjust the tyre pressure against the
following table according to the conditions in the mine area.
Bearing Capacity and Air Pressure of Single Tyre
Maximum Vehicle Recommended Inflation Pressure

Tire specification 10km/h 50km/h
Speed (MPa)
Bearing capacity 11050kg 6500kg
14.00-25 1.0-1.1
Air pressure 1.1 MPa 0.85 MPa
Bearing capacity 11150KG 7000KG
14.00R25 1.0-1.15
Air pressure 1.1 MPa 0.95 MPa
1. Air pressures in the above table are recommended for use in the vehicle mine area. If the
user’s inflation pressure exceeds this range, resulting in relevant faults, the user shall assume
responsibilities alone.
2. The above instructions are only applicable to original tyres of the vehicle when the vehicle is
delivered out of factory. For tyres of other brands purchased by the user, please carry out
operation according to relevant instructions.
3. Before inflation, lower the tyre temperature and check the tyres, rims and inflating valves.
During inflation, the tyre shall be put in a safety cage to prevent personal injury caused by tyre
explosion.
Pay attention to the following aspects during tyre inflation:

1. Check with a pressure gauge whether tyre pressure meets specified requirements. If not, inflation is
required.
2. Check whether any foreign matters hang on the tyre surface. If yes, remove them.
3. Check the depth of tread pattern. If it is less than 5 mm, the tyre must be replaced. During
measurement, select at least six measuring points along the tyre circumference.
4. Check for cuts, looseness and chipping of tread cap and sidewall. Where the loose tread cap or
sidewall length exceeds 30 cm, the shoulder chipping area is greater than 200 cm2 and the cut is
larger than 25 cm, the tyre is deemed scrapped and shall be timely replaced.
127
10.6Use of Tyre
Pay attention to the following aspects for use of tyres in the mine area:
1. During driving, try to avoid sudden startup or braking and lower the speed when making a turn.
2. Try to avoid overloading and uneven loading which will result in overloading of wheels on one side.
3. While driving in the loading area or on transport roads, avoid road shoulders and sharp stones, and
raised and sunken parts of pavements so as to prevent scratches, impacts and other damages.
4. The driver shall regularly check the use of tyres and check for abnormal damage of tyres and rims.
5. To extend the tyre service life, tyre rotation is required according to specified method after a drive of
4,000-5,000 km each time.
During vehicle running, the maximum vehicle speed shall not exceed 50 km/h. Otherwise, tyres
tend to suffer such damages as tread loosening and bulging due to the heat generated.
10.7Tyre Rotation and Maintenance
10.7.1Pay attention to the following aspects for tyre rotation. Carry out tyre rotation according to vehicle
use conditions and regular maintenance periods. Nevertheless immediate tyre rotation is required where
the existence of abnormal wear traces is confirmed. Refer to Fig. for tyre rotation method.
1. Front tyres shall be of the same model with few damages and little wear (remaining tread
pattern depth greater than 20 mm) where possible.
2. The outer diameter difference of two tyres assembled in parallel shall not be greater than 12
mm and the one with smaller outer diameter shall be installed on the inner side.
3. Where there are marks of rotation directions on the tyres (directional tread pattern), install the
tyres according to the directions marked.
4. Tyres of the same specification and tread pattern must be installed on the same axle.
Otherwise, such problems as braking deviation, abnormal body shaking and uncontrolled
steering will be caused.
5. New tyres must be used in pairs.
6. Check the threads of the hub bolts and wheel nuts for scratches. For the sake of safety, if the
thread is damaged on either side, the pair as a whole must be replaced.
7. Check the rim contact surface and mounting holes for deformation and damage. If any, replace
the rim.
8. Check the rim for cracks. If any, timely replace it.
9. Deflation is required before a tyre is removed to ensure safety.
128
Cross-pattern Rotation of Ten Tyres on Three Axles
First time Second time Third time Forth time Fifth time
Sixth time Seventh time Eighth time Ninth time Tenth time
129
DW90A 11.Maintenance and Service of Suspension System
11.Maintenance and Service of Suspension System
The thrust bar repair kit of the vehicle which has been used for 4 months (20,000 km) must be
replaced. The user shall bear the consequences for the vehicle failure caused by the use of the
thrust bar beyond the time limit.
For vehicle driving for 4 months (20,000 km), wear-resistant block and wear-resistant side plate of
leaf spring seat shall be replaced.
1.When the gap between the guide plate and the rear leaf spring is greater than 3mm, an
adjustment plate must be added to ensure that the gap is less than 1mm.
2.When the abrasion loss of a guide plate is greater than 5mm, it must be replaced.
3.The balance shaft gear oil shall be replaced every 5000 km.
130
11.Maintenance and Service of Suspension System DW90A
11.1Front Suspension System
As shown in the figure, the front suspension system mainly includes front support seat of front leaf
spring, front thrust bar, auxiliary spring bracket, main spring, auxiliary spring, front spring pressing plate,
rubber stop block, rear support of front leaf spring, wear-resisting side plate and leaf spring pin.
Structural Diagram of Front Suspension
1 2 3 4 5 6 7 8
10
P1T000149
1. Front support seat of 4. Main spring 7. Rubber stop block 10. Leaf spring pin
front leaf spring 5. Auxiliary spring 8. Rear support of front leaf
2. Front thrust bar 6. Front spring pressing spring
3. Auxiliary spring bracket plate 9. Wear-resistant side plate
11.1.1Tightening Torque of Bolts and Nuts at Important Parts
Tightening Torque
Applied to Specification
(N.m)
U-shaped bolt and nut of the front spring 900-1000 M24×2
Connecting bolt of front plate spring support and auxiliary
500-600 M20
spring bracket
Connecting bolts and nuts of front thrust bar 500-600 M20
Fixing bolts and nuts of wear-resistant block 200-250 M16
To ensure traffic safety, the tightening torque of the above connecting parts shall be checked
regularly.
131
11.1.2 Descriptions of Front Leaf Spring
DW90A is of a structure with an enhanced longitudinal front plate spring and main auxiliary spring. The
leaf spring configuration has undergone strict vehicle performance check and shall not be changed
without authorization; otherwise it may lead to inconsistent movements with other systems and cause
the vehicle to lose control, resulting in unnecessary personal injury and property loss.
11.1.3Fault Diagnosis
The failure of the front suspension system is related to many systems, including steering mechanism,
front axle, wheel and brake. In case of any abnormality (abnormal sound, deviation, vibration and
abnormal damage) during the process of driving, the vehicle shall be stopped immediately for a
comprehensive inspection, and any related items below shall be checked:
a. Whether the suspension parts are damaged or loose (e.g., leaf spring breakage and looseness of
relevant bolts);
b. Whether each support connection gets loosened;
c. If the lubrication fails, please apply lubricating grease in time;
d. Whether the tire pressure is normal;
e. Whether the tire wear is uniform and whether the tire is damaged;
f. Whether the steering parts (e.g., tie rod ball joint) have abrasion and looseness
g. Whether the alignment of front axles and wheels has a deviation.
11.1.4Repair and Maintenance
a. If the leaf spring and clamp are damaged, they shall be replaced in time. Overloading and poor
road conditions will make these parts more vulnerable to damage. Once damaged parts are found,
they shall be replaced or repaired in a timely manner. Otherwise, serious accidents will occur.
b. The leaf spring pin (as indicated by 10 in Fig. 11-1) shall be checked and lubricated in a timely
manner. If the bolt sheath is seriously worn, please replace it in time.
c. For U-shaped bolts and nuts, and center bolts of leaf spring, they shall be re-tightened according
to torque requirements every 2,000 km.
d. If the stop block is damaged or lost, please replace it in time. Otherwise axles will jump too much
in bad road conditions, resulting in accelerated fracture of the leaf spring.
e. If the abrasion loss of wear-resistant block exceeds 50% of the total thickness or the wear-
resistant block falls off, it shall be replaced in time. Otherwise, the leaf spring seat will be damaged
and its service life will be shortened.
11.2 Rear Suspension System
As shown in the figure, the rear suspension system mainly includes rubber stop block, stop block
support, guiding wear-resistant plate, adjustment plate, guide plate, rear leaf spring, pressing plate of
rear leaf spring, balance shaft assembly, upper thrust bar support (frame side), U-shaped bolt, upper
thrust bar assembly, lower thrust bar assembly, thrust bar support (axle side) and door-type frame.
132
Structural Diagram of Rear Suspension
1 2 3 4 5 6 7 8 9 10 11 12 13 14
P1T000150
1. Rubber stop block 5. Guide plate 9. Upper thrust bar support 13. Thrust bar support (axle
2. Stop block support 6. Guide plate (frame side) end)
3. Guiding wear-resisting 7. Pressing plate of rear 10. U-Shaped bolt 14. Door-type frame
plate leaf spring 11. Upper thrust bar
4. Adjusting plate 8. Balance shaft assembly assembly
12. Lower thrust bar
assembly
11.2.1Tightening Torque of Bolts and Nuts at Important Parts
Tightening Torque
Applied to Specification
(N.m)
U-shaped bolt and nut of rear spring 1700-1900 M30×2
Double-end stud and nut 380-450 M18×1.5
Connecting bolt and nut of thrust bar 1300-1500 M27×2
Upper thrust bar support (frame side) 500-600 M20
Thrust bar support (axle end) 900-1000/1300-1500 M24×2/M27×2
Fixing bolts and nuts of guide plate 200-250 M16
To ensure traffic safety, the tightening torque of the above connecting parts shall be checked
regularly.
133
11.2.2Descriptions of Rear Leaf Spring
DW90A is of fourteen enhanced longitudinal elliptical rear plate springs in total (including four main
ones) The leaf spring configuration has undergone strict vehicle performance check and shall not be
changed without authorization; otherwise it may lead to serious failure and loss.
11.2.3Balanced Suspension Assembly

Structure Drawing of Balanced Suspension Assembly
Left
Right
Oil port
P1T000151
Through a balance shaft, two supports and shaft casing are connected by the balanced suspension
assembly. The vehicle assembly support is connected with the frame, forming a rigid connection.
Through the leaf spring set installed on the balanced shaft casing and the lower reaction lever assembly
on the support thrust bar seat, coupled with the upper reaction lever assembly connected with the axle
and frame cross member, force transmission is conducted among them, thus achieving the balancing
and bearing functions of the balanced suspension system.
134
11.2.3.1Composition of Balanced Suspension Assembly

Balanced Suspension Assembly Parts
1 1
14 15
7 13
12
6
11
10
9 16 17
8
18
3 5 6
2 4
P1T000152
S/N Name Qty. Remarks

