DW90A (Weichai T3) Service Manual 202006000-EN

202006000
DW90A
Off-road wide-body dump truck
Service Manual
Applicable model: DW90A

June 9, 2020 Table of Contents
DW90A
Table of Contents
General Information...........................................................................................................1-1
Power System ...................................................................................................................2-1
Drive system......................................................................................................................3-1
Hydraulic System...............................................................................................................4-1
Air conditioning system......................................................................................................5-1
Cab and covering parts .....................................................................................................6-1
Structure ............................................................................................................................7-1
Electrical system................................................................................................................8-1
Braking system ..................................................................................................................9-1
Annex ..............................................................................................................................10-1
Table of Contents June 9, 2020
DW90A
1-1
June 9, 2020 General Information
DW90A
General Information
How to use this Manual .....................................................................................................1-3
Important Safety Tips ........................................................................................................1-4
Manual identification..........................................................................................................1-5
Engine Identification ..........................................................................................................1-6
Cable Identification Method ...............................................................................................1-7
Coating Materials...............................................................................................................1-9
Weight List.......................................................................................................................1-11
Unit Conversion Table .....................................................................................................1-12
Standard Torque Table....................................................................................................1-13
Torque parameters - metric metal parts...............................................................................................1-13
Specification for Use of Oil ..............................................................................................1-17

Maintenance Interval Schedule .......................................................................................1-18
Technical Specification of Complete Machine.................................................................1-23
Main components of the machine ..................................................................................1-24
Main technical parameters ..............................................................................................1-25
Parameters of complete machine....................................................................................1-27
Parameters of Components.............................................................................................1-29
Checklist of whole machine .............................................................................................1-32
1-2
General Information June 9, 2020
DW90A
1-3
June 9, 2020 How to use this Manual
DW90A
How to use this Manual Instructions to Users
● Since the machine is affected by area or

This Manual is prepared by experienced processing to different extents, it is
technicians. In this Manual, basic tools required necessary to confirm which machine is
for certain maintenance work are identified and applicable and which working devices it has.
recommended. ● Some accessories and optional parts in this
This is a safety warning symbol. When Manual may not be transported to relevant
you see this symbol on your machine or in areas. If required, please consult local
this Manual, you shall follow instructions in distributor of Liugong.
the safety information and watch out for ● Materials and technical specifications in this
possible personal injuries. Manual vary with changes. All the
information, charts and specifications in this
The technical manual consists of two parts: Manual are the latest product information
maintenance and test. The maintenance part available at the time of publication. Liugong
describes how to maintain components. and the reserves the right to make changes without
test part helps you quickly identify most common any notice. For the latest technical
faults. information, please consult local distributor of
Information is grouped for various components Liugong or the Service Department of
requiring maintenance instructions. Each group Liugong Loader Marketing Co., Ltd.For the
begins with a summary list of all applicable basic replacement of environment-friendly key
tools, maintenance tooling, other materials parts and components when maintaining an
required, service kit, specifications, wear engine, please use the OEM parts and
tolerances and torque values. components of the same type and the same
specifications. Otherwise, LiuGong accepts
The technical manual is a concise guide of a no legal liability for any consequence
specific machine, containing as much important resulting from the use of unapproved parts.
information as possible for fault diagnosis,
analysis, test and maintenance.
Basic maintenance information is available from
other sources and it covers basic operation
theory, basic principle of troubleshooting, general
maintenance, and basic type and cause of faults.
Other reference manuals
● Parts catalogue
● Operation and Maintenance Manual
● Parts manual of Weichai engine
● Weichai Engine Overhaul Manual
● Faster Transmission Overhaul Manual
● Hande Drive Axle Overhaul Manual
1-4
Important Safety Tips June 9, 2020
DW90A
Important Safety Tips As it is impossible for Liugong to predict all

hazardous working environments, the warnings
in this Manual and those on the product may be
Most accidents related to product operation, incomplete. If you adopt a tool, procedure,
maintenance and repair are caused by ignorance working method or operation technology that has
of basic safety rules or protection measures. An not been specially recommended by Liugong,
accident can be avoided if any potential accident you shall pay attention to the safety of yourself or
hazard can be observed. Relevant personnel others and be able to ensure that the operation,
must be familiar with potential accident hazards, lubrication, maintenance and repair procedures
receive necessary training and have certain skills you have selected will not cause damage to the
in troubleshooting with tools. machine or make the machine unsafe.
Incorrect operation, lubrication, maintenance and The instructions, figures and illustrations in this
repair are dangerous and may, in serious cases, Manual are based on the latest information
cause personal death. available at that time. Continuous improvement
Do not perform any operation, lubrication, in the design of the machine will result in
maintenance or repair on the machine before changes in details, which may not be reflected in
reading and understanding the contents in these this Manual. Please contact Liugong or Liugong's
respects. distributor for the latest information about the
machine or for questions concerning the
Safety precautions and warnings are listed in this information in this Manual.
Manual and on the product. Ignorance of these
warnings may cause death of relevant California Proposition 65
personnel.
California believes that diesel engine exhaust
All hazards are marked with a "safety warning and some of its components can cause cancer,
symbol" and corresponding "signal term", such birth defects or other reproductive harms.
as "Danger", "Warning" and "Caution". The
safety warning label "Warning" is as follows: As battery columns, battery electrodes and
relevant accessories contain lead and lead
compounds, please wash hands after touching
them.
The meaning of the safety warning symbol is

as follows:
Attention! Watch out! For your Safety!
The hazard is explained with words or pictures

below the warning board.
Operations that may cause damage to the
machine are marked with "Caution" or "Warning"
labels on the machine and in this Manual.
1-5
June 9, 2020 Manual identification
DW90A
Manual identification PIN code nameplate
Important: Use a maintenance manual matching

the machine. Improper maintenance may be
carried out if an incorrect manual is selected.
Please check the PIN code of product and
engine model when selecting the correct manual.
Select a correct service manual
Based on the demands of different sales

markets, LiuGong loaders have different
configurations. There are different service P2TM00002
manuals for models with different configurations.
If necessary, the product serial number and
engine model will be listed on the inside cover of
the whole machine manual. It is used to identify
the correct service manual of machine.
Identification product serial number
The product PIN code nameplate is located on

the right side of the front end of the vehicle
frame, with the running direction of vehicle as the
front. On the nameplate of each machine, the
factory number is 17-digit PIN code, and the last
6 digits of PIN code represent the product serial
number of the machine.
Location of nameplate with PIN code
P2TM00001
1-6
Engine Identification June 9, 2020
DW90A
Engine Identification
The engine serial number nameplate is located

on the left side of the engine. Each engine has
eight engine numbers on its nameplate.
Identify the engine emission levels
Emission control information: In the United

States, only the engines to be exported are
exempt from the emission standard of 40 CFR
1068.230 and the related requirements. Outside
the United States, engines can comply with other
emission regulations.
Location of Engine Serial Number Nameplate
P2TM00003
Engine Serial Number Nameplate
P2TM00004
1-7
June 9, 2020 Cable Identification Method
DW90A
Cable Identification Method
In a circuit diagram, the combination of wire number, wire type, color abbreviation code and wire gauge
is adopted to identify a wire for maintenance, For example:
108 AEX RD 50.0 It refers to the heat-resistant and low-voltage wires for vehicles, with the color
of red, the wire number of 108 and the wire diameter of 50.0mm2
Wire gauge (note: Unless otherwise indicated, the wire gauge is taken as 0.85m2.)
Color Abbreviation Code
Type of Wire
Wire number P2TM00011
Wire number
The wire number is a digital code that identifies a wire with three Arabic numerals according to certain
rules.
Type of Wire
Generally, the types of wires for construction machinery include AEX, AV, AVS, AVSS and QVR. Refer to
the table below for the applicable ambient temperature range of various wires.
Type of
S/N Name of Wire Description Heat resistance
Wire
Heat resistant 70 °C (158 °F), copper core
1 QVR LV wire for road vehicle ≤ 70 °C(158 °F)
PVC insulation
Thin-wall insulated LV
2 AVSS Insulation layer thickness: 0.30~0.40mm ≤80 °C (176 °F)
wire for automobile
Thin-wall insulated LV
3 AVS Insulation layer thickness: 0.50~0.70mm ≤ 80 °C (176 °F)
wire for automobile
Insulated LV wire for
4 AV Insulation layer thickness: 0.60 ~2.0mm ≤ 80 °C(176 °F)
automobile
Heat-resistant LV wire for
5 AEX Heat-resistant, crosslinked polyethylene ≤ 110 °C(230 °F)
automobile
Color Abbreviation Code
Color In English Abbreviation Color In English Abbreviation

黑色 BLACK BK 蓝色 BLUE BU
灰色 GREY GY 绿色 GREEN GN
红色 RED RD 黄色 YELLOW YL
棕色 BROWN BR 粉红色 PINK PK
1-8
Cable Identification Method June 9, 2020
DW90A
Color In English Abbreviation Color In English Abbreviation

紫色 VIOLET VT 橙色 ORANGE OR
白色 WHITE WH 浅蓝色 LIGHT BLUE LTBU
红色 / 绿色 RED/GREEN RD/GN 黄色 / 蓝色 YELLOW/BLUE YL/BU
Remarks: A code composed of 2 colors indicates a double-color wire.

For example, "RD/GN" refers to a red-green wire.
Wire Specification
For the allowable current and voltage drop of AV conductor, the performance of AVS, AVSS and QVR
are similar, which can be executed with reference to the following table.
Ambient
30°C (86 °F) 40 °C (104 °F) 50 °C(122 °F) 60 °C (140 °F) 70 °C(158 °F)
temperature
Allowable
current/ A mV/m A mV/m A mV/m A mV/m A mV/m
voltage drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
Nominal 8 74 213 66 190 57 164 47 135 33 95
cross-
15 103 176 92 157 30 137 65 111 46 79
sectional
area 20 135 148 121 133 105 116 85 94 60 66
(mm2) 30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 60 252 53 178 37
Type of Circuit and Color Abbreviation Code
Refer to the table below for the general rules of correspondence between the type of circuit and the color
abbreviation code.
Type of Circuit Color Abbreviation Code

Power line OR, RD
Signal line WH
Grounding BK, GY
Communication line RD/GN, YU/BU
1-9
June 9, 2020 Coating Materials
DW90A
Coating Materials
Description Specifications Main features & applications

Characteristics: anaerobic and fast air drying.
1277 Thread locking sealant 1277
Application: for the parts that are seldom removed.
1243 Thread locking sealant 1243 For removable parts (speed sensor in general)
Characteristics: long rust prevention time.
Long-term rust inhibitor LONG #2 light yellow Application: for pump mounting surface, sensor and
hydraulic connector, etc.
Highly efficient cleaning agent Characteristics: strong cleaning capacity.
1755
1755 Application: for pumps and motors.
Characteristics: high temperature resistance, self-
lubrication, medium resistance; used for sealing taper/
taper threads of oil, gas, steam, water and other medium
Anaerobic pipe thread sealant 1567
pipes.
Application: for water temperature sensor and oil
pressure sensor.
Detergent for E&M equipment HD-10 For cleaning of oil pipe connectors.
Diesel engine sealant 1515 Used for flange mounting surface of diesel engine
Polyurethane sealant 1924 For waterproofing of starting motors and fit-up gaps.
Mobilux No Used for rust prevention of rear cover hinge
Print standard:
There are two main colors used in this model:

Yellow: matt (50%) RAL1006 yellow
Gray: matte (40%) RAL7021 gray
The quality standards of paint are as follows (refer to QJ/LG 08.44-2013 for details):
S/N Item Index Testing method Remarks

Refer to the
The film is even in color and luster,
requirements of
Film and free from blisters, cracks,
1 Visual inspection surfaces at each
appearance wrinkles, bottom leakage, rust,
level for details on
damage, dirt and other defects.
allowable defects.
For details, refer to
the requirements of
Meet the minimum requirements for surfaces at each
2 Film Luster Visual Inspection/Luster Meter
luster of films at each level. level and follow the
special requirements
for matt paint.
Film Meet the minimum requirement for the requirements of
3 Film thickness gauge
thickness thickness of films at each level. surfaces at each
level.
1-10
Coating Materials June 9, 2020
DW90A
S/N Item Index Testing method Remarks

Mark five horizontal lines and five
longitudinal lines with a spacing of The grid film is
1mm~ 1.5mm on the film with a acceptable if no
single side blade or scriber till the whole film peels off,
Paint film The adhesion is good, and no films
4 bottom of steel plate can be seen. and a small number
adhesion peel off upon inspections.
Adhere and tightly press a of films peeling off
transparent adhesive tape on the are allowed at the
film. Finally, tear down the tape line edges.
quickly.
Meet the color difference
Chromatic Visual Inspection/Color Difference the requirements of
5 requirements of surfaces at each
aberration Meter surfaces at each
level.
level.
A non-coated surface is free from
6 Shield paint liquid pollution, mechanical Visual inspection
impurities, rust and dirt.
The labels shall be correct,
7 Label complete, neat, firm, even and free Visual inspection
from blistering.
1-11
June 9, 2020 Weight List
DW90A
Weight List
The following table is the reference value of the weight of each component. When using the lifting
equipment, please refer to the following table to select the lifting appliance.
Component Weight (Kg)
Frame 3478
Second beam (tubular beam) 75
Third beam (round girder) 54
Diesel engine 1050
Fuel tank 700
Radiator 1066
Air filter 52
Drive shaft (tenth gear) 78
Rear drive shaft (tenth gear) 42
Oil cylinder support assembly 116
Hydraulic oil cylinder 102
Hydraulic oil tank 230
Battery box support 40
Battery cell (single) 40
Cab assembly 1000
Platform 150
Cab front cover 55
Grating plate support 28
Cab shock absorber 27
Radiator assembly 120
Front protective screen 85
Battery box support 37
Rear anti-backward tilt assembly 30
Fender 24
Rear axle assembly 2000
Intermediate axle assembly 2000
Front axle 1000
Rear Suspension 350
Rear laminated leafspring 430
Thrust bar 37
Intermediate and rear axles support (single) 50
Transmission 500
Clutch 54
Front suspension bracket (single) 45
Front laminated leafspring 282
Dump body 11300
Tyre (single) 300
1-12
Unit Conversion Table June 9, 2020
DW90A
Unit Conversion Table
This Manual uses the ISO international system of units, which is converted into British unit s as follows:
Parameter Metric Unit Imperial Unit Multiple

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Volume L US qt 1.057
m³ Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Force
N lbf 0.2248
Nm kgf·m 0.10197
Torque
Nm lbf·ft 0.7375
MPa 3 10.197
kgf/cm
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C × 1.8+32
km/h mph 0.6214
Speed
min-1 rpm 1.0
L/min US gpm 0.2642
Flow
mL/rev cc/rev 1.0
1-13
June 9, 2020 Standard Torque Table
DW90A Torque parameters - metric metal parts
Standard Torque Table
Torque parameters - metric metal parts
Please use the following torque when torque parameters are unknown.
These torque values are suitable for plated or unplated or coarse thread fasteners lubricated with oil.
These torque values are not suitable if graphite or molybdenum disulfide grease or oil is used.
Bolts, nuts and screws with strength of Grade 8.8

Thread Size Standard torque (N.m\lbf•ft)
M6 7.7 ± 1.1N.m \ 5.7 ± 0.8lbf·ft
M8 19 ± 2.9N.m \ 14 ± 2.1lbf·ft
M10 38 ± 5N.m \ 28 ± 4lbf·ft
M12 66 ± 9N.m \ 48 ± 7lbf·ft
M14 107 ± 15N.m \ 79 ± 11lbf·ft
M16 166 ± 26N.m \ 122 ± 19lbf·ft
M18 229 ± 33N.m \ 169 ± 24lbf·ft
M20 302 ± 37N.m \ 223 ± 27lbf·ft
M22 443 ± 59N.m \ 327 ± 44lbf·ft
M24 561 ± 74N.m \ 414 ± 55lbf·ft
M27 811 ± 111N.m \ 598 ± 82lbf·ft
M30 1106 ± 148N.m \ 816 ± 109lbf·ft
M33 1512 ± 221N.m \ 1115 ± 163lbf·ft
M36 1955 ± 258N.m \ 1442 ± 190lbf·ft
1-14
Standard Torque Table June 9, 2020
Torque parameters - metric metal parts DW90A
Bolts, nuts and screws with strength of Grade 10.9/12.9

Thread Size Standard torque (N.m\lbf•ft)
M10 72 ± 6N.m \ 53 ± 4lbf·ft
M12 120 ± 10N.m \ 89 ± 7lbf·ft
M14 195 ± 15N.m \ 144 ± 11lbf·ft
M16 305 ± 25N.m \ 225 ± 18lbf·ft
M18 415 ± 35N.m \ 306 ± 26lbf·ft
M20 600 ± 50N.m \ 443 ± 37lbf·ft
M22 800 ± 70N.m \ 590 ± 52lbf·ft
M24 1020 ± 100N.m \ 752 ± 74lbf·ft
M27 1500 ± 100N.m \ 1106 ± 77lbf·ft
M30 1850 ± 150N.m \ 1364 ± 111lbf·ft
M33 2900 ± 400N.m \ 2139 ± 295lbf·ft
M36 3100 ± 250N.m \ 2286 ± 184lbf·ft
Tightening torque for 24° tapered sealed pipe connector with O-ring
Inner Diameter of Tightening Torque

Series Thread Size
Hose (mm) N.m kgf.m
M12 × 1.5 5 16 ± 1 1.6 ± 0.1
M14 × 1.5 6.3 16 ± 1 1.6 ± 0.1
M16 × 1.5 8 26 ± 2 2.7 ± 0.2
M18 × 1.5 10 37 ± 2 3.8 ± 0.2
M22 × 1.5 12.5 47 ± 2 4.8 ± 0.2
Light-duty type
M26 × 1.5 16 89 ± 4 9.1 ± 0.4
M30 × 2 19 116 ± 5 11.8 ± 0.5
M36 × 2 25 137 ± 6 14.0 ± 0.6
M45 × 2 31.5 226 ± 11 23.1 ± 1.1
M52 × 2 38 347 ± 16 35.4 ± 1.6
M14 × 1.5 5 26 ± 2 2.7 ± 0.2
M16 × 1.5 6.3 42 ± 2 4.3 ± 0.2
M18 × 1.5 6.3 53 ± 2 5.4 ± 0.2
M20 × 1.5 8 63 ± 3 6.4 ± 0.3
M22 × 1.5 10 79 ± 4 8.1 ± 0.4
Heavy type
M24 × 1.5 12.5 84 ± 4 8.6 ± 0.4
M30 × 2 16 126 ± 6 12.9 ± 0.6
M36 × 2 19 179 ± 8 18.3 ± 0.8
M42 × 2 25 263 ± 12 26.8 ± 1.2
M52 × 2 31.5 368 ± 17 37.6 ± 1.7
1-15
June 9, 2020 Standard Torque Table
Tightening Torque for Bolt of Flange Sealed Pipe Connector
Performance Tightening Torque