1 Balance shaft with support assembly 1 Component
Bracket 2
Balance shaft 1
Round pin 2
2 Type ring 2
3 O-shaped ring 2 614130062
4 Bearing oil seal cover 2
5 Shaft sealing ring 2
6 Spherical bearing outer/inner ring 4/4
7 Balance shaft casing (two structures) 2
8 Hexagon head bolt 2 Q150B0810
9 Copper washer 2 Q72308
10 Distance tube 2
11 Positioning washer Adjustable
12 Slotted nut (right) 2 45 ＃
13 Thrust washer (left) 2 40Cr
14 Balance shaft casing cover 2 Q235
15 Fueling test bolt 2 Z1/4 Q61902
16 Bolt 16 Q150B0820
17 Spring washer 16 Q40308
18 Lock gasket 2 Q235
135
11.2.3.2Disassembly, Installation and Adjustment of Balanced Suspension Assembly
(1) Disassembly and assembly of balanced suspension assembly (with steps shown in the figure)
P1T000153 P1T000154
Use a flat spade to pry up or remove the

Remove bolts of balance shaft casing
tongue (12 mm in length) of the stop
cover
gasket
P1T000155 P1T000156
Remove the slotted nut (right) Remove the lock gasket
P1T000157 P1T000158
Remove the thrust washer (left) Remove the shaft casing
P1T000159 P1T000158
Remove bushing and adjust gasket and Assemble bearing outer ring and adjust
outer ring of the bearing gasket and bushing
136
P1T000157 P1T000160
Install the shaft casing, bearing outer ring Screw the thrust washer (left) to the
and space washer bottom with a torque of 1200-1300 N/m
P1T000155 P1T000161
Screw the slotted nut (right) and the lock

Install the lock gasket gasket to the bottom with a torque of 900-
1000 N/m
P1T000162 P1T000163
Adjust the bearing clearance to 0.1-0.3

Lock the lock gasket
mm
P1T000164 P1T000153
Apply silicone sealant HZ1213 on the end

Install the end cover
face
137
P1T000165 P1T000166
Add 0.8-1L of GL-5.8W-90 heavy duty

Tighten the oil plug
gear oil
(2) Installation and adjustment of balance shaft casing assembly (steps are shown in the figure)
P1T000167 P1T000168
Press the bearing outer ring into the

Press the shaft sealing ring
press machine
In the absence of a press machine, after the bearing outer ring and shaft sealing ring are respectively
aligned, a tooling plate shall be cushioned and a copper rod shall be used for hammering.
11.2.3.3Repair and Maintenance of Balanced Suspension Assembly
11.2.3.3.1Key Points for Repair and Maintenance
(1) Before driving the new vehicle, check the fastening of the bolts at the connection of the balanced
suspension assembly.
● Check the tightening of all bolts at the balanced suspension assembly, especially that of 8 locknuts
on the U-shaped bolts of the suspension. Since the locknut requires a high tightening torque (up to
about 1800 N.m), it is necessary to use a lengthening bar to tighten it. A tightening machine is
preferred. It is required that the middle part of the plate spring should be flattened and put against the
balance shaft casing. A simple judgment method is that there is no obvious gap between the top
plate spring and the cover plate (especially both ends of the cover plate). If the extremely thick nut
can be tightened under a heavy load, the effect will be better.
● Check whether the M18x1.5 bolts (28 in total) connecting the support and the middle support seat
are loose. If so, they shall be tightened as required, and the tightening torque shall be 380-450 N.m.
(2) During running-in process of a new vehicle, it is necessary to tighten U-shaped bolts and nuts of the
support, middle support seat and plate spring, and re-tighten corresponding bolts and nuts 2-3 times
every driving distance of about 200-300 km. Only in this way, can the bolts and nuts be tightened.
138
(3) After running-in of the new vehicle, it is necessary to check the bearing clearance (0.1-0.3mm) once
and adjust it. Then, remove the end cap of the balance shaft, loosen locknut bolts and use a fork
spanner with an opening of 120mm to tighten the locknut bolts. After cleaning the junction surface,
install end cover of the balance shaft and tighten the bolts. Detailed operation methods are shown in
11.2.3.2 Disassembly, Installation and Adjustment of Balanced Suspension Assembly. In particular,
when the shaft sealing ring does not fail, the balance shaft casing is suggested not to be removed, so
as to prevent the damage to the shaft sealing ring during the removal process.
(4) When the new vehicle is put into normal use after running-in, the bolts and nuts shall be tightened
again according to the above method 1 every driving distance of 1,500-2,000 km.
(5) All bolts and nuts of the balanced suspension assembly shall be checked once during maintenance
of the vehicle after a driving distance of 5000 km, and the lubricating oil 85w-90 (GL-5 heavy-duty
gear oil) shall be added through the oil filler of the balance shaft casing, with filling quantity of 2.4L. In
the future, maintenance shall be conducted once every 5,000 km. If the road condition is bad, the
interval mileage should be correspondingly shortened to ensure that your vehicle is always in a good
working condition.
11.2.3.3.2Replacement of Lubricating Oil
(1) The steps for disassembly, installation and adjustment of the balanced suspension assembly in
11.2.3.3 shall be followed.
(2) Remove the shaft casing:
(3) Check oil seal:
The oil seal must be replaced if the following are found:
● Uneven abrasion
● Internal frame springs fail or become weak
● Bending and deformation
● Scratching and trimming
● Crack and deterioration
(4) Check whether the bearing has cracks or is damaged:
(5) From a perspective of preventive maintenance, some parts within the repair or wear limit shall be
replaced before they exceed such a limit.
(6) The disassembled parts may be stained with greasy dirt and sludge. Kerosene shall be used to clean
the parts after reassembly. Cleaning parts is a necessary process.
(7) Reassemble balanced suspension assembly a according to the steps for disassembly, installation
and adjustment. Finally, add specified type and dose of lubricating oil from the oil filling port as
required.
139
11.2.3.4Main Failure Mode of Balanced Suspension Assembly
S/N Fault mode Troubleshooting method