Series Bolt
Grade of Bolt N.m kgf.m
M8 25.2 ± 1.2 2.57 ± 0.12
M10 52.5 ± 2.5 5.35 ± 0.25
8.8
M12 96.6 ± 4.6 9.85 ± 0.47
M16 220 ± 10 22.5 ± 1.07
Light-duty type
M8 33.6 ± 1.6 3.42 ± 0.16
M10 73.5 ± 3.5 7.5 ± 0.35
10.9
M12 136 ± 6 12.8 ± 0.6
M16 310 ± 15 31.6 ± 1.5
Tightening Torque for Bolt of Flange Sealed Pipe Connector
Performance Tightening Torque

Series Bolt
Grade of Bolt N.m kgf.m
M8 25.2 ± 1.2 2.57 ± 0.12
M10 52.5 ± 2.5 5.35 ± 0.25
M12 8.8 96.6 ± 4.6 9.85 ± 0.47
M16 220 ± 10 22.5 ± 1.07
M20 420 ± 20 42.8 ± 2.0
Heavy type
M8 33.6 ± 1.6 3.42 ± 0.16
M10 73.5 ± 3.5 7.5 ± 0.35
M12 10.9 136 ± 6 12.8 ± 0.6
M16 310 ± 15 31.6 ± 1.5
M20 577 ± 27 58.9 ± 2.8
1-16
Standard Torque Table June 9, 2020
Tightening Torque for Thread Angle Sealed Pipe Connector
Material of
Connection Carbon Steel, Alloy Steel Aluminum
Fitting
Tightening Torque Tightening Torque
Thread Size
N.m kgf.m N.m kgf.m
G1/8 8.75 ± 1.25 0.90 ± 0.12 / /
G1/4 36 ± 2 3.67 ± 0.2 29.3 ± 2.2 3.0 ± 0.2
G3/8 73.5 ± 4.5 7.5 ± 0,46 49 ± 3 5.0 ± 0.3
G1/2 110 ± 10 11.2 ± 1.0 55 ± 5 5.6 ± 0.5
G3/4 165 ± 15 16.8 ± 1.5 74 ± 4 7.5 ± 0.4
G1 225 ± 25 23.0 ± 2.55 / /
G1-1/4 275 ± 25 28.0 ± 2.55 / /
G1-1/2 285 ± 15 29.1 ± 1.5 / /
Tightening Torque of Connector
Tightening Torque
Thread Size
N.m kgf.m
M12 24 ± 2 2.4 ± 0.2
M14 30 ± 2 3.1 ± 0.2
M16 30 ± 2 3.1 ± 0.2
M18 30 ± 2 3.1 ± 0.2
Tightening torque for inch thread
Standard torque lb.ft

Thread Size Thread Size Standard torque lb.ft (N•m)
(N•m)
1/4 9 ± 3 (12 ± 4) 9/16 110 ± 15 (150 ± 20)
5/16 18 ± 5 (25 ± 7) 5/8 148 ± 18 (200 ± 25)
3/8 33 ± 5 (45 ± 7) 3/4 266 ± 37 (360 ± 50)
7/16 52 ± 11 (70 ± 15) 7/8 420 ± 59 (570 ± 80)
1/2 74 ± 11 (100 ± 15) 1 645 ± 74 (875 ± 100)
1-17
June 9, 2020 Specification for Use of Oil
Specification for Use of Oil
Type Description Volume Applying part Remarks

Above 4°C ★ 0# diesel oil
Diesel oil Above -5°C -10# diesel oil
(consistent 50L filled during
Above -5°C~-14°C -20# diesel oil 600L Diesel engine
with GB252- delivery
2000) Above -14°C~-29°C -35# diesel oil
Above -29°C~-44°C -50# diesel oil
Below -30°C CF4 0W/40
-30°C~-15°C CF4 5W/40 SAE 15W/40 API
Oil 27L Diesel engine
-15°C~30°C ★ CF4 15W/40 CF-4
Above 30°C CF4 20W/50
-15°C~49°C 85W-140 GL-5 33.6L for
intermediate axle
-25°C~49°C ★ 85W-90 GL-5 Intermediate axle/rear axle/
Gear oil 81L 29.6L for rear axle
transmission
17.5L for
-40°C~40°C 75W-90 GL-5
transmission
Above 50°C HM68
25°C~50°C HM46
10°C~25°C HM46 Working hydraulic system
Hydraulic oil 141L and steering hydraulic
-10°C~10°C HM46 system
-40°C~-10°C HM32
Below -40°C HM15
Brake fluid Above -40°C ★ 4604 1.5L Braking system
★ LiuGong
Antifreeze Above -45°C Gaorun - 45°C 60L Radiator
antifreeze
Refrigerant ★ R134a 1.3Kg Air conditioner
Each rolling bearing, sliding
★ Molybdenum bearing, steering cylinder
Lubricating
disulfide lithium 2Kg pin shaft, rear axle swing
grease
grease 2# frame, transmission shaft
spline, universal joint, etc.
★ refers to the oil to be filled during delivery.
Mixed oil is prohibited for drive axle, transmission and engine. Using mixed oil will damage
components.
Consult your local dealer for the winter fuel requirements. If the fuel temperature is lower than
the condensation point, the engine will lose power or cannot start.
Use the low- sulfur fuel. Using incorrect fuel will damage the engine.
1-18
Maintenance Interval Schedule June 9, 2020
Maintenance Interval Schedule
Mainten- First Frequency (hours)

ance Maintenance parts mainte- Clean Lubri- Repla- Adjus-
intervals nance Check it
Replace Emission
cating cement tment
Coolant level of radiator ★
Tire ★
Hydraulic oil filter ★
On-demand
Air filter ★ ★
Air conditioner ★
Fire extinguisher ★
Check the engine oil level 10
Check coolant level 10
Check hydraulic oil level 10
Check the diesel level. 10
Drain the diesel prefilter and remove its
10
impurity.
Check the oil level of intermediate
10
support
Every 10
Visually inspect the engine fan and belt 10
hours
Check the working condition of light 10
Check the working condition of
10
instruments
Check the tire pressure and tire damage. 10
Check the working condition of the
10
backup alarm
Visually check each system for leakage. 10
Daily check others 10
Maintain the air filter (the maintenance
time shall be shortened in bad
50
environment), and replace the filter
element every five times of maintenance.
Check gearbox oil level 50
50
support
Every 50 High-pressure air is required to clean the

hours filter screen of the evaporator air return 50
port (inner).
High-pressure air is required to clean the
filter screen of the evaporator fresh air 50
port (outer).
Check whether there is oil stain, dirt and
foreign matter on the condenser,
50
affecting the heat emitted from the
condenser.
1-19
June 9, 2020 Maintenance Interval Schedule

Replace Emission
cating cement tment
Lubricate the drive shaft support bearing. 100
Check the brake accumulator for its
100
nitrogen precharge pressure.
Check the front and rear drive axles for
100
their oil levels.
100
support
Check whether the captive bolts of the
intake and exhaust system brackets are
100
loose or not, and whether the bracket
shakes or not.
Check whether the equipment pin bolt is
100
loose.
Check the mounting bolts of radiator rear
100
cover assembly for looseness.
Check the clamps and hoses of the
intake and exhaust system for 100
looseness.
Check the clamps and hoses of the
100
engine cooling system for looseness.
Check the connecting bolt (front end) of
100
the front drive shaft.
Check the connecting bolt (rear end) of
100
the front drive shaft.
Check the connecting bolt of the middle
100
drive shaft
Check the connecting bolt of the rear
100
Every 100 drive shaft
hours Check the connecting bolt of the
100
transition drive shaft.
Grease the spline of the front drive shaft
(except for maintenance-free drive 100
shaft).
Grease the front universal joint (except
100
for maintenance-free drive shaft).
Grease the spline of the intermediate
drive shaft (except for maintenance-free 100
drive shaft).
Grease the intermediate universal joint
shaft).
Grease the spline of rear drive shaft
shaft).
Grease the rear universal joint (except
100
for maintenance-free drive shaft).
Grease the spline of the transition drive
shaft (except for maintenance-free drive 100
shaft).
Grease the universal joint of the
transition drive shaft (except for 100
maintenance-free drive shaft).
Clean the engine cylinder head 100
Check the battery 100
Clean the radiator assembly 100
Clean the filter strainer of the fuel tank 100
1-20

Replace Emission
cating cement tment
Check the tightening torque for the
mounting bolts of the engine and 250
damping pad
Check the tightening torque of the
250
transmission mounting bolts
Check the tightening torque of the rim
250
fixing bolts
Check the battery voltage state 250
Check the work devices, and each stress
weld and mounting bolt of the front and 250
rear frames for cracks and looseness
Check the air filter blockage alarm of the
intake and exhaust system, and clear or
250
replace the air filter (the air filter element
can be cleared up to 5 times).
Check the oil level of the front and rear
250
axles (end face)
Check the oil level of the front and rear
250
axles (axle package)
Replace the engine oil (oil drain) 100 250
Replace the engine oil (oil filling) 100 250
Every 250
Replace the engine oil filter element 100 250
hours
Replace the diesel pre-filter element of
250
the engine
Replace the diesel filter element of the
250
engine
Check the DCA4 concentration of
coolant, and replace the engine coolant 250
filter element if the concentration is low.
Check the brake accumulator for its
250
nitrogen precharge pressure.
Check whether the refrigerant in the air
250
conditioning reservoir is sufficient
Check the tension and wear conditions
of the engine drive belts and air 250
conditioning compressor belts.
Check whether the traveling brake works
250
properly
Check whether the parking brake works
250
properly.
Check the drive belt of the air conditioner
250
compressor for its tightness.
Replace the air filter element. 250
1-21
June 9, 2020 Maintenance Interval Schedule

Replace Emission
cating cement tment
Replace the filter screen of hydraulic oil
500
tank breather valve.
Replace the fresh air filter screen of the
500
air conditioning system.
Check the brake accumulator and the
ride control accumulator for their nitrogen 500
Every 500 precharge pressure.
hours Check whether the connecting bolts of
500
each pin shaft are loose.
Check whether the connecting bolts
between the front and rear drive axles 500
and the frame are loose.
Check antifreeze / coolant additive
500
concentration
Replace the drive axle oil (hub oil drain) 100 1000
Replace the drive axle oil (oil drain of
100 1000
axle package)
Replace the drive axle oil (hub oil filling) 100 1000
Replace the drive axle oil (oil filling of
100 1000
axle package)
Replacement of Transmission Oil 100 1000
Replace the transmission oil filter
100 1000
element
Clean transmission oil pan and course
100 1000
filter element
Replace the intermediate support oil of
Every 1000 100 1000
drive shaft
hours
Replace the hydraulic oil filter 1000 2000
Replace the return oil filter element of the
250 1000
hydraulic system
Replace the high pressure oil filter
250 1000
element of the brake system
Clean the fuel tank 1000
Clean the filter strainer of the diesel tank 1000
Adjust the engine valve clearance 1000
Check the energy accumulator for its
1000
nitrogen precharge pressure
Check the engine tensioner bearing and
1000
fan shaft housing.
1-22

Replace Emission
cating cement tment
Replace the engine coolant 2000
Replace the coolant filter 2000
Clean engine cooling system 2000
Replace the hydraulic oil (oil drain) 1000 2000
Clean hydraulic oil tank 2000
Replace hydraulic oil (oil filling) 1000 2000
Replace the hydraulic oil filter 1000 2000
Check and adjust the drive axle brake
2000 2000
disc clearance.
Check the airtightness of the distribution
valve and work cylinder by measuring 2000
the natural settlement of oil cylinder
Check the refrigerant pipe and water
pipe of the air conditioner for cracks,
2000
wear, or greasy foaming. Check the
Every 2000 connectors and clamps for looseness
hours
Replace the air filter inside the cab 2000
Check whether the coolants in the tank
receiver of the air conditioning system 2000
are sufficient.
Check whether the steering system
2000
works normally.
Check all connecting bolts of the drive
2000
shaft
Check the engine shock absorber bolt for
2000
its torque.
Check whether the engine shock
2000
absorber pad is cracked.
Check the transmission shock absorber
2000
bolt for its torque.
Check whether the transmission shock
2000
absorber pad is cracked.
Note: Items with ★ are to be maintained as required.

1-23
June 9, 2020 Technical Specification of Complete Machine
Technical Specification of Complete Machine
P2TM00005
Purpose:
The wide-body dump truck is a large-scale construction machine mainly for transporting bulk materials. It
is suitable for open pits (surface soil stripping), large-scale sandstone mines, small and medium-sized
nonferrous metal mines, etc. It is a multipurpose and highly efficient construction machine.
The wide-body dump truck is a common construction machine that is not suitable for flammable,
explosive, toxic and corrosive working environments.
Working environment requirements:
Altitude ≤2500 m
Normal working environment temperature -30°C~45°C (no additional auxiliary cold start device)
Extreme working environment temperature -40°C ~ 55°C (special configuration is required)
1-24
Main components of the machine June 9, 2020
Main components of the machine
3 4
5
P2TM00006
7
6
9
8
10
11 P2TM00007
1. Navigation bridge 4. Hydraulic oil tank 7. Engine 10. Intermediate axle

2. Dump body 5. Desert filter 8. Front axle 11. Rear axle
3. Fuel tank 6. Transmission 9. Lifting cylinder
1-25
June 9, 2020 Main technical parameters
Main technical parameters
All rated operation/lifting capacity of the machine is based on the machine working on a firm flat support
surface. This shall be taken into account by the operator. in case the machine is operated in conditions
that differ from the above-mentioned conditions (e. g. operations on soft or uneven ground, or on a
slope).
The table below shows the technical parameter values for standard configuration, and the changes in
technical parameters for other special configurations are shown in the table attached to this chapter.
Outline Dimension Drawing
P2TM00008
1-26
Main technical parameters June 9, 2020
P2TM00009
P2TM00010
1-27
DW90A Parameters of complete machine
Parameters of complete machine
Item Parameter
Product model DW90A
Configuration Standard Reinforced Powerful
Gross vehicle weight (kg) 90000
Curb weight (kg) 31000
Payload mass (kg) 59000
Overall dimensions (L×W×H) (mm) 9075 × 3450 × 3986
Wheel base (mm) 3800+1550
2765 (front)
Tread (mm)
2500 (back)
Front overhang (mm) 1760
Rear overhang (mm) 2060
Approach angle (°) 37
Departure angle (°) 42
Maximum speed (km/h) 45
Maximum gradeability (%) 35
Maximum tractive force (kN) 415 445 335
Minimum turning diameter (m) ≤ 22
Minimum ground clearance (mm) ≥ 380
Laden (t) 20/35/35
Model WD12.430 (CHINA III) WD12.460 (CHINA III)
Power (kW) 316 338
Speed (r/min) 2100
Torque (N*m)/speed (r/min) 1870/(1200-1600) 2000/(1200-1600)
Model 430 diaphragm spring clutch, pneumatic control and power-assistance
Model 10JSD220 mechanical transmission 8DS240A mechanical transmission
Gear 10 8
Maximum input torque (N.m) 2200 2400
Struck capacity 32
Bucket capacity
(m3) Heaped capacity
38
SAE (2:1)
1-28
Parameters of complete machine DW90A
Dimension parameter
The configurations of the following parameters are: Weichai WP12.460 (China III) diesel engine/Faster 8DS240A
transmission/Hande 20-35-35 axle/radial tire/wide-body cab/32 cubic standard cargo compartment/desert filter
Full-load travel height 3915
1 H1 mm
No-load travel height 3985
2 L5: Maximum length of the whole machine mm 9010
3 W1: Width of complete machine mm 3450
4 H8: Loading height mm 3950
5 H6: height of full-load dump body bottom plate mm 1701
6 L6: internal length of dump body mm 5800
7 W4: internal width of dump body mm 3200
8 H7: internal height of dump body mm 1750
9 L1: front suspension mm 1760
10 L4: rear suspension mm 1704
11 L2: 1-2 wheelbase mm 3800
12 L3: 2-3 wheelbase mm 1550
13 W2: front tread mm 2765
14 W3: rear tread mm 2542
15 a: Approach angle ° 32
16 B: departure angle ° 42
17 H9: minimum ground clearance with full load mm 371
18 R1: tire turning radius mm 9474
19 R2: maximum turning radius of the whole machine mm 10485
20 H2: full-load approaching height mm 610
21 H3: longitudinal crossing height mm 525
22 Υ : maximum lifting angle of dump body ° 48
23 H0: maximum lifting height mm 7790
24 H5: minimum height of liftgate from ground mm 469
25 H4: minimum lifting height of dump body mm 268
Struck capacity of dump
body m3 32
26 V
Heaped capacity of dump
body m3 38
1-29
DW90A Parameters of Components
Parameters of Components
Engine
1 Manufacturer / Weichai
2 Model / WP12G460E310
3 Displacement L 11.596
4 Rated power Kw 338
5 Emission standard / China phase III
6 Number and arrangement of cylinders / Six-cylinder in-line
7 Induction system / Turbocharged & Intercooled
8 Rated speed rpm 2100
9 Number of cylinders/number of valves / 6/24
10 Compression ratio / 17:1
11 Rotation speed under maximum torque rpm 1200~1600
12 Maximum torque Nm 2000
Electronic-control high-
13 Fuel system /
pressure common rail
Drive system
1 Manufacturer Fast
2 Model 8DS240A
MT/mechanical gear shift
3 Transmission Type
transmission
4 Number of gears 8
5 Shift pressure No/mechanical shift
6 Manufacturer Hande
7 Model 20/35/35
Front axle steering/
8 Type intermediate and rear axle
Drive axle driving
9 Maximum traction 335KN
Reduction ratio of
10 16.086
intermediate and rear axles
11 Swing angle of front axle 28/38
12 Tire Specifications 14.00R25
1-30
Parameters of Components DW90A
Operation hydraulic system

1 Implement pump Type Duplicate gear pump
Front pump 83.6
2 Working pump displacement ml/r
Rear pump 41.8
3 System pressure MPa 22
Type Slide valve type
4 Main control valve
Pressure 25MPa
5 Work system flow L/min 220
6 Lifting time (full load) s ≤20
7 Descent time s ≤22
Steering hydraulic system

Internal steering angle 38
1 Steering angle ° External steering angle
27°48′
2 Displacement of steering pump ml/r 640
3 Steering system pressure MPa 16
4 Steering system flow L/min 38.4
Braking system
Double-circuit pneumatic
1 Service brake Type
brake
2 Brake pump Type Drum brake
3 Brake pressure MPa 0.8MPa
Double-circuit pneumatic
4 Parking brake Type
brake
5 Auxiliary brake Type Exhaust brake
Air conditioning system