Clean the balance shaft casing cover and confirm that it has a good
Oil leakage caused by the failure of contact plane with the shaft casing. Then evenly apply silicone
1 sealing property of the balance shaft sealant HZ1213 before installation. Otherwise, replace end cover of
casing cover balance shaft and carry out assembly according to the steps for
removal and assembly of balance shaft assembly in a.
Replace the whole set of bearings, and adjust the bearing clearance
at the same time to prevent axial transmission of the shaft casing
2 Bearing crack caused by large clearance, and fracture of the bearing due to local
stress. Detailed steps are shown in b. Installation and adjustment of
balance shaft casing assembly.
Oil leakage caused by the failure of Detailed steps for replacement of the shaft sealing ring are shown in
3
shaft sealing ring b. Installation and adjustment of balance shaft casing assembly.
Detailed steps for replacement of the balance shaft casing and
4 Breakage of balance shaft casing components are shown in a. Installation and adjustment of balance
shaft casing assembly.
5 Cracks or breakage of support Replace the shaft support assembly
6 Cracks or breakage of balance shaft Replace the shaft support assembly
Cracks or breakage of balance shaft
7 Replace the balance shaft casing and component
casing
(Original parts shall be used, otherwise the original assembly performance requirements cannot be
guaranteed)
11.2.3.5Main Maintenance Parameters
Technical
S/N Item Unit Detection means
standard
Tightening Torque of the bolt M18×1.5
1 380-450 N. m Torque wrench
connected with balance shaft and frame
2 Tightening torque of M8 bolt of end cover 21-25 N. m Torque wrench
3 Tightening torque of M14x1.5 locking bolt 180-230 N. m Torque wrench
4 Bearing clearance 0.1-0.3 mm Dial Indicator
5 Lubricating oil charging amount 0.8-1.2 L Display of oiling machine
6 Thrust washer 1200-1300 N. m Torque wrench
7 Slotted nut 900-1000 N. m Torque wrench
11.2.3.6Handling of Daily Problems
11.2.3.6.1Seepage and Oil Leakage of Balanced Suspension Assembly and Cause Analysis
Since frequent replacement of the assembly is caused by oil seepage and leakage of the balanced
suspension assembly, then the following are provided to reduce repair cost, eliminate oil seepage and
leakage in a timely manner and locate the cause, as well as give precautions for replacement:
140
1. If a timely maintained fails to be conducted according to the requirements of 11.2.3.3 Repair and
Maintenance of Balanced Suspension Assembly, the balance shaft casing will be deformed under a
heavy load, leading to failure of shaft sealing ring, clearance at the joint between the balance shaft
casing cover and balance shaft casing and stretched bolts. In a serious case, the balance shaft
casing cover will be broken, thus resulting in oil seepage and leakage from the inner side and the
outer side of the balance shaft casing.
2. In the case of a poor road condition, the impurities such as water and sediment generated in the
operation of the vehicle will make the shaft seal ring (oil seal) fail, and the sealant at the balance
shaft casing cover will have accelerated aging, which can also cause failure, oil seepage and
leakage.
3. If daily maintenance is not conducted in a timely manner, 2--M80x2 nuts (or 12-M16X1.5 bolts) on
both ends of the balance shaft assembly during the overloading process will get loosened normally,
which will increase the fit clearance inside the balance shaft casing, resulting in leaping of indirect
parts, failure of shaft sealing ring, clearance between the balance shaft casing cover and balance
shaft casing, and oil seepage and leakage.
4. Treatment of oil seepage and leakage
a. The maintainable of balanced suspension assembly shall be conducted by strictly following the
routine maintenance regulations in 11.2.3.3 Balanced Suspension Assembly Repair and
Maintenance. GL-5 and 80W-90 heavy-duty gear oil shall be added into the balance shaft casing
every driving distance of 2,500~3,500 km and the torque of bolts at each part of the balance shaft
assembly shall be checked. See 11.2.3.5 for main maintenance parameters.
b. In case of the oil seepage and leakage
at the balance shaft casing cover and balance shaft casing seal, it is suggested that the balance shaft
casing cover should be removed. The balance shaft casing cover shall be checked carefully for cracks. If
any, the balance shaft casing cover shall be replaced directly. The 12-M16X1.5 bolt shall be tightened
according to the requirements for torque. After the lock washer is locked, the outer end face of the
balance shaft casing shall be cleaned. Silicone sealant HZ1213 shall be applied evenly on the fitting
surface or rubber gaskets shall be added on both fitting surfaces. After that, 8-M8 bolt shall be tightened
and the stress is required to be uniform, i.e., fastening bolts shall be crossed.
c. If the shaft sealing ring has failed when interior lateral seepage occurs in the inner side of the
balance shaft shell, then the shaft sealing ring shall be replaced. The detailed steps are shown in
11.2.3.2 Disassembly, Installation and Adjustment of Balanced Suspension Assembly.
11.2.3.6.2Bearing Cracking and Cause Analysis
1. If the lubricating oil fails to be added and replaced in a timely manner according to the requirements
of 11.2.3.3 Repair and Maintenance of Balanced Suspension Assembly, when the vehicle is
overloaded, dry friction of the bearing will lead to over-burning, which may result in breakage.
2. If the bearing clearance fails to be adjusted and the bearing locking bolts or nuts fail to be checked
and tightened according to the requirements of 11.2.3.3 Repair and Maintenance of Balanced
Suspension Assembly, when the vehicle is overloaded, the clearance between bearings may
increase and axial displacement of the bearing will intensify, and the bearing will have local stress,
leading to bearing breakage.
3. Treatment of bearing breakage: In case of bearing breakage, it must be replaced for whatever
reason. The detailed steps are shown in 11.2.3.2 Disassembly, Installation and Adjustment of
Balanced Suspension Assembly.
141
11.2.3.6.3Cracks and Fracture of Support and Cause Analysis
1. If the connecting bolts of the support and frame fail to be checked and fastened in a timely manner
according to the requirements of the 11.2.3.3 Repair and Maintenance of Balanced Suspension
Assembly, when the vehicle is overloaded, the frame will have a severe stress condition, leading to
cracks of the support.
2. Treatment of crack and fracture of the support
a. Replace one set of balance shaft assembly.
b. If conditions permit, knocked down can be conducted by following the steps below:
● Steps for drilling with a combination of the support and balance shaft:
1. Apply efficient cleaning agent (Loctite) evenly to the joint between the balance shaft and support to
clean it.
2. Coat the cleaned joint evenly with sufficient Retaining Compound Adhesives (Loctite 680).
3. Apply a layer of accelerator (Loctite) on the surface with retaining compound.
4. Push two supports inward quickly to the root of the balance shaft and place the back surfaces of the
two supports of the component on two planes with an equal height to ensure the back surfaces of the
two supports are in the same plane. The bend position of the balance shaft shall deflect 15°from the
underside of the support. There shall be no clearance at the joint between the support and the
balance shaft, otherwise, subsequent installation will be affected.
5. After 30-minute curing of the balance shaft and support, turn their combination by 180°to ensure the
drilling surface is aligned with the undersides. After that, press them tightly and drill pin holes
according to the location and size of the figure.
6. After cleaning iron filings with high-pressure blast, apply enough Retaining Compound Adhesives
(Loctite 680), and then install two cylinder pins.
Notes:
1. The fitting surface must be cleaned without any damage, sharp burr, grease and other factors not
conducive to assembly.
2. After accelerant is sprayed to the adhesive, assembly and placing shall be carried out quickly.
Otherwise, the retaining compound will be solidified soon, bringing difficulties for assembly. If
retaining compound is applied but accelerant is not sprayed on a component, it has to be put on a
platform for 24 hours until the retaining compound is totally dry. Then, further drilling can be
conducted.
3. The two undersides of the support must be in the same plane, otherwise, it is not conducive to
installation of components and frame.
4. After drilling of the combination, the size of each installation hole shall be checked in a timely
manner.
142
11.2.4 Repair and Maintenance of Rear Suspension
a. Suspension is an important part of the vehicle bearing system, so it shall be replaced in time when
damaged. Overloading and poor road conditions will make such parts more vulnerable to be
damaged. Once damaged parts are found, they shall be replaced or repaired in a timely manner.
Otherwise, serious accidents will occur.
b. The following parts shall be checked regularly: the upper and lower thrust bars and their
connecting bolts shall be checked for damage and looseness; the stop block shall be checked to
see if it falls off; whether the leaf spring has fragments or dislocation or whether its pressing plate
has cracks.
c. For U-shaped bolts and nuts, and the bolts and nuts of thrust bar, they shall be re-tightened
according to torque requirements every 2,000 km.
d. Lubricating grease shall be applied to the part between the leaf spring and the sliding plate every
10 hours, and the gap between the guiding wear-resisting plate and the leaf spring shall be
adjusted by an adjustment plate. The correct gap shall be no more than 2mm.
e. The normal life of the guide wear-resistant plate and the door-shape frame sliding plate seat on
the axle is half a year. If the wearing loss exceeds 30% of the total thickness, replacement shall be
made in time.
f. The repair and maintenance of balanced suspension is shown in 11.2.3.3.
g. After each replacement of suspension parts, the center distance on left and right sides of the
middle and rear axles shall be checked and measured to see if there is an error. If any, a correction
shall be made.
a. The number and thickness of leaf springs are forbidden to be changed at will. Change of the
suspension structure is not allowed either. It is forbidden to use the thrust bar, slide seat, guide
plate and other parts not approved by the company.
b. When the shaft sealing ring does not fail, the balance shaft casing is suggested not to be
removed, so as to prevent the damage to the shaft sealing ring during the removal process.
143
DW90A 12.Dump Body Lifting System
12.Dump Body Lifting System
12.1. Dump Body Lifting System Structure and Working Principle
12.1.1Lifting System Structure
Dump body lifting system is mainly composed of hydraulic oil tank, control valve, oil pump, oil cylinder
and oil pipe, as shown in the figure.
Dump Body Lifting System Structure
1
10 11
9 12
2
8
7
6
5 4 3
P1TH00026
1. Oil cylinder 5. Support seat assembly 9. Fuel return pipe

2. Main control valve 6. Fuel suction pipe 10. Return oil filter
3. High-pressure pipeline 7. Hydraulic oil tank 11. Pneumatic control valve
4. Gear pump 8. Air filter 12. Air duct
144
12.Dump Body Lifting System DW90A
12.1.2Hydraulic Principle of Lifting System
Refer to Fig..
Hydraulic Principle Diagram of Dump Body Lifting System
Lift
air-in
Lower air-out
From steering system

priority valve of EF port
P1TH00021
1. Oil cylinder 3. Oil pump 5. Hydraulic oil tank 7. Limit valve

2. Lifting valve 4. Oil return filter 6. Converging valve block 8. Pneumatic control valve
for lifting
Introduction to operating principle: When the driver operates pneumatic control valve 8, gas will go into
the lifting valve 2 to control its element to move leftwards and rightwards, achieving dump body lifting,
holding and lowering. When the driver operates the pneumatic control valve 8 to the lifting position, gas
will enter the right position of lifting valve 2 , and the confluent high-pressure oil of oil pump 3 and
steering pressure-gradient control valve will flow into the lifting valve 2. Through the right position of the
lifting valve 2, oil will enter the lifting cylinder 1, thus lifting the dump body. When the driver operates the
pneumatic control valve 8 to the lowering position, the control gas will enter the left position of the lifting
valve 2; the oil from lifting cylinder 1 and pump 3 returns back to oil tank 5 from the lifting valve 2, thus
lowering the dump body. When the driver operates the pneumatic control valve 8 to a holding position,
there is no gas from the pneumatic control valve 8 to lifting valve 2. The lifting valve 2 will return to the
middle under the spring force, realizing the holding action of lifting cylinder 1.
145
12.2. Structure and Working Principle of Main Parts
12.2.1Duplicate Gear Pump Structure
3D Explosive View
3
4
16
5
6
7
8
9
10
17
11
13 12
14
15
18
P1TH00024
146
Parts Breakdown in 3D Explosive View (BOM)
Name and
S/N Part code Qty. Remarks
specification
1 GB893.1-86 Retainer 72 1
2 (d) Puyuan JHP2-02 Set 1
3 GB9877.1-88( 参考 ) Rotary shaft lip seal 1 SW 32×52×12
4 (n)(SAE)JHP2-02 Front cover 1
Nameplate (for LiuGong
5 LiuGong BP-01 1
only)
6 (n)JHP2-07 Locating sleeve 8
7 JHP2-09 Ear-shaped stopper 4
8 JHP2-10 Ear-shaped seal 4
9 JHP2-08 Side plate 4
10 (d) Tianjin LiuGong JHP2/2-01 Driving gear shaft 1
11 (d)JHP2-04 Driven gear shaft 2
12 (d) Puyuan JHP2-01 Needle bearing 8
13 JHP2B-09 Baring 33×37×35 8
14 JHP2/2-04 Rectangular O-ring 2
15 (n)(SAE)JHP2/2-02(Y) Pump body I 1
16 (d)JHP2/2-03 Driving gear shaft II 1
17 (n)(SAE)JHP2/2-5(Z) Rear cover body 1
12.9grade in
18 (n)JHP2/2-06 Bolt M16 4
GB3098.1-2000
Specific parameters of duplicate gear pump:

Technical parameters Front pump Rear pump
Theoretical displacement (mL/r) 83.6 41.8
Direction Right-handed rotation
Rated/maximum speed (r/min) 2200/2500
Rated/maximum pressure (MPa) 23/28
Volume efficiency (≥%) 92
147
Parameters of Duplicate Gear Pump and Internal Schematic Diagram
P1T000173
12.2.1.1Installation Position
Duplicate gear pump is located at PTO output port at the rear end of diesel engine.
12.2.1.2Operating Principle
When the teeth of the two gears are separated from each other, a low pressure will be formed, and the
liquid will be inhaled and pushed to the other side by the casing wall. On the other side, two gears snap
together, creating a high pressure that pushes the liquid out.
12.2.1.3Function
To supply power hydraulic oil to the oil cylinder.
12.2.1.4Installation Requirements
(1) The inlet and outlet of gear pump shall be clean without any dirty; the plane of inlet and outlet shall
not be damaged, so as to ensure the sealing effect of O-shaped ring.
(2) The mounting surface of oil port and seam allowance of the gear pump shall be free from bump and
scratch. In case of any bump during the logistics transportation process, simple treatment shall be
conducted before installation.
(3) Before installation of the gear pump, it is necessary to check the depth connected with the mounting
hole to see if it is greater than the effective length of the gear shaft, so as to prevent burnout of the
gear pump resulting from shaft pushing. Bond axis and key sleeve shall be installed freely without
clamping. During the installation process, the gear pump shall be manually sent to the installation
position. It is forbidden to install the gear pump by means of knocking, or forcibly tightening and
installing the gear pump with bolts.
(4) The tightening torque of the four fixed bolts shall be even.
148
12.2.2Structure and Working Principle of Lifting Valve

Structure and Working Principle of Lifting Valve
3
4
2
6 1 P1TH00023
1. Oil outlet - to the oil cylinder inlet 3. Oil inlet P - to pump oil outlet 5. Lifting air tube
2. Oil return port-to the oil tank for oil 4. Oil inlet P1 - to priority valve EF 6. Lowering air tube
return port
1) The lifting valve is located at the oil inlet of the lifting cylinder. It is a six-way selector valve with lifting
position, holding position and descending position. The lifting valve is used to guide the hydraulic oil
to the lifting cylinder. It belongs to a hydraulic control element and plays the role of lifting, keeping or
lowering the dump body.
When the vehicle runs normally, the lifting valve shall be in the middle position to ensure the
safety of the vehicle.
149
12.2.3Structure and Working Principle of Limit Valve

Structure and Working Principle of Limit Valve
P1T000175
1. Air inlet (connected with the 2. Air outlet (connected with the lifting 3. Discharge outlet
pneumatic control valve) valve)
The limit valve is installed at the bottom of the lifting cylinder.