1 Type / Air conditioner
2 Heating capacity W 4000
3 Refrigerating Capacity W 4400
4 Refrigerant Model R134a
Electrical system
1 System voltage / DC24V
1-31
Capacity parameters
1 Diesel tank L/ US gal 600/158.52
2 Engine oil L/ US gal 27
3 Antifreeze L/ US gal 60/15.85
4 Transmission oil L/ US gal 36/9.51
Intermediate axle 33.6/8.88
5 Drive axle oil L/ US gal
Rear axle 29.6/7.82
6 Hydraulic oil L/ US gal 160/42.27
7 Brake fluid L/ US gal 1.5
1-32
Checklist of whole machine June 9, 2020
Checklist of whole machine
Inspection
S/N Inspection methods and acceptance criteria
Item
Whole machine information: Visually check whether the whole machine number is consistent with the model description, and
1
check whether the label and certificate are consistent with the whole machine information.
Fastening bolts: Visually check to ensure that the mounting bolts of the front and rear shock absorbers of the engine are
2
fastened in place.
3 Fastening bolts: Visually check to ensure that the front, middle and rear wheel rim bolts are installed and fastened.
4 Fastening bolt: Visually check to ensure that the auxiliary support bolt is installed and fastened.
5 Fastening bolt: Visually check to ensure that the drive shaft bolt is installed and fastened.
Fastening bolt: Visually check to ensure that the thrust rod bolts of the intermediate and rear axles are installed and fastened,
6
and check the torque of bolts to ensure that the torque is acceptable.
Fastening bolt: Visually check to ensure that the U-bolt of the leaf spring of the intermediate and rear axles is installed and
7
fastened, and check the torque of bolt to ensure that the torque is acceptable.
Fastening bolt: Visually check to ensure that the front axle leaf spring is installed and fastened, and check the torque of bolt to
8
ensure that the torque is acceptable.
Engine lubricating oil: Start the engine and then stop it for 5 minutes before checking. The lubricating oil level shall be between
9
two scales on the dipstick.
10 Engine coolant: Visually check to ensure that the cooling antifreeze shall be filled to the 2/3 position of the expansion tank.
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
11 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.
Fuel: Observe the fuel indicator light on the instrument when the engine is started, and inject a proper amount of fuel based on
12
the performance and operating requirements of the engine. Fuel must be injected if the fuel level is lower than 1/8.
Hydraulic oil: Park the vehicle on a flat ground, lift the dump body 5 times consecutively and then shut down the engine. After
13 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.
Brake fluid: Conduct inspection after air is exhausted from the clutch system to ensure the brake fluid level between MAX and
Inspection before 14
MIN.
test run
Coolant: Start the engine and switch on the air heater to run for 2 min. At this moment, the engine water temperature shall be
15
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.
Windshield washer fluid: Visually observe the windshield washer fluid level which shall vary between MAX and MIN. If the level
16
is lower than MIN, it needs to inject windshield washer fluid.
Sealing performance: After the vehicle is started, go around the vehicle to check for any leakage of lubricating oil, coolant and
17
air lines.
18 Tire pressure: In case of insufficient air pressure, inflate tires with special tools.
Engine air intake system: Check the prefilter for any blockage by foreign matters. Check for any breakage of the pipeline
19
between the supercharger inlet and the air filter outlet, and if any, replace the pipeline in time.
Check for water in the brake air reservoir: When the vehicle is stationary, pull down or push up the exhaust valve to remove
20 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.
21 Circuit system: After the key switch is turned on (the key switch is at the "ON" position), all instruments are in normal indication.
Engine oil pressure: After the engine is started, observe the pressure value indicated by the pressure gauge. The engine oil
22
pressure indicator light shall be off.
23 Visually check to ensure that the diesel filter is installed firmly and sealed well, and the joint has no leakage.
24 Visually check to ensure that the fuel tank is firmly installed and it is decent without defects such as damage and collision.
Inspection and adjustment for clearance between clutch master pump push rod and piston: When adjusting, gently push the
25 pedal with a hand to feel that the clutch master pump push rod contacts the piston; then, adjust the height of stopper bolt to
ensure a clearance of 0.5mm-1mm between push rod and piston (slightly shake as shown in Figure); finally, tighten the nut.
Visually check to ensure that all electrical and gas circuit pipelines shall be tied tightly and fixed, and the joints shall be firm and
26
free from looseness and oil leakage.
Visually check to ensure that the brake chamber is firmly and reliably installed, and the air nylon tube has no bending or
27
flattening phenomenon.
28 Visually check to ensure that the steering gear assembly is firmly and reliably installed.
1-33
June 9, 2020 Checklist of whole machine
Inspection
Item
1 When the cab door is opened and closed, it shall be free of stagnation and abnormal noise.
2 When the interior trim is shaken by hand, it shall be intact and free from looseness.
3 The cab lamp, radio-cassette player, sun cloth, cigarette lighter and the like shall work properly.
Open the electric lock: Turn on the headlamp, dome lamp, warning lamp, parking lamp and other lamps in turn, and get off the
4
vehicle to check whether they work normally.
Start the whole machine: turn the engine speed adjustment switch, and visually inspect the corresponding speed change in the
Cab 5
tachometer on the dashboard.
Steering gear: It can be adjusted upwards, downwards, backwards and forwards normally. It is free from looseness after it is
6
locked. Lift the steering wheel upwards by hand. The steering wheel is free from axial play (≤ 3 mm).
Wiper: It works properly and the water spraying direction is correct (the water column is directly sprayed to the middle of front
7
windshield).
Horn: Press the horn button on the combination handle/horn button on the steering gear/horn button on the control handle, and
8
then check the horn for abnormal noise and failure.
Press the "AC" switch. The lamp shall be turned on, the refrigerating system shall work properly, and several gears shall have
Air conditioning 1
different air speeds.
system
2 When the warm air switch is pressed, the air outlet shall have obvious warm air blown out.
Start-up of whole machine: The whole machine starts normally, the engine and air filter have no abnormal sound, and the
1
flameout is normal without delay.
Start-up of whole machine: Visually check to ensure that there is no fault code on the LCD screen of the dashboard, no
2
indication marks on the dashboard, and no alarm indicator flashing or constantly on.
Gear position check: Shift the gears manually. 1. Turn the Manual/Automatic Shift rotary switch to the "Manual" position.
2. Start the whole machine and keep it idling.
3
3. Release the parking brake.
4. Operate the transmission shift lever. All gears of the whole machine shall be engaged successfully.
4 Backup alarm: After the reverse gear is engaged, the backup alarm buzzes immediately.
Braking deviation check: If emergency braking is performed when the vehicle speed is 30 Km/h, the deviation shall not be
5 greater than half of the tire mark. If the braking is performed when the vehicle speed is 30~35 Km/h (and both hands are on the
steering wheel), the deviation shall not be allowed. (Note: The emergency braking test is prohibited in rainy or snowy days).
Trial run
Braking system: Drive the vehicle to run around the field for 10 laps. Depress the foot brake pedal while driving twice every lap.
experiment
6 When the pedal is depressed, the vehicle braking is achieved. When the accelerator pedal and brake pedal are depressed
during driving, there is no stagnation and the braking system works properly.
7 Check the hydraulic pipe joint after the dump body is lifted by 20 times. There shall be no oil leakage.
When the dump body is being lifted, there shall be no interference or abnormal noise in the hydraulic oil cylinder, dump body
8
support pin and other parts.
Steering during driving: When steering (leftwards or rightwards) during driving, the driver shall not feel any stagnation,
9
heaviness or drifting.
10 Power transmission system check: When driving, check the diesel engine and the front and rear axles for abnormal noise.
Fault alarm check: When driving, observe the axle oil pressure indicator, engine oil pressure indicator, service brake indicator,
emergency brake indicator, transmission oil pressure indicator, hydraulic oil temperature indicator and other alarm indicators on
11
the dashboard for their alarm indications, and visually check whether the engine coolant and oil temperatures are shown in the
green area.
1-34
Checklist of whole machine June 9, 2020
Inspection
Item
1 Visual inspection: The PIN code and engine number are intact, and the information is correct.
2 Visual inspection: The filling amount of engine lubricating oil and coolant is rational.
3 Visual check + touch by hand: The engine suspension is tight and there is no leakage on the surface.
4 Visual check + touch by hand: The pipelines and lines around the engine are firmly fixed and in reasonable directions.
5 Visual check + touch by hand: The diesel filter is installed properly and its interface is free of leakage.
6 Visual check + touch by hand: The diesel tank is installed reasonably and the surface paint is qualified.
7 Visual check + touch by hand: The fuel pipeline is fixed, free from bending and leakage.
8 Visual inspection: reasonable installation of intake pipe
9 Visual check: The air filter is installed reasonably and there is no oil leakage in the pipeline.
10 Visual check: The exhaust pipe is firmly installed, and there is no air around or pipeline in contact.
11 Visual check: The radiator and expansion tank are installed reasonably.
12 Visual check + touch by hand: The position of fan is reasonable.
23 Visual check + touch by hand: The water pipeline is well sealed and free of bending.
24 Visual check: The filling of transmission oil is reasonable.
Static check
30 Visual check: The auxiliary support is installed correctly.
36 Visual check + touch by hand: The steering gear and oil pipe are installed reliably.
38 Visual check: The cab bracket is installed and fastened, and the overall installation is decent.
39 Visual check: The cab has intact exterior paint, clean interior trim and no damage.
40 Visual inspection: reliable installation of steering cylinder
41 Visual check: The installation of the air reservoir and accessories is reasonable.
42 Visual check: Check to ensure that the installation of brake chamber is reasonable.
43 Visual check: Check to ensure that the brake pipe has a reasonable direction, no bending, and firm fixation.
44 Visual check: The tire appearance is free from abrasion.
45 Visual check + touch by hand: The hydraulic oil tank is firmly installed and the surface paint is intact.
46 Visual check + touch by hand: The hydraulic pipeline is installed correctly and fixed reliably without interference.
47 Visual check: The oil cylinder nameplates are complete and intact.
48 Visual check + touch by hand: Both ends of balance shaft shall be filled with lubricating oil as required.
49 Visual check + touch by hand: The clearance between the rear leaf spring and the guide plate is not more than 2 mm.
2-1
June 9, 2020 Power System
DW90A
Power System
Basic information ...............................................................................................................2-3
Safety .....................................................................................................................................................2-3
Overview - Components and Locations .................................................................................................2-5
Main technical parameters of powertrain ...........................................................................................2-6
List of General Tools and Toolings ....................................................................................................2-6
Structure and Function ......................................................................................................2-8

Diesel engine system .............................................................................................................................2-8
Overview - Components and Locations .............................................................................................2-8
Description of Operating Principle......................................................................................................2-8
Diesel engine .........................................................................................................................................2-9
Technical parameters.........................................................................................................................2-9
Operating principle of diesel engine.....................................................................................................2-10
Intake and exhaust systems ................................................................................................................2-11
Air Intake and Exhaust Assembly ....................................................................................................2-11
Fuel system..........................................................................................................................................2-14
Fuel tank assembly ..........................................................................................................................2-14
Fuel line............................................................................................................................................2-15
Cooling system ....................................................................................................................................2-16
Overview - Components and Locations ...........................................................................................2-16
Radiator assembly ...........................................................................................................................2-20
Fan ...................................................................................................................................................2-20
Test and Adjustment........................................................................................................2-21

Check and adjust the clearance of the inlet valve and exhaust valve..................................................2-21
Replace the oil filter or element........................................................................................................2-22
Replace the fuel filter element..........................................................................................................2-23
Replace the water collector..............................................................................................................2-23
Replace the diesel engine oil ...........................................................................................................2-23
Exhaust method of low-pressure pipeline ........................................................................................2-24
Removal and Installation .................................................................................................2-25

Removal and installation of diesel engine assembly............................................................................2-25
Removal of Diesel Engine Assembly ...............................................................................................2-25
Installation of Diesel Engine Assembly ............................................................................................2-30
2-2
Power System June 9, 2020
DW90A
Disassembling, check and assembling of air filter ...............................................................................2-34

Disassembling of air filter .................................................................................................................2-34
Inspection of air filter ........................................................................................................................2-35
Assembling of air filter......................................................................................................................2-35
Removal and installation of intake and exhaust assembly...................................................................2-36
Requirements for the removal and installation of intake and exhaust system .................................2-36
Removal and installation of fuel tank ...................................................................................................2-38
Removal of fuel tank ........................................................................................................................2-38
Installation of fuel tank .....................................................................................................................2-40
Removal and installation of radiator assembly.....................................................................................2-42
Removal of radiator assembly..........................................................................................................2-42
Installation of radiator assembly.......................................................................................................2-45
Inspection of radiator assembly .......................................................................................................2-48
Removal and installation of fan ............................................................................................................2-49
Removal of Fan................................................................................................................................2-49
Installation of Fan.............................................................................................................................2-50
Inspection of fan...............................................................................................................................2-51
Troubleshooting...............................................................................................................2-52
Precautions for Fault Diagnosis ...........................................................................................................2-52
Common Faults and Troubleshooting ..................................................................................................2-53
Engine Fault Code Table.................................................................................................2-59

2-3
June 9, 2020 Basic information
DW90A Safety
Basic information Preventing Burns
After a certain period of operation, some

Safety components of the machine, such as engine,
post-processor and intercooler steel pipe, will
become hot. Maintenance or inspection of the
Compressed air machine shall be conducted after these
components are cooled down.
Compressed air can cause personal injury. When
using compressed air for cleaning, wear a
protective face shield, protective clothing,
hearing protection and protective shoes. The
maximum pressure of compressed air for
cleaning shall be lower than 0.2MPa (29psi).
Safe disposal of waste liquid

P2TP00047
● As improper disposal of waste engine oil,
diesel and urea will endanger the Coolant
environment and ecosystem, the disposal
shall follow local laws and regulations. At an operating temperature, hot pressure
● Collect all liquid discharge when performing engine coolant and hot water or steam in the
inspections, maintenance, testing, adjusting radiator and all pipes leading to the radiator will
and repairs to the machine. Prepare to collect cause serious burn in case of touching.
liquids with suitable containers before ● Before inspection of coolant level, the engine
opening any compartment or disassembling shall be shut down and the filler cap shall be
any component that contains liquids. Use cold enough to be opened by bare hands.
suitable containers to collect liquid discharge. The filler cap of cooling system shall be
● Do not use food containers or beverage slowly loosened to release pressure.
bottles as they could mislead people to drink ● Coolant contains alkali that can cause
their content. personal injury. Avoid contact with the skin,
eyes and mouth.
P2TP00048
P2TP00046
2-4
Basic information June 9, 2020
Safety DW90A
Measures to Prevent Fire and Explosion
● All fuels, most lubricants and some coolant

mixtures are flammable.
● Fuel leaked or spilled onto hot surfaces or
electrical components can cause fire.
● Do not smoke while refueling or in a refueling
area, or where flammable materials are
stored.
P2TP00049
● Keep all fuels and lubricants stored in

properly marked containers and away from
all unauthorized persons.
● Store all oily rags or other flammable
materials in a protective container away from
naked flames or other sources of ignition.
● Do not weld or flame pipes that contain
flammable liquids.
● Cutting. Before electric welding or cutting,
cleaning with non-flammable liquid shall be
carried out.
● Remove all flammable materials such as fuel,
lubrication and other materials on the
machine.
Diethyl Ether
● Do not start the machine with diethyl ether.

● Starting the machine by use of ether could
result in serious damage to the engine,
personal injury or death.
P2TP00050
2-5
DW90A Overview - Components and Locations
Overview - Components and Locations
The function of the power system is to convert chemical energy of fuel into mechanical energy for the
machine. The powertrain includes: diesel engine assembly, intake and exhaust system, heat dissipation
system, and fuel system.
Modular Structure Chart of Power System
P2TP00001
Position Drawing of Powertrain on the Machine
3
4
5
P2TP00002
1. Fuel system 3. Cooling system 5. Exhaust system

2. Air intake system 4. Diesel engine installation assembly
2-6
Overview - Components and Locations DW90A
Main technical parameters of powertrain
Model WP12.430/WP12.460
Six-cylinder inline,and four-stroke
Type
turbocharged
Emission Tier 3/Stage III
Engine Rated power (kW) 316/338
Maximum no-load speed (r/min) 2310
Minimum no-load speed (r/min) 600
Engine oil level 27L
Rotation direction Counterclockwise (facing the flywheel)
Fan (mm) 750
Cooling system Opening temperature: 76 °C
Thermostat
Full opening temperature: 88 °C
Engine oil system Oil filter Three-stage filter element
Preheating system Preheating mode Grid heater
Core type Plate-type
Water radiator Dimension of core (height X width X
1152*880*104
thickness)
Air-to-air intercooling radiator Dimension of core (height X width X
860*700*80
thickness)
List of General Tools and Toolings
Description Specifications
Open-end wrenches 7#, 10#, 13#, 16#, 17#, 18#, 24#, 25#
Sleeve 24#
Plastic sealing film
Traveling crane (more than 2t)
Steel wire rope with hook that can bear more than 1,000 Kg
(2,205Ib)
Vessels
Steel ruler
Load-bearing tool or tooling
2-7
DW90A Overview - Components and Locations
Precautions for Installation and Removal:
1. The engine must be removed and installed under cooling conditions. Generally, the diesel engine
can be cooled down by opening the engine hood after shutdown and then waiting for 15 min.
2. Measuring equipment,such as torque wrench, and tools shall have inspection certificates issued by
the measuring department;
3. As the installation and removal of components involve a large number of other relevant components
on the machine, the components removed (particularly standard ones) shall be properly placed to
avoid incorrect installation, missing and loss of parts during reinstallation.
4. If the installation and removal of a component involve other components on the machine, please
refer to the list of tools for removal and installation of other components for the tools required which
are not covered in the list of tools for the component.
5. The removal and installation of open-end wrench, that of blower gun and socket and that of ratchet
wrench and socket, all of which can achieve the desired effect, can be optional.
2-8
Structure and Function June 9, 2020
Diesel engine system DW90A
Structure and Function
Diesel engine system
The diesel engine assembly mainly consists of diesel engine, support, and shock absorber.
2 3
P2TP00003
1. Diesel engine 2. Shock absorber 3. Seat
Description of Operating Principle
The function of the diesel engine mounting assembly: to enable the engine to be effectively installed.
Operating principle: The engine is fixed to the machine through engine suspension composed of a
mounting base and a shock absorber, and operates in a better operating environment under the vibration
isolation effect of the shock absorber. In this way, the transmission of vibration from the engine to the
machine is reduced, thereby improving the riding comfort.
Generally, the engine mounting assembly shall meet the following requirements:
1. It shall be able to withstand dynamic and static loads under all operating conditions, and to make the
displacement of the engine in all directions within an acceptable range without any interference with
other components on the chassis. Meanwhile, there shall be no damage to any parts and
components before overhaul of the engine.
2. This assembly can fully isolate the vibrations generated by engine from both frame and cab, thus
improving the comfort of cab control and prolonging the service life of vehicle.
3. This assembly can also effectively isolate the engine from the impact generated from uneven
pavement and passing through the engine mounting, thus reducing the influence of pavement on the
engine.
2-9
June 9, 2020 Structure and Function
DW90A Diesel engine
Diesel engine
Technical parameters
Model/weight (wet weight) WP12G460E310/1050kg