Connection and disconnection of the gas circuit are controlled through the pneumatic control valve.
When gear pump works, hydraulic oil is pumped into the lifting cylinder by the lifting valve, thus lifting the
dump body. When the dump body is lifted to the position of the maximum design angle, the adjusting bolt
of the pneumatic control valve will cut off the gas circuit when it touches the stop block, making the lifting
valve return to the middle position and lifting stop. It can effectively prevent the cylinder from being lifted
to the limit position, damaging the oil cylinder and causing impact.
150
12.2.4Pneumatic Control Valve

Structure and Working Principle of Pneumatic Control Valve
Gas Circuit Schematic
22-Lift
1-Inlet
21-Lower
3-Exhaust
P1T000176
1. Air source inlet 3. Exhaust port 21. Lowering inlet 22. Lifting inlet (connected
(connected with the with the lifting valve)
lifting valve)
The pneumatic control valve is located in the cab. The driver operates the pneumatic control valve to
realize the lifting, holding and descending actions of the dump body.
151
12.2.5Lifting Cylinder
Structure of Lifting Cylinder
P1T000177
152
List of Parts (Partial)
Specificat Qty. of
Name of Supplier* S/N Supplier PN Part Name
ion Single Unit
Deepkaler (China) Machinery
1 1001030-12.9 M10*30 bolt M10*30 6
Co., Ltd.
2 1001006 φ10 spring washer φ10 6
Co., Ltd.
3 32050091 Locking piece 3
Co., Ltd.
4 32050090 Bottom cover 1
Co., Ltd.
5 09604700J1 Barrel-type ring 1
Co., Ltd.
Deepkaler (China) Machinery Sleeve for outer
6 320500196-K1 1
Co., Ltd. cylinder
7 320500196-F1 196 clip key 1
Co., Ltd.
8 320500196-Y1 196 secondary seal 1
Co., Ltd.
9 320500196-R1 196 primary seal 1
Co., Ltd.
10 320500196-Q1 196 support ring 5
Co., Ltd.
11 320500196-X1 196 Dust ring 1
Co., Ltd.
12 320500196-T1 196 guide ring 1
Co., Ltd.
13 09604700J2 196 stop key 1
Co., Ltd.
14 320500172-K1 Level-1 sleeve 1
Co., Ltd.
15 320500172-K1 172 clip key 1
Co., Ltd.
16 320500172-F1 172 clip key 1
Co., Ltd.
17 320500172-Y1 172 secondary seal 1
Co., Ltd.
18 320500172-R1 172 primary seal 1
Co., Ltd.
19 320500172-Q1 172 support ring 5
Co., Ltd.
20 320500172-X1 172 Dust ring 1
Co., Ltd.
21 320500172-T1 172 guide ring 1
Co., Ltd.
153
Specificat Qty. of
ion Single Unit
22 09604700J3 172 stop key 1
Co., Ltd.
23 320500150-K1 Level-2 sleeve 1
Co., Ltd.
24 320500150-K2 150 clip key 1
Co., Ltd.
25 320500150-K1 150 clip key 1
Co., Ltd.
26 320500150-F2 150 secondary seal 1
Co., Ltd.
27 320500150-Y2 150 primary seal 1
Co., Ltd.
28 320500150-R2 150 support ring 5
Co., Ltd.
29 320500150-Q2 150 Dust ring 1
Co., Ltd.
30 320500150-X2 150 guide ring 1
Co., Ltd.
31 320500150-T2 150 stop key 1
Co., Ltd.
32 09604700J4 Level-3 sleeve 1
Co., Ltd.
33 320500129-K2 129 clip key 1
Co., Ltd.
34 320500129-K3 129 clip key 1
Co., Ltd.
35 320500129-F3 129 secondary seal 1
Co., Ltd.
36 320500129-Y3 129 primary seal 1
Co., Ltd.
37 320500129-R3 129 support ring 5
Co., Ltd.
38 320500129-Q3 129 Dust ring 1
Co., Ltd.
39 320500129-X3 129 guide ring 1
Co., Ltd.
40 320500129-T3 129 stop key 1
Co., Ltd.
41 09604700J5 Plunger shaft sleeve 1
Co., Ltd.
42 320500129-T3 129 stop key 1
Co., Ltd.
43 09604700J6 Jacket sleeve 1
Co., Ltd.
154
Specificat Qty. of
ion Single Unit
44 100105605 φ56 flat washer φ56 1
Co., Ltd.
45 1001056G M56*3 self-locking nut M56*3 1
Co., Ltd.
46 1001273H Protective cap 1
Co., Ltd.
Maintenance package
Part No. Name

FC179-4 seal kit:
719 07 741 K
Including full set of seal kit, lubricating grease and O-shaped ring
Main Parameters
Weight of Oil Cylinder 200kg

Cylinder volume 105L
Maximum pressure 25MPa
Cylinder diameter of each stage 196/172/150/129mm
Stroke of each stage 1172/1172/1172/1184mm
The lifting cylinder is an executive device for lifting and lowering the dump body. The wide-body dump
truck is generally provided with a single-acting four-stage oil cylinder.
12.2.6Hydraulic Fuel Tank Assembly
1
6
2
5
4
P1T000179
1. Return oil filter 3. Oil tank 5. Oil dipstick

2. Cable tie 4. Rack 6. Fuel filler
155
12.2.6.1The hydraulic oil tank is installed between the right-side cab and the dump body.
12.2.6.2Oil return filter: Filtering oil to ensure cleanliness of oil.
12.2.6.3Air filter: The change in the tank level will allow the air in the tank to be exchanged with outside,
and the air filter can filter the air to prevent external pollutants from entering the tank.
Please keep clean the filter element during installation and replacement to prevent dust from
contaminating the filter.
12.3.Lifting Steps
12.3.1Lifting
Make the dump body lifting/lowering switch move backward, i.e., in the "lifting position", and the lifting
cylinder will gradually rise to jack up the dump body. When the dump body tips to the limit angle, lifting
will automatically stop.
During the lifting process, the engine speed is not greater than 2,100 RPM, and the optimal speed is
1,200~1,600 RPM. If the engine speed is too fast, it will not be conducive to oil supply of the pump, and
insufficient oil supply will cause damage to the oil cylinder and pump.
When lifting is conducted, the vehicle must be stopped on a level and solid road. When the dump
body is lifted, it must be confirmed that the vehicle is in neutral and the hand brake is in the
braking position.
12.3.2Lifting Suspension
When the dump body is lifted to any position, if the "dump body lifting/lowering switch" is pushed back to
the middle position, then the dump body can be parked at any position.
12.3.3Lowering Operation
Slowly pull forward the "dump body lifting/lower switch" to make it stay in the "lowering" position, and the
dump body will drop under the action of self-weight.
Please wait for about 15s when the dump body drops to the frame before putting the “dump body
lifting/lowering switch” to the middle position. Only when the “dump body lifting/lowering
switch” is put in the middle position, can the vehicle be started. Otherwise, damage of hydraulic
components will occur. The control lever shall not be used in high-gear position area and at a
reverse gear.
156
12.3.4Lowering Suspension
When the dump body is lowered to any position, if the "dump body lifting/lowering switch" is pushed back
to the middle position, then the dump body can be parked at any position.
12.4Precautions
12.4.1 Warning: In case of filling or replacement of oil, avoid water flowing into the oil tank. Especially in
rainy days, fill oil indoors or at the place with rain shelter
12.4.2 Warning: All removed sealing elements, such as O-shaped ring, oil seal and sealing washer must
be replaced and not be reused.
12.4.3 Warning: Before startup of the gear pump, especially in cold regions and seasons, low-speed
inching without load shall be conducted first. Before each operation, the pump shall be idled for 10-30
minutes. Check whether the gear pump rotates smoothly and steadily; whether there is abnormal noise,
oil leakage and air admission; whether the system has vibration and impact.
12.5Maintenance and Servicing
12.5.1For the first filling of hydraulic oil, fill the oil till the oil level reaches the middle position of dipstick.
After the engine is started, supplement the oil till the oil level reaches the middle position again.
Meanwhile, check the hydraulic oil level before startup every day, to ensure that the hydraulic oil level is
in the middle of dipstick.
12.5.2.During the process of driving, put the pneumatic control valve in the middle position and it is
forbidden to lift the dump body.
12.5.3.The oil cylinder shall not be in the lifting state for a long time, and the dump body shall be put
down when the engine stops for a long time, so as to ensure that the cylinder is in the recovery state. In
this way, the cylinder piston rod can be prevented from the damage from the external environment. And
hydraulic oil level can be checked easily next day.
12.5.4.High-pressure oil pipes shall be replaced periodically (every two years) to avoid the risk of aging
and blasting.
12.5.5.Hydraulic oil: L-HM46# anti-wear hydraulic oil is recommended for general areas; low-
temperature L-HV46# hydraulic oil is recommended for cold and plateau sections; for grades of
hydraulic oil for other special areas, please consult the manufacturer.
12.5.6.Regularly (20h weekly) apply the lubricant to the oil cylinder support (pin shaft at the link joint), as
shown in Fig.
12.5.7.Oil drainage of hydraulic oil tank: Turn off the engine, unscrew the drain plug at the bottom of the
hydraulic oil tank to discharge the hydraulic oil, and use a container to collect it.
12.5.8When the dump body is lifted for maintenance of components under it, its support rod must be
lowered to the position allowing safe support. After maintenance, the support rod must be restored to its
original position.
157
12.5.9 Hydraulic Oil Level--Check
1. Park the machine on level ground. Straighten the machine to ensure that the bottom of carriage
coincides with the upper surface of the frame without dead angle.
2. Stop the engine and remove the key. Check the sight glass of the hydraulic oil tank. At this time, the
oil level should be in the middle of the visible area of the sight glass (For the round sight glass, the oil
level should be in the middle of the visible area of the top sight glass).
P1TH00008
P1TH00015
3. If the oil level is in the invisible area, add the hydraulic oil.
158
12.5.10 Hydraulic Oil Level--Add
The hydraulic oil tank is located on the machine platform, and on the right side of the cab.
P1TH00013
1. Unscrew the breather filter cap of the hydraulic oil tank slowly and take off the breather filter cap.
P1TH00014
2. Refill the hydraulic oil tank and check the sight glass. The hydraulic oil level should be in the middle
of the visible area of the sight glass.
3. Install the breather filter cap.
159
12.5.11 Hydraulic Oil Level--Replace
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with
suitable containers before disassembling any component containing fluids or dismounting any
hydraulic line. Dispose of all fluids according to local regulations.
Pay close attention to the cleanliness when replacing the hydraulic oil, do not allow dirt enter the
hydraulic system.
1. Park the machine on flat ground, and pull up the parking brake.
2. Start and run the engine at idle speed for 10 minutes.Raise or lower the carriage repeatedly or
perform back and forth steering operation in neutral position to raise the hydraulic oil temperature.
3. Raise the carriage to the highest position, and stop the engine.
4. Operate the pilot control lever to lower the carriage. The carriage will descend by its deadweight, and
discharge the hydraulic oil in the lifting cylinder.
5. Loosen the oil drain plug to drain out hydraulic oil and collect with a container.
P1TH00009
6. Meanwhile, open the breather filter cap (oil filler cap) of the hydraulic oil tank to quicken the oil
discharging speed.
Because the hydraulic oil temperature is still high when draining, wear protective clothing and be
careful to prevent injury.
7. Remove the end cap of the return oil filter from the hydraulic oil tank, take out the return oil filter
element and replace with a new one.
8. Open the breather filter cap (oil filler cap), take out the strainer.
160
9. Wash the breather filter cap (oil filler cap), strainer and oil drain plug with nonflammable detergent.
Dry them in the air or with compressed air.
10. Install the oil drain plug, return oil filter.
11. Refill the hydraulic oil tank from the hydraulic oil filler until the oil level reaches the upper graduation
of the sight glass. Tighten the breather filter cap (oil filler cap) after finishing.
12. Start the engine. Operate the pilot control level to raise or lower the carriage for 2~3 times and turn
from left to right to the maximum angle to fill cylinders with hydraulic oil. Then run the engine at idle
speed for five minutes to drain air in the system.
13. Stop the engine. Open the hydraulic oil filler cap, add clean hydraulic oil to a range of 5mm above or
below the middle scale of the sight glass of the hydraulic oil tank.
12.5.12 Serious Polluted Hydraulic Oil--Replace
suitable containers before disassembling any component containing fluids or dismounting any
hydraulic line. Dispose of all fluids according to local regulations.
Pay close attention to the cleanliness when replacing the hydraulic oil, do not allow dirt enter the
hydraulic system.
1. Park the machine on flat ground, and pull up the parking brake.
2. Start and run the engine at idle speed for 10 minutes.Raise or lower the carriage repeatedly or
perform back and forth steering operation in neutral position to raise the hydraulic oil temperature.
3. Raise the carriage to the highest position, and stop the engine.
4. Operate the pilot control lever to lower the carriage. The carriage will descend by its deadweight, and
discharge the hydraulic oil in the lifting cylinder.
161
5. Loosen the oil drain plug to drain out hydraulic oil and collect with a container.
P1TH00009
6. Meanwhile, open the breather filter cap (oil filler cap) of the hydraulic oil tank to quicken the oil
discharging speed.
7. Disconnect one end of the oil inlet pipe to drain the residual hydraulic oil from the steering cylinder,
oil cooler and other pipes.
8. After finish draining, install the oil drain plug and all the disconnected pipes.
9. Open the breather filter cap (oil filler cap) of the hydraulic oil tank and fill with clean oil to proper level.
10. Replace the polluted hydraulic oil according to the procedures described in section "Hydraulic Oil--
Replace". Replace the return oil filter element, suction oil filter element (if equipped), and wash the
breather filter cap (oil filler cap) and hydraulic oil tank.
162
12.5.13 Breather Filter of Hydraulic Oil Tank--Clean
The breather filter is located on the top of the hydraulic oil tank.
P1TH00014
1. Take out the filter element.