Qty. of cylinders 6
Cylinder diameter (mm) 126
Stroke (mm) 155
Displacement (L) 11.596
Induction system Turbocharged & Intercooled
Rated power (kW) 338
Maximum torque (N·m) 2110
Compression ratio 17:1
Maximum no-load speed (r/min) 2310+10
Minimum no-load speed (r/min) 600
Engine oil pressure alarm value 0.08±0.012
Exhaust temperature (°C) 354
2-10
Operating principle of diesel engine DW90A
Operating principle of diesel engine
Fuel is taken by the engine from the fuel tank and then enters the engine fuel high-pressure pipe through
the fuel line. The high-pressure pipe is connected to the fuel injector. The engine ECM controls the
injection time and amount of the fuel injector. Air drawn by the engine from the atmosphere enters the
cylinder after prefiltration and air filtration, and is mixed with the injected fuel to form a combustible
mixture. When the piston goes up to the top dead center, the mixture is greatly compressed, and the
temperature rises to the ignition point and burns violently, giving off a large amount of energy to push the
piston to move. The piston is connected to the crankshaft through a piston rod, and the piston moves up
and down to drive the crankshaft to rotate. The crankshaft outputs the energy outwards through the
flywheel. The combusted exhaust gas enters the exhaust manifold and collects in the turbocharger to
drive the turbocharger to rotate. The exhaust gas enters the muffler from the exhaust pipe and then is
discharged into the atmosphere from the exhaust tailpipe.
2-11
DW90A Intake and exhaust systems
Intake and exhaust systems
Air Intake and Exhaust Assembly
Components and Locations
The intake and exhaust assembly mainly consists of air prefilter, air filter, muffler and bellows.
1 2
P2TP00004
1. Air filter 2. Air prefilter 3. Bellows 4. Muffler
Schematic diagram and operating principle description
Function of air intake and exhaust assembly is:

1. It is intended to provide the diesel engine with clean and dry air of appropriate temperature for
combustion, so as to minimize diesel engine wear and maintain optimal performance of the diesel
engine.
2. At the same time of ensuring the best performance of the diesel engine, all exhaust air shall be safely
transported away from the diesel engine and quietly discharged into the atmosphere.
2-12
Intake and exhaust systems DW90A
Operating principle of air intake and exhaust assembly is:
Air enters from the prefilter. The air prefilter is specially designed as a rotary air inlet passage. The air
passes through specially designed blade surfaces and rotates. When the air rotates rapidly, certain
centrifugal force is generated. The centrifugal force separates impurities such as dust, water and the like
from the air. The dust and impurities are blown and discharged to a special discharge port by a rotating
device that is driven by the air inlet flow and rotates rapidly, thus achieving the effect of air filtration. The
intake air becomes clean and dry after removal of dust and water via filter element of the air filter, and
then is sent to the turbo compressor, which is driven by the engine exhaust turbine in the same axis to
pressurize the intake air, increase the intake air volume, and ensure the full combustion of the fuel. Air
from the turbo compressor enters the diesel engine cylinder through the air-to-air intercooler of the heat
dissipation system for combustion. Exhaust gas generated during combustion is sent to the turbocharger
through the exhaust manifold, and drives the turbocharger to pressurize the intake air, and then is
emitted to the muffler, and finally exhausts from the tailpipe.
P2TP00005
2-13
DW90A Intake and exhaust systems
Introduction of Component Structure and Principle
The air filter is composed of housing, main filter element, safety filter element and end cover.
The air filter is of a two-stage -filtration type with a main filter element and a safety filter element,
ensuring the cleanness and dryness of air entered to the diesel engine.
When the engine is working, air enters the air filter from the prefilter, passes through the main filter
element and then passes through the safety filter element for secondary filtration
P2TP00006
1. Bracket 3. Prefilter 5. Filter assembly 7. Main filter element

2. Oil level 4. Connecting hose 6. Oil pan 8. Oil filter element
2-14
Fuel system DW90A
Fuel system
System composition: fuel tank assembly and fuel line.
Fuel tank assembly
Effective volume 600L
Introduction of Component Structure and Principle
The fuel tank assembly mainly comprises a fuel tank, a fuel tank cover, an oil pipe joint, a bracket and a
rubber strip.
2 3
1
5
4 P2TP00007
1. Fuel tank 3. Oil line connector 5. Oil tank cover

2. Rubber strip 4. Bracket
2-15
DW90A Fuel system
Fuel line
Components and Locations
The fuel lines mainly consist of fuel pipe, fuel-water separator and fuel filter.
3
2
P2TP00008
1. Oil-water separator 2. Fuel filter 3. Fuel pipe
Description of Operating Principle
The function of fuel lines is to supply clean and adequate fuel for the engine, so as to ensure normal
operation of the engine.When the engine works, the fuel transfer pump sucks fuel from the fuel tank.
Water in the fuel is removed in the fuel-water separator. Then, the fuel is delivered to the fuel transfer
pump. After passing through the fuel transfer pump, the fuel passes through the fuel filter again before
entering the fuel injection pump. After the fuel enters the fuel injection pump, its pressure increases. The
high-pressure fuel enters the fuel injector through the high-pressure fuel pipe and is injected into the
cylinder, and the excessive fuel flows back to the fuel tank.
Check
1. Check whether the sealing ring is missing from the oil line and whether the joint is tightened.
2. Check whether the oil line is damaged or not. If damaged, replace it with a new one.
Test requirements
1. Start the machine and run it for several minutes. Then observe whether there is leakage in the oil
line.
2. If the leakage occurs at the joint, it may be that the screw is not tightened or the gasket is damaged,
and the screw needs to be tightened or the gasket needs to be replaced.
2-16
Cooling system DW90A
Cooling system
The heat dissipation system consists of a radiator, a heat dissipation pipeline and an expansion tank.
3
P2TP00009
1. Expansion tank 2. Radiating pipe 3. Radiator

2-17
DW90A Cooling system
Schematic diagram and operating principle description
The heat dissipation system comprises a radiator and corresponding connecting pipelines. The radiator
is composed of an air-to-air intercooler and a water radiator.
The function of the system is to dissipate heat generated by each component (or system) during
operation to the air along with cooling air, so as to ensure the normal operation of each component within
an appropriate temperature range.
1
P2TP00010
1. Water radiator 2. Air-to-air intercooling radiator
The diesel engine heat dissipation system mainly consists of radiator (water tank), water pump, fan,
thermostat, engine oil cooler, water inlet and outlet pipes and other parts.
2-18
The heat dissipation system of this machine is equipped with a hydraulic drive fan and performs the air
suction for cooling. The system is a forced closed circulating water heat dissipation system. The
operating principle of the system is as follows: The water outlet at the lower part of the water radiator is
connected to water pump through water pipes, and the water pump pumps the coolant into the water
channel of the cylinder block. The coolant first passes through the water jacket inside the cylinder block
to cool the cylinder, then flows upward to cool the cylinder cover, and then is collected by the water outlet
header to the thermostat. When the coolant temperature is lower than 82°C, the thermostat is off, and all
coolant is bypassed to the inlet of the water pump. At this time, the coolant runs circularly between the
cylinder block and cover to warm up the car quickly. When the coolant temperature is up to 82°C, the
thermostat is opened gradually, and partial coolant runs to the upper inlet of the radiator till gets in the
radiator, and then the coolant is cooled down by the radiator fan. When the coolant temperature is over
94°C, the thermostat is fully opened, with all bypass holes closed, and all coolant is cooled down by the
radiator.At this time, the flow direction of the coolant is as the drawing
P2TP00011
2-19
DW90A Cooling system
Air-to-air intercooling radiator
An air-to-air intercooling radiator mainly cools down the high temperature and high pressure gas
pressurized by the turbocharger to reduce the temperature of the gas entering the combustion chamber
of the engine, thus increasing the density of air. The operating principle is as the following drawing. After
the air is pressurized by the turbocharger, its temperature rises sharply and its pressure also increases.
The air flows into the air-to-air intercooler. Through the core of the air-to-air intercooler, the external
cooling air flows in and takes away the heat of the air in the intercooler to reduce the air temperature to
be less than 80°C. Then the air flows into the engine intake manifold and combustion chamber from the
right air pipe of the air-to-air intercooler.
P2TP00012
2-20
Radiator assembly

Water radiator Dimension of core (height X width X
1152*880*104
thickness)
Air-to-air Intercooler Dimension of core (height X width X
860*700*80
thickness)
Structure of components
The radiator assembly comprises an air-to-air intercooler and a water radiator.
Fan
Number of blades Diameter Type

Fan 11 760 Air suction
P2TP00013
2-21
June 9, 2020 Test and Adjustment
DW90A Check and adjust the clearance of the inlet valve and
Test and Adjustment
Check and adjust the clearance of the inlet valve and exhaust valve.
Valve clearance adjustment for models with Youshun auxiliary braking system:
Valve clearance adjustment sequence: See Fig. 3-1.
P2TP00014
1. Turn the motor till the compression top dead center of the 1st cylinder is reached (the scale line on
the flywheel housing observation window is aligned to flywheel groove). Adjust the intake valve
clearance of the 1st, 2nd and 4th cylinder. Adjust the brake clearance and exhaust valve clearance of
the 3rd cylinder (adjust the brake clearance before the exhaust valve clearance).
2. Turn the motor in the CCW direction facing the flywheel end until the scale line on the flywheel
housing observation window is aligned to the scale line marked with "16" on the flywheel. Adjust the
brake clearance and exhaust valve clearance of the 6th cylinder (adjust the brake clearance before
the exhaust valve clearance).
intake valve clearance of the 3rd, 5th and 6th cylinders. Adjust the brake clearance and exhaust valve
clearance of the 4th cylinder (adjust the brake clearance before the exhaust valve clearance).
2-22
Test and Adjustment June 9, 2020
Check and adjust the clearance of the inlet valve and exhaust valve. DW90A
Adjustment method of exhaust valve clearance and brake clearance: See Fig. 3-2.
P2TP00015
1. Turn the motor to the corresponding adjustment position (see Fig. 1).
2. Brake clearance adjustment: Insert a feeler gauge between the exhaust valve axle and the small
piston of the exhaust rocker arm, adjust the adjusting bolt on the push rod side, and keep the brake
clearance at 2.05 mm.
3. Exhaust valve clearance adjustment: Insert a feeler gauge between the exhaust valve axle and the
cushion block, and adjust the exhaust valve clearance as 3.00 mm.
4. After adjusting the intake valve cold-state clearance, brake clearance, and exhaust valve cold-state
clearance, check the opening of intake valve and the closing of exhaust valve of the first cylinder.
Replace the oil filter or element
1. Remove the old oil filter;