2. Wash the breather filter with clean and nonflammable detergent. Dry it in the air or with compressed
air.
3. Install the breather filter element.
163
12.5.14 Return Oil Filter Element of Hydraulic Oil Tank--Replace
Replace the return oil filter element at first 250 service hours, replace it every 1000 service hours later on
(Or take the visual pollution indicator that comes with the oil return filter as the standard. If the pointer
reaches the red area, the filter element should be replaced immediately.).
1. Remove the four bolts on the upper cover of the return oil filter.
1
2
3
P1TH00010
1. Bolt 2. Cover 3. Filter element
2. Take out the return oil filter element and replace a new element. Install the cover bolts and tighten
them.
164
12.5.15 Hydraulic Oil Tank--Clean
suitable containers before disassembling any hydraulic line or component containing fluids.
Dispose of all fluids according to local regulations.
1. Stop the engine.
2. Unscrew the oil drain plug at the bottom of the hydraulic oil tank to drain hydraulic oil. Collect with a
container.
P1TH00009
3. Remove the oil return filter.
P1TH00011
165
4. Remove the stop valve and the O ring. Place the stop valve and the O ring properly.
2
P1TH00012
1. O ring
2. Stop valve
5. Wash the bottom and four walls of the hydraulic oil tank with fuel through the flange port. Then wipe
with clean cloth.
6. Wash the bottom and four walls of the hydraulic oil tank with hydraulic oil again.
7. Replace the new return oil filter element and install the return oil filter. Replace the new O ring of
each flange, and install the oil drain plug.
8. If necessary, remove the hydraulic oil tank for cleaning.
166
Table 12-12.1Maintenance and Inspection

Inspection Item Interval
Inspect whether oil pipes of the vehicle have abrasion Once every day
Inspect the oil level and dipstick of the hydraulic oil tank Once every day
Check whether the oil cylinder support and the big nut on the top are loose and
Once every day
whether the clearance of the cylinder support is reasonable
Lift the oil cylinder when the vehicle has no load to see if the cylinder tilts Once every day
Check whether the support bolts of oil tank and pump are loose Once a week
Check whether the limit valve is able to work normally Once a week
Replace the return oil filter element and air filter element Once half a year
Check the lifting angle Once every day
Check the tightness of oil circuit and gas circuit Once a week
Replace hydraulic oil Once half a year
Table 12-12.2Maintenance Interval of Hydraulic System

Interval Period
Maintenance Item 10 hours 50 hours 250 hours 500 hours 1000 2000
When 100 hours
or every or every or every or 3 hours or hours or 1
necessary or 2 weeks
day week month months half a year year
Check the hydraulic
oil level
Add hydraulic oil
Replace hydraulic
★★★
oil
Replace the heavily
contaminated
hydraulic oil
Clean air filter of
hydraulic oil tank
Replace return oil
filter element of ★★★
hydraulic oil tank
Clean hydraulic oil
tank
Note: The item marked with ★ means first maintenance.

167
Table 12-12.3Common Fault Diagnosis of Double Pump
Fault Possible cause Troubleshooting method

Air enters system Tighten all connectors
The oil supplied is insufficient. Add oil to a proper level
Oil cooling Low-speed operation
The oil suction filter is too dirty Clean or replace the filter
Abnormal sound and noise Remove the blockage and replace the oil
The oil suction pipe is blocked
inlet filter
The air filter of the oil tank is clogged Clean or replace the air filter
Serious resonance with oil tank and Inspect whether erection bolts of the
parts around the pipeline pipeline and components are tightened
The oil supplied is insufficient. Add oil to a proper level
Pressure regulating of overflow valve is Readjust the pressure of the overflow
The pump has slow or no insufficient valve
reaction Interior plate of the gear pump and the
Repair or replacement
gear face have been worn or damaged
Valve abrasion, leakage or clamping Repair or replacement
Insufficient flow or pressure of
The side plate has been damaged Replace the site plate or gear pump
gear pump
Oil leakage of gear pump Abrasion or damage of sealing ring Replace the seal ring
The casing body has shrinkage and
Oil leakage on the casing surface Replace the gear pump
blister
Oil leakage of junction surface or The sealing components have been
Replace the seal.
screw hole damaged
The casing body has shrinkage and
Replace the gear pump
blister
Table 12-12.4Common Fault Diagnosis of Lifting System
Fault Cause Solution

Check whether the main air supply pipeline is
Without main air supply
unobstructed
Start the engine to make the pressure reach
Air pressure is too low
over7.5 kilograms
The oil cylinder fails Internal fault of pneumatic control valve Replace the pneumatic control valve
to be lifted The limit valve fails to work normally Replace the limit valve
Inner valve rod of the lifting valve is clamped Clean and inspect the lifting valve body and rod
Check whether the gas circuit or oil pipeline is
Wrong connection of gas circuit or oil pipeline
connected correctly
No oil comes out from the gear pump Check the oil circuit and pump
168

Start the engine to make the pressure reach
Air pressure is too low
over7.5 kilograms
Fault of gear pump Check or replace the gear pump
Leakage of air pipe Replace air pipe and tighten the connector
The oil cylinder is The air pipe is bent Rearrange the air pipe direction
lifted and lowered
too slowly Inner valve rod of the lifting valve is clamped Clean and inspect the lifting valve body and rod
Blow-by of air cavity of the lifting valve Replace the lifting valve repair kit
The one-way valve inside the lifting valve is Replace the one-way valve inside the lifting
damaged valve
Viscosity coefficient of hydraulic oil is too large Replace with appropriate hydraulic oil
Excessive overload Manual unloading
Oil level of the tank is not enough Add hydraulic oil of the same grade
The oil cylinder Fault of gear pump Check or replace the gear pump
cannot be lifted Air pressure is too low Make the pressure reach over7.5 kilograms
completely
The limit valve is not installed at a correct Readjust the installation position of the limit
position valve
Fault of overflow valve Replace the overflow valve
Piston rod and The limit valve is not installed at a correct Readjust the installation position of the limit
head of the oil position valve
cylinder is pulled Goods are of a large blocked structure and the Adjust the lifting angle to make the stroke reach
together lifting angle is too small the maximum angle
Eccentric load Correct handling of goods
The clearance of cylinder support bracket goes
beyond the specified tolerance zone and the Adjust the support clearance
Damage of oil cylinder is not mounted vertically
cylinder barrel
Follow the installation and operation
The roadbed was uneven at unloading
requirements strictly
Hydraulic oil is dirty Replace the hydraulic oil and the filter element
Repeated unbalance loading Load goods correctly and replace the seal kit
Oil penetration and
Damage of cylinder barrel Replace the cylinder barrel and seal kit
leakage of oil
cylinder Installation position of the oil cylinder fails to Replace the cylinder barrel and readjust the oil
meet requirements cylinder position
Leakage of air pipe Replace air pipe and tighten the connector
Sudden failure of The air pipe is bent Rearrange the air pipe direction
pneumatic control
valve There are impurities in pneumatic control valve Replace the pneumatic control valve
The limit valve element acts up Replace the limit valve
169

The one-way valve inside the lifting valve does
Replace the check valve with a new one
not work
Leakage in the lifting valve Replace the lifting valve
Cylinder slippage
Air leakage of pneumatic control valve Replace the pneumatic control valve
occurs during the
lifting process The lifting valve rod cannot be reseated Clean the valve body and rod, and replace the
normally seal kit
Replace the damaged cylinder barrel and seal
Oil leakage of the oil cylinder
kit
The limit valve element is obstructed Change the limit valve element
The gas circuit between the lifting valve and
Check or replace the pipeline
The oil cylinder pneumatic control valve is obstructed
does not drop The dump body or stable frame is deformed Rectify dump body or stable frame
The pneumatic control valve is not ventilated Replace the pneumatic control valve
The lifting system has no main air source Check the main gas circuit
The gear pump is damaged Replace the gear pump
Oil cylinder jitters The oil tank is lack of oil Add hydraulic oil of the same grade
Flow of oil inlet pipe varies too much Check the oil circuit
The air filter element of the oil tank is dirty Replace the air filter element
The oil level in the tank has exceeded the oil
Drain a little oil from the oil tank
dipstick
Oil spillage from air
Fail to operate correctly as required, and the oil Please operate correct by following the
filter of oil tank
cylinder is lowered during the driving process requirements strictly
The gear pump is damaged Replace the gear pump
The hydraulic oil grade is not correct Use the hydraulic oil meeting requirements
170
13. Electrical System DW90A
13.Electrical System
13.1Main Power Switch
The main power switch is located outside the battery container body of the longitudinal beam of the
frame. It is used to connect and disconnect circuits of the whole vehicle. Access: clockwise rotation;
circuit break: counterclockwise rotation.
P1T000180
13.2Battery
Two maintenance-free batteries are used in series, and the voltage of the whole vehicle is 24V. When
the device is not started for a long time, the main power switch shall be disconnected. If the engine is
shut down for a month, it is necessary to start the engine for 2-4 hours to charge the battery, so as to
prevent the whole vehicle from failing to start due to severe battery feeding.
The electric quantity of battery can be checked through the observation hole above the battery:
Green: Insufficient electric quantity of battery
Black: Insufficient battery charging; charging in time is required
Transparent: low liquid level of battery; the battery needs to be replaced
P1T000181
171
DW90A 13. Electrical System
13.2.1 Battery--Check
Stop the engine before working with batteries.

1. Open the battery box cover to get access to the battery..
P1T000181
2. Measure the battery voltage through battery tester (discharge fork) and multimeter.
(1) Measuring method of a multimeter:
1)Use a multimeter to measure the voltage of a battery: Select DC voltage on the multimeter, connect
the red lead to the battery positive terminal and the black lead to the battery negative terminal.
2).Observe the reading on the multimeter, charge the battery in time if the voltage value is lower than
12.5V (lower than 25V if two batteries are measured in series). The states of voltage and electric charge
are shown as below:
Battery voltage state

Electric charge state
(for one battery)
Above 12.5V 60%
12V-12.5V 30%~60%
11V-12V 0~30%
8V-11V Over-discharging
Below 8V Serious over-discharging
(2) Measuring method of a battery tester:

172
1). The pointer of the battery tester should be in the “0” position before testing, and the battery terminals
should be clean.
P18E00341
2). Clip the battery negative terminal by the negative testing clamp, and clip the battery positive terminal
by the positive testing clamp. The pointer of the battery tester should deflect rightwards. Observe the
reading, and disconnect the testing points quickly (the measuring time: 3s~5s).
3).There are graduation lines for different capacity batteries on the battery testing gauge board. Observe
the relative graduation line and judge the battery condition.
P18E00340
Discharging indication Reason Solution

Green zone Normal ----
Yellow zone Electricity insufficiency Charge battery
Red zone Electricity insufficiency or short circuit Test after charging
3. Close the battery box cover.

173
13.2.2 Battery--Charge
A long-time use of the electric appliances without starting the engine or a long-time stop, electricity
leakage, or the alternator can not charge; all these reasons could lead to an abnormal battery charge
and result in an electricity insufficiency or even can not start the machine. Recharge the battery if this
happens.
Charge the battery to let it work normally if the above-mentioned phenomenon happens.
1. Check the outlook of the battery before charging
(1) Do not charge the battery if the battery housing cracks or there is an acid leakage. Check the reason
and replace with a new one.
(2) Do not charge the battery if the battery terminal cracks. Check the reason and replace with a new
one.
(3) Do not charge the battery if it is distensible by over-charging or over-discharging. Replace with a new
one.
2. Battery charging
Measure the battery voltage before charging. The battery voltages can be divided into several levels, if
the difference of battery voltages is within 0.2V, the batteries can be connected in series and charged
together. Check the battery terminal voltage after finishing charging for 12 hours. The voltage shouldn’t
be lower than 12.8V (shouldn’t be lower than 25.6V if two batteries are measured in series), otherwise
recharge the battery.
Wear safety goggles when charging.

Keep ventilated when charging. Charge the battery under normal temperature.
Do not smoke when charging the battery, keep any kindling away.
The battery could have an explosion danger if it is deposed improperly when charging.
When removing a battery with low power before charging, first disconnecting the negative
terminal of the battery.
Check the terminals for cleanness before charging, the oxide layer of terminal surface should be
removed.
The battery temperature shouldn’t exceed 45°C.
(1) Turn the start switch to OFF position and take out the key, and then turn the disconnect switch to
OFF position.
174
(2) Clean the battery terminals and surface with a clean cloth, remove the oxidation surface.
(3) Remove the battery from the machine. When removing, first disconnecting the negative terminal of
the battery, and then the positive terminal.
(4) Connect the cables after finishing charging. Connect the positive cable first.
When connecting the battery, first connect its positive terminal; when disconnecting the battery,
first disconnect its negative terminal.
(5) Connect the positive clamp of the charger to the positive terminal of the battery, the negative clamp
to the negative terminal under room temperature.
(6) In general, the battery can be charged by constant voltage and constant current. Constant voltage
charging can satisfy battery recharging in most cases, so it is recommended to charge battery with a
constant voltage. It is easy to over charge a battery by constant current if the current is too high, and
damage the battery. Voltage setting: use a simple charger of 12V to charge one battery, the voltage
should be set at 14.5V-15V. Use a simple charger of 24V to charge two batteries at the same time,
the voltage should be set at 29~30V.
(7) Table of charge time and battery voltage for reference (lower current means a longer charging time).
Battery Voltage Charge Time

12.55-12.45VDC 2h
12.45-12.35VDC 3h
12.35-12.20VDC 4h
12.20-12.05VDC 5h
12.05-11.95VDC 6h
11.95-11.80VDC 7h
11.80-11.65VDC 8h
11.65-11.50VDC 9h
11.50-11.30VDC 10h
11.30-11.00VDC 12h
Below 11.00VDC 14h
● Check the hydrometer color after finishing charging. Green hydrometer indicates that the battery is
fully charged.
● If the hydrometer is black, check the cable connection and connecting points. Charge the battery
again according to the above table until the hydrometer is green.
● If the hydrometer lost color, bubbles might exist in the hydrometer. Shake the battery slightly to
remove the bubbles. If the hydrometer still lost color, then electrolyte is lost seriously, discard the
battery and replace with a new one.
175
(8) As for a battery with a voltage under 11.0VDC, it may not be able to be charged at the beginning.
Due to the serious insufficiency of electricity, the proportion of vitriol is close to water, therefore, the
battery resistance is higher. The vitriol proportion increases during recharge and the circuit can get
right gradually.
Fix the two terminals tightly. Do not charge the battery of 24VDC voltage in serial connection.
Stop charging immediately to check the reason if the battery discharge hole spurts acid during
the charging process.
(9) Stop charging if the battery temperature exceeds 45°C during the charging process. Halve the circuit
before recharging after the battery temperature drops to the ambient temperature.
(10)Check the battery voltage 12 hours after finished charging or carried out discharging operation
once. If the battery voltage dropped over 0.5V within 12-24 hours, replace the battery directly to
avoid empty voltage of the battery.
(11)It is recommended applying vaseline on the battery terminals to avoid electric corrosion after charge
is completed.
Charge the battery according to the following method when the battery voltage is low, but the machine
still can be started and alternator works normally.
(1) Start the engine, and ensure that the battery charging system is in normal (observe the battery
voltage through gauge), keep the engine speed at second gear to charge the battery until it is fully
charged.
(2) Turn off the A/C, radio, lights (except night) and other high-power electric equipment during battery
charging.
(3) Avoid starting the machine frequently as far as possible during battery charging. If restart is
necessary, it is recommended to restart the machine after finishing charging the battery.
13.2.3Battery--Store/ Service
1. Turn off the battery disconnect switch when storing the batteries being installed on a machine, and
check the battery voltage state at least every other month.
2. For the machine needs to be stored over 30 days, the batteries should be removed and managed
together. Check the battery voltage once every 30 days. Recharge the battery in time if its voltage is
lower than 12.5V (lower than 25V if two batteries are measured in series).
3. For the machine needs to be stored less than 30 days, disconnect the battery disconnect switch.
Check the battery voltage once over 15 days to ensure that the battery voltage is above 12.5V.
4. As for the machine which has not disconnected the battery terminals, check the battery voltage state
every month. Recharge if the battery lacks for electricity. Recharge according to special procedures.
5. As for the machine which is stored over one year, replace with a new battery and dispose the old one
if the above- mentioned requirements can not be followed.
176
13.2.4Battery--Recycle
When discarding a battery, its inner material such as lead, acid and plastic shell can pollute the
environment due to its outer frayed structure or other reasons. Therefore, do not throw away the old
battery randomly, deal with it by collecting for a battery disposal station or put it into a recycle can set by
the manufacturer (if there is any) in a local place.
13.3Centralized Control Box of Electric Appliance
1 2
P1T000182
1. Fuse group 2. Relay

177
Functional Layout of Fuse and Relay
P1T000183
The centralized control box of electric appliance is located in the cab, under the sleeper. The centralized
control box integrates the vehicle relay with most fuses, for easy maintenance.
178
13.4 Common Faults and Troubleshooting
Faults in electrical systems are usually caused by abnormal operation of electrical components. The
steps below can be followed for inspection:
(1) Voltage measurement: Use a multimeter to measure the wiring harness connector to see if it has a
voltage of 24V. If does, check the component or replace it. If not, go to step (2).
(2) Check the fuse and open the central control box to check whether the corresponding fuse and relay
are damaged. If so, a replacement shall be made. If they still fail to work normally after replacement,
turn to step (3);
(3) Use a multimeter to measure whether there is any electricity in the wire, from the wiring harness to
the upper connector. If any, it indicates that there is a fault of the wire from the connector to the
component. Then, troubleshooting shall be conducted. If no, then continue to check the connector.
(4) Find out the fault area of wiring harness and conduct troubleshooting.
Common fault cause:
(1) Poor contact of connector leads to circuit break; solution: reconnect the connector.
(2) Water ingress of connector leads to short circuit; solution: dry the moisture and take connector
protection measures again.
(3) The wire harness is squeezed, causing the wires to break and overlap with each other; or the wires
are broken, resulting in a short circuit; solution: If extrusion marks are found on the outer surface of
the wire harness, it is necessary to strip off the bellows to check the integrity of the wires, and replace
the damaged or broken ones in time.
13.5Schematic Diagram
See sections of the attached list for the schematic diagram.

179
DW90A 14. Air Conditioning System
14.Air Conditioning System
14.1Air-conditioning System Structure
8
7
2
4 5
P1T000189
1. Hot water pipe 3. Condenser 5. Receiver dryer 7. Evaporator

2. Stop valve 4. Condenser pipe 6. Compressor 8. A/C control panel
180
14. Air Conditioning System DW90A
14.2Refrigerating System
14.2.1Principle of refrigeration
1 2 4
High-temperature
high-pressure air 7
5
High-temperature and
high-pressure gas-liquid
mixture
High-temperature and
high-pressure liquid
6
Low-temperature
low-pressure liquid
Medium-temperature and
low-pressure gas
P1T000190
1. Compressor 3. Evaporating fan 5. Condensate fan 7. Receiver dryer

2. H-shaped expansion 4. Evaporator 6. Condenser
valve
181
DW90A 14. Air Conditioning System
14.2.2Operating Instructions
1 2 3
P1T000191
1. Position selector switch 2. Refrigerating capacity switch 3. Mode selector switch
Knob 1 is a position selector switch of a fan, which can be used to regulate the fan speed, thus adjusting
the air volume at the outlet.
Knob 2 is the refrigerating capacity selector switch, which can be used to adjust the refrigerating capacity
of the system.
Knob 3 is the mode selector switch, which can switch modes of air conditioning refrigeration and
defrosting.
When the driver needs to start the refrigerating system, he needs to start the engine, turn on the position
selector switch (knob 1) and then adjust the refrigerating capacity (turn knob 2), and turn knob 3 to the
left (to the right if defrosting is required for the front window).
When refrigeration or defrosting starts, it is necessary to close the stop valve of the hot water
pipe. Otherwise, it may lead to refrigeration failure or poor refrigeration effect of the air
conditioner.
14.2.3Maintenance
1) Clean the condenser regularly to ensure good heat dissipation performance of the air conditioning
system. The condenser can be flushed directly with water.
2) Check the quantity of refrigerants of air conditioning system on a regular basis to ensure good
refrigeration performance. Inspection method: turn the air conditioner into refrigeration mode, and
observe the number of bubbles through the viewport above the liquid reservoir to determine the
quantity of refrigerants. If the refrigerant is insufficient, it shall be supplemented in time.
182
14. Air Conditioning System DW90A
14.3Heating System
14.3.1Working Principle of Heating System
2 P1T000192
1. Water outlet of engine 2. Water return inlet of engine
14.3.2Operating Instructions
When the driver needs to turn on the heating system, the engine needs to be started for some time, and
the engine water temperature should be raised to a certain temperature. Before the heating system is
turned on, it is necessary to open the stop valve of hot water pipe and the position selector switch (knob
1) of the fan, and close the refrigeration switch (with knob 2 screwed to the far left).
14.3.3Repair and Maintenance
1) Check the connection of the water pipe to ensure there is no water leakage.
2) Make sure the engine cooling water is clean and free of impurities, so as to prevent the impurities
from entering the evaporator core and causing the core blockage when the heating system is turned
on.
183
January 13, 2022 IV. Schedule
DW90A 1. Tightening Torque of Bolts and Nuts at Important Parts
IV. Schedule
1.Tightening Torque of Bolts and Nuts at Important Parts
Tightening Torque of Bolts and Nuts

Tightening torque
Connected Part Bolt specification
(Nm)
Connecting bolt of the front plate spring support 500-600 M20
U-shaped bolt of the front spring 900-1000 M24×2
U-bolts of plate spring 1700-1900 M30×2
Rear thrust bar and support connecting bolt 900-1000/1300-1500 M24×2 / M27×2
Connecting bolt of intermediate support assembly and
380-450 M18×1.5
balance shaft
Fastening bolt of transmission shaft 180-200 M14×1.5
184
IV. Schedule January 13, 2022
2. Oil Filling Part, Grade and Capacity DW90A
2.Oil Filling Part, Grade and Capacity
Oil filling part and grade

Oil filling part of the engine Oil filling part of clutch control
P1T000194 P1T000195
Oil filling part of transmission Oil filling port of middle axle
P1T000196 P1T000197
Oil filling port of rear axle Oil filling port of hub of middle and rear axles
P1T000198 P1T000199
185
DW90A 2. Oil Filling Part, Grade and Capacity
Schematic Diagram of Lubrication Position
P1T000200
Type of
No. Below -30°C -30°C~-15°C -15°C~30°C Above 30°C
Lubricant
A1 Engine oil CF4 0W/40 CF4 5W/40 CF4 15W/40 CF4 20W/50
A2 Transmission oil SHELL II lubricating oil special for long-acting enhanced automatic transmission
B Gear oil GL-4 75W/90 GL-5 80W/90 GL-5 85W/90 GL-5 85W/140
HV46 low- HV46 low-
HM46 anti-wear HM46 anti-wear
C Hydraulic oil temperature anti- temperature anti-
hydraulic oil hydraulic oil
wear hydraulic oil wear hydraulic oil
D1 No. 2 universal lithium-based grease
Lubricating grease
D2 No. 2 extreme-pressure compound lithium-based grease
186
2. Oil Filling Part, Grade and Capacity DW90A
Loc
Lubric Lubric Lubric Lubric
S/N Description atio 10 h 100 h 500 h 1000 h
ant ant ant ant
n
Hinge pin of
1 1 D1 Filling
dump body
Brake
2 2 D1 Filling
adjustment arm
Rear driving
3 3 B Filling
axle
Intermediate
4 4 B Filling
driving axle
5 Drive shaft tube 5 D1 Filling
Hydraulic oil
6 6 C Filling
tank
7 Steering oil tank 7 C Filling
Spherical hinge
8 of steering tie 8 D1 Filling
rod
Universal joint of
9 9 D1 Filling
steering column
10 Radiator fan 10 D1 Filling
Spherical hinge
of steering
11 11 D1 Filling
actuation
cylinder
Oil tank of
12 engine 12 A1 Check A1 Replace
crankshaft
Automatic
13 transmission 13 A2 Check A2 Replace
(AT)
Manual
14 transmission 14 B Check B Replace
(MT)
Fuel tank and Troublesho
15 15
precipitate oting
Plate spring pin-
16 16 D1 Filling
support
Plate spring pin-
17 17 D1 Filling
lifting lug
18 Balance shaft 18 B Filling
187
DW90A 3. Number and Consumption of Working Medium for Each Assembly
3.Number and Consumption of Working Medium for Each

Assembly
(1) Diesel oil (consistent with GB252-2000)
Range of ambient temperature Grade of Diesel Oil

Above 4°C 0# diesel oil
Above -5°C -10# diesel oil
Above -5°C~-14°C -20# diesel oil
(2) Engine oil
Range of ambient temperature Oil Grade Filling Quantity

-30°C~40°C 5W/40
-25°C~40°C 10W/40
-25°C~50°C 10W/40
Filling quantity of diesel engine
-20°C~40°C 15W/40
27L
-20°C~50°C 15W/40
-15°C~40°C 20W/40
-15°C~50°C 20W/40
The diesel oil of engine shall be replaced every 250 operating hours of the engine. If the engine operates
continuously, change the oil and oil filter at most 15 days.
Otherwise specified, 15W-40 CF diesel oil is added for delivered WD12.430 engine of Guangxi
LiuGong Machinery Co., Ltd. Please use appropriate diesel oil for replacement in a timely manner
according to local ambient temperature.
Users are recommended to use Mobil Delvac or oil with SHELL CH-4 and above. The viscosity grade
shall be selected according to the local ambient temperature. For the engine oil filter, a dedicated one
must be purchased from the maintenance station.
Air filter element must be replaced every 10-15 days.
(3) Gear oil
Range of ambient temperature Gear Oil Grade Filling Quantity

-15°C~49°C 85W-140 GL-5 33.6L for middle axle
-25°C~49°C 85W-90 GL-5 29.6L for rear axle
-40°C~40°C 75W-90 GL-5 17.5L for transmission
The gear oil shall be replaced every 5000 km of driving.

188
3. Number and Consumption of Working Medium for Each Assembly DW90A
Unless otherwise specified,85W-90 GL-5 heavy-duty gear oil is added for the axles and
transmissions of the delivered vehicles of Guangxi LiuGong Machinery Co., Ltd. Users are
recommended to replace gear oil in a timely manner according to local temperature and
environment.
(4) Hydraulic oil
Range of ambient Viscosity of hydraulic

Oil Grade Filling Quantity
temperature oil
Above 50°C HM68 68
25°C~50°C HM46 46
10°C~25°C HM46 46
160L in hydraulic oil tank
-10°C~10°C HM46 46
-40°C~-10°C HM32 32
Below -40°C HM15 15
Every 6 months, the two filters in the hydraulic oil tank shall be replaced and the hydraulic oil shall be
replaced or filtered once.
The low-temperature anti-wear HM46 hydraulic oil for the hydraulic tank of the delivered vehicles
of Guangxi LiuGong Machinery Co., Ltd. can be used between +50? and +10?. Users are
recommended to replace the hydraulic oil in time according to local air temperature and
environment.
(5) Brake fluid

Since No. 4604 brake fluid (brake oil) added for the delivered vehicles of Guangxi LiuGong Machinery
Co., Ltd. can work normally at -40°C, there is no need for users to replace it. The brake fluid with the
same grade of the same manufacturer shall be added for supplement.
The clutch brake fluid shall be replaced once every year.
(6) Antifreeze
Boiling Freezing Applicable
Coolant Content of Proportion
point point minimum Filling Quantity
Model Glycol (%) (15.6°C)
(°C) (°C) temperature (°C)
OAT -35°C engine
48 (volume) 1046(KG/m3) 107 -35 -27 Radiator (60L)
coolant
Unless otherwise described, the water tanks of vehicles manufactured by Guangxi LiuGong
Machinery Co., Ltd. are filled with OAT engine coolant at -35°C when they leave factory. The users
need to replace the antifreeze in time based on the local air temperature.
189
DW90A 3. Number and Consumption of Working Medium for Each Assembly
The engine antifreeze needs to be replaced once every two years, or its freezing point needs to be
checked in winter. In case failure to meet requirements, the antifreeze shall be replaced in time. During
the replacement of antifreeze, the antifreeze applicable to aluminum water tank and radiator shall be
selected as per the manual; otherwise, we will not undertake any responsibilities or losses due to
corrosion of water tank and radiator!
190
3. Number and Consumption of Working Medium for Each Assembly DW90A
191
January 13, 2022 Index
DW90A
Index
A E
Access Door.....................................................31 Electrical Layout of Instrument Panel .............. 44

Access Door of Fixed Cab ...............................32 Electrical system............................................ 170
Access Door of Rollback Cab ..........................31 Engine Hood Access Door of Fixed Cab ......... 33
Air conditioning system ..................................179
Air conditioning system structure ...................179
F
B Filling of Coolant .............................................. 64
Foreword ........................................................... 3
Battery............................................................170 Front Suspension System ............................. 130
Battery--Charge .............................................173 Fuel Strainer--Clean ........................................ 68
Battery--Check ...............................................171
Battery--Recycle ............................................176
Battery--Store/ Service...................................175
H
Brake system ...................................................98
Breather Filter of Hydraulic Oil Tank--Clean ..162 Heating system .............................................. 182
Hydraulic Oil Level--Add ................................ 158
Hydraulic Oil Level--Replace ......................... 159
C Hydraulic Oil Tank--Clean ............................. 164
Hydraulic Schematic Diagram ....................... 195
Cab ..................................................................29
Centralized control box of electric appliance..176
Clutch and Its Control Parts .............................77
J
Common Faults and Troubleshooting84, 94, 115,
...............................................................167, 178 Installation of Clutch ........................................ 79
Control and Precautions for Transmission .......74 Installation of Flexible Shaft............................. 73
Control Structure ..............................................72 Installation Requirements for Clutch Control
Cooling system ................................................63 System............................................................. 80
Instructions for brake use ................................ 61
Instructions for Cab Rollback......................... 112
D Instructions for preventing overspeed ............. 60
Instructions to Drivers ........................................ 5
Daily Maintenance and Precautions ................59 Internal Devices in Cab ................................... 39
Description of Main Important Components...100 Introduction to Main Functions of Electrical
Description of Signs .........................................12 Components and Switches .............................. 48
Diagnosis and Removal of Common Faults of
Brake System.................................................109
Dump Body Lifting System.............................143
L
Dump body lifting system structure and working
principle..........................................................143 Left and Right Rearview Mirrors ...................... 34
Lifting steps ................................................... 155
192
Index January 13, 2022
DW90A
M Product Overview ............................................ 19
Main Components ............................................21 R

Main Functions of Instrument Panel and Indicator
Lights ...............................................................45 Rear suspension system ............................... 131
Main Power Switch ........................................170 Refrigerating system...................................... 180
Maintenance ......................60, 92, 108, 114, 156 Replacement of Engine Oil, Filter and Prefilter 56
Maintenance and Service of Suspension System Restrictions on Service Environment of Vehicle 6
....................................................................... 129 Return Oil Filter Element of Hydraulic Oil Tank--
Maintenance of Air Intake System ...................65 Replace ......................................................... 163
Maintenance of Engine and Its Auxiliary System Run-in of New Vehicle ..................................... 28
......................................................................... 56
Maintenance of Fuel System ...........................68
Maintenance of Transmission ..........................75 S
N Safe Operation .................................................. 7

Safety Instructions ............................................. 4
Safety Precautions ............................................ 4
Number and Consumption of Working Medium for Safety Signs .................................................... 11
Each Assembly ..............................................187 Schedule........................................................ 183
Schematic Diagram ....................................... 178
O Schematic Diagram of Electrical System....... 196
Schematic of brake system ........................... 197
Seat and Seat Belt........................................... 35
Oil Filling Part, Grade and Capacity...............184 Serious Polluted Hydraulic Oil--Replace ....... 160
Operation and Maintenance of Engine ............56 Start and Shift.................................................. 26
Operation Instructions and Principles of Brake Start of Engine ................................................. 25
System .............................................................98 Steering Control............................................... 91
Operation Instructions of Rollback Cab Lifting Steering System .............................................. 87
System ...........................................................111 Steering Wheel and Steering Column ............. 38
Operation of Door ............................................29 Structure .......................................................... 63
Operation Precautions ...................................114 Structure and Principle of Main Components
Operation Specification for In-cylinder Braking of .................................................................89, 145
the Engine ........................................................60 Structure and Principle of Steering System ..... 87
Overview of Clutch Control System .................77 Structure of Air Intake System with Desert-type
Overview of Vehicle Axles .............................118 Filter................................................................. 65
Outline Drawing of the Vehicle.........................19 Structure of Air Intake System with Oil-bath Air
Filter................................................................. 66
P Structure of Transmission................................ 69
Positions of Safety Signs .................................11 T

Precautions ..............................................91, 156
Precautions for Repair of Wheel Axles ..........121 Tightening Torque of Bolts and Nuts at Important
Precautions for Use and Maintenance of Clutch Parts .............................................................. 183
Control System ................................................83 Transmission ................................................... 69
Preparation for Driving .....................................24 Tyre Pressure and Bearing Capacity............. 126
Preparations.....................................................24 Tyre Rotation and Maintenance .................... 127
Principles of Cab Rollback Mechanism..........111
193
January 13, 2022 Index
DW90A
Water and Impurity--Remove ...........................68

Vehicle Axle and Tyre Systems .....................117
Vehicle Parameters..........................................20
What are the reasons for engine overspeed ....60
What faults or failures may be caused by engine
overspeed ........................................................60
What is engine overspeed ...............................60
Wheel Replacement.......................................125
Use and Maintenance of Vehicle Axles .........117
Use of Tyre ....................................................127
Use of Vehicle ..................................................24
Use of Vehicle Axles ......................................118
194
Index January 13, 2022
DW90A
195
January 13, 2022
DW90A Hydraulic Schematic Diagram
Hydraulic Schematic Diagram
举升
进气
Lift
Air intake
降落排气
Lower Exhaust
50Y2038
196
January 13, 2022
DW90A Schematic Diagram of Electrical System
Schematic Diagram of Electrical System
50Y2013
197
January 13, 2022
DW90A Schematic Diagram of Brake System
Schematic Diagram of Brake System
50Y2034
198
January 13, 2022
DW90A Schematic Diagram of Brake System

DW90A (Yuchai Fast Transmission Hande Axle) OM 202201000-En

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DW90A (Yuchai Fast Transmission Hande Axle) OM 202201000-En

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202201000

Operation and Maintenance

Foreword 8.Brake System ............................................... 98

9.Operation Instructions of Rollback Cab Lifting

2.Instructions to Drivers .....................................5 11.Maintenance and Service of Suspension Sys-

4.Safe Operation ................................................7 13.Electrical System ...................................... 170

5.Safety Signs ..................................................11 14.Air Conditioning System ........................... 179

II. Product Overview IV. Schedule

4.Maintenance of Engine and Its Auxiliary System

6.Clutch and Its Control Parts ..........................77

2.Instructions to Drivers due to falling during running of the vehicle.

3.Restrictions on Service According to the technical parameters in

4.Safe Operation In case of poor road conditions and unstable

After unloading, it is strictly prohibited from

At the time of stopping the vehicle, the dump

No open flame is allowed during inspection at

Breathing asbestos dust can be hazardous to

5.1Positions of Safety Signs

12. Caution sign 21. Safety sign 27. Sign

Positions of Safety Signs on DW90A (48Y1499 Sign Group)

3. Safety sign 9. Sign

25.Sign for caution before operation

30.Refueling safety sign

33.Sign indicating protection against hydraulic oil scald

II. Product Overview

1.Outline Drawing of the Vehicle

(2) Engine, transmission and drive axle

1. Here is the engine number.

1. Here is the transmission number.

Reinforced Integrated Frame for Mining Area

1. Here is the front axle number.

1. Here is the intermediate axle number.

1. Here is the rear axle number.

4.Main Purpose and Service Environment Requirements

III. Use of Vehicle

1.Preparation for Driving

2) Inspection of engine oil pressure after start

1.3Start and Shift

All DWA90 series vehicles must be started at 1st gear!

1.3.4Lifting and Falling of Dump Body

Refer to "12.3. Lifting Steps" on page 155" for operation details.

1.3.5Use in Low-temperature Environment

a. Engine cooling system

1.4Run-in of New Vehicle

1 The running-in mileage of a new vehicle shall be 1,000~2,000 km.

Do not drive the vehicle with the doors not closed!

2.1.1Opening/Closing of Doors from Outside

2.1.2Opening/Closing of Doors from Inside

1. Door lock and key 3. Interior handrail

Door Lock (Fixed Cab)

1. Door lock and key 3. Interior handrail

2.2.1 Access Door of Rollback Cab

Access Door Lock

1. Access door lock

2.2.2 Access Door of Fixed Cab

1. Access door lock 2. Grab handle

2.2.3 Engine Hood Access Door of Fixed Cab

1. Pull-locks 2. Valve support 3. Hood access door

2.3Left and Right Rearview Mirrors

Rearview Mirror (Rollback cab)

Rearview Mirror (Fixed cab)

2.4Seat and Seat Belt

1. Headrest 3. Forward/backward height 5. Damper locking handle