2. Fill the new filter up with clean engine oil;
3. Apply engine oil to the pad before installing a new oil filter.
4. After the pad contacts the base, tighten it by 3/4 ~ 1 turn to seal it.
5. Start the diesel engine and check for oil leakage.
2-23
DW90A Check and adjust the clearance of the inlet valve and
Replace the fuel filter element.
1. Remove the old fuel filter core. If the water collector vessel installed on the coarse filter can be
reused, please remove the water collector vessel.
2. Lubricate the seal.
3. Screw on the filter by hand until the seal is combined with the interface.
4. Continue to tighten the filter by hand until it is firmly installed (about 3/4 turns).
5. Exhaust until no air bubbles are seen.
6. Carry out the leakage test
7. Note: Exhaust the coarse filter when replacing a spinning coarse filter or reinstalling an oil pipeline.
8. Specific steps are as follows:
9. Stop the engine;
10. Remove the bleed screw;
11. Charge with a hand pump until only oil comes from the bleed screw.
12. Tighten the bleed screw again.
Replace the water collector
1. Turning off the engine;

2. Discharge water from the water collector.
3. If possible, remove the screw 1 of the water collector by hand. If it is too tight, use the handling tool in
a new water collector.
4. Lubricate the sealing ring of the new water collector with several drops of oil.
5. Install the screw by hand and tighten it with a tool.
6. If the water collector vessel will be reused on a new spinning filter, check for damage.
7. Install with torque wrench having torque of 20 N M.
Replace the diesel engine oil
Remove the oil drain plug on the bottom of the oil pan, drain the oil completely, and then screw on the oil
drain plug.
Remove the oil filler cap, fill oil through the oil filler, observe the dipstick scale until the requirement is
met, and then install the oil filler cap.
2-24
Check and adjust the clearance of the inlet valve and exhaust valve. DW90A
Exhaust method of low-pressure pipeline
The high-pressure common rail fuel system shall exhaust after component replacement, when the fuel
tank is empty, when air enters the low-pressure oil line, or when the vehicle is used for the first time. The
operation procedures below shall be followed during exhaust.
1. Check all connection joints of the pipeline, especially the oil tank inlet and outlet, for looseness and
leakage, and then tighten them.
2. Exhaust the air inside the coarse filter as follows: Loosen the oil inlet connector on the coarse filter
seat (or the plug of the oil inlet on the opposite side), press the hand pump of water removal filter
until the bubble-free fuel continuously flows out, and then tighten the screw.
3. Exhaust the air inside the fine filter as follows: Loosen the oil inlet connector of the fine filter (or the
plug of the oil inlet on the opposite side), press the hand pump of water removal filter until gas is
exhausted from the oil inlet and the bubble-free fuel continuously flows out, and then tighten the
screw.
4. Exhaust the air inside the pipeline as follows: Loosen the oil return connector of the high-pressure oil
pump, continue to press the hand pump until the bubble-free fuel continuously flows out from the oil
return connector, and tighten the connector.
5. Continue to press the manual oil pump until more fuel continues to enter the high-pressure oil pump.
6. Start the engine after exhausting the gas. Keep the engine running at a high speed for more than 5
minutes (the accelerator pedal can be depressed) after the engine is successful started. Then
completely exhaust the residual air.
2-25
June 9, 2020 Removal and Installation
DW90A Removal and installation of diesel engine assembly
Removal and Installation
Removal and installation of diesel engine assembly
1.To avoid arcing, remove the battery cable of negative (-) pole before removal.
2.When the machine is working, the antifreeze is in a high temperature state. To prevent possible
personal injury, when removing the water radiator or opening the water radiator cover, the
operator shall ensure that the diesel engine has stopped and the antifreeze has been cooled
down to the temperature at which it can be touched.
3.Before removal, turn the revolving frame of the machine to an angle suitable for removal, park
the machine on a flat and hard ground, put down the equipment, and stop the engine.
Removal of Diesel Engine Assembly
Tools Required
Tools Part description Standard Qty.
1 Plastic sealing film 1
2 Oil collecting basin 1
3 Open-end wrenches 7#, 10#, 13#, 16#, 24# 5
4 Plastic sealing bag 1
5 Traveling crane 1
6 Wire rope with hook 1
2-26
Removal and Installation June 9, 2020
Removal and installation of diesel engine assembly DW90A
Figure Operation steps

1. Turn off the negative switch and hang a "No Operation"
warning sign.
P2TP00016
P2TP00017
2. Remove the engine cover according to the requirements
and steps for the “removal and installation of the engine
cover”.
3. According to the air filter removal steps, remove the air
filter and seal each port with a plastic sealing film as
required.
4. According to the removal procedure of muffler, remove
muffler and connecting pipe, and seal each port with a
plastic sealing film as required.
5. Drain out the cooling water from the engine to the oil
collecting basin for unified treatment.
6. Remove electrical connectors and wiring on the engine
according to the requirements and steps for the “removal
and installation of the electrical system”.
7. Remove the air conditioning compressor, air
conditioning tube and heater water pipe respectively
from the engine according to the requirements and steps
for the “removal and installation of the air conditioning
system”. And seal each port with plastic sealing film as
required.
8. Remove the heat dissipation pump according to the
removal requirements and steps of the heat dissipation
pump in the hydraulic system. (Plastic sealing film and
oil collecting basin)
2-27

9. Remove the fuel pipe connector screw from the fuel
pump of diesel engine with a wrench. Take out the screw
and seal gasket. Properly put them in a plastic sealing
bag. Shield the fuel pipe connector with sealing film.
(open-end wrench 7#, plastic sealing bag, and plastic
sealing film)
P2TP00018
10.Loosen the fixing clamp and bracket of the intercooler
steel pipe. Loosen the clamps on both ends of the
intercooler steel pipe, take out the intercooler steel pipe,
and seal each port with a plastic sealing film. (open-end
wrenches 10#, 16# and plastic sealing film)
P2TP00019
11.Loosen the clamp at the connection between the intake
pipe and the engine and take out the intake pipe. Loosen
the connecting clamp between the air inlet steel pipe
and the air inlet hose, and take out the air inlet steel
pipe. Seal each port with a plastic sealing film. (open-
end wrench 10#, and plastic sealing film)
P2TP00020
2-28

12.Loosen the clamp at the connection between the
exhaust pipe and the engine, and take out the exhaust
pipe. Seal each port with a plastic sealing film. (open-
end wrench 13#, and plastic sealing film)
P2TP00021
pipe and the engine, take out the intake pipe, and seal
each port with a plastic sealing film. (open-end wrench
7#, and plastic sealing film)
P2TP00022
pipe and the engine, take out the intake pipe, and seal
each port with a plastic sealing film. (open-end wrench
7#, and plastic sealing film)
P2TP00023
2-29

15.Slowly operate the traveling crane, hook the lifting lug
on the engine with a steel wire rope, and tension the
steel wire rope but do not lift the engine. (Traveling
crane, and steel wire rope with hook)
Lifting lug P2TP00024

16.According to the removal and installation requirements
and steps of the transmission assembly, remove the
captive bolts on the joint surface between engine and
transmission.
P2TP00025
17.Hold the engine fixed nut with an open-ended wrench,
and remove the engine captive bolt from the upper side
of the engine mount with an air gun, a connecting rod
and a socket wrench. Remove the upper shock absorber
and cover of the engine mount. (Open-end wrench
16#and 24#)
P2TP00024
2-30

18.Operate the steel wire rope with hook of the traveling
crane sleeve to pass through the lifting hole on the belt
pulley end of the engine, and lift the engine as slowly as
possible. It is recommended that the lifting height should
not exceed 5 mm. (Traveling crane, and steel wire rope
with hook)

19.Slowly operate the traveling crane, and hold both sides
of the engine to ensure that the engine is lifted out of the
whole machine slowly and smoothly without collision
with other parts of the whole machine.
Holding points
P2TP00026
2-31
Installation of Diesel Engine Assembly

1. Install the engine mount to the engine with a captive
bolt, and pre-tighten the bolt with a wrench.
2. Use a torque wrench to tighten the engine mount captive
bolt with the torque of 305 ± 25N.m \ 225 ± 18lbf·ft
(open-ended wrench 24#).
3. Place the shock absorber and cover on the upper and
lower sides of the engine mount. Adjust and install the
shock absorber into the mount hole.
4. Penetrate the engine captive bolt, nut and other
fasteners through the shock absorber, cover and engine
mount, and then assemble the fasteners together.
P2TP00024
5. Operate the traveling crane to lower the engine as
slowly as possible, and then release the hook.

6. Move the transmission assembly to assemble it with the
engine flywheel housing; then install the fixing bolts and
quench-hardened gaskets of the transmission housing
and the engine housing and tighten them. Tightening
torque: 72 ± 6N.m \ 53 ± 4lbf·ft (16# socket wrench,
pneumatic impact wrench, and torque wrench)
P2TP00025
2-32

7. Install the cover plate for mounting window of the
transmission. (Open-end wrench 10#)
P2TP00027
8. Hold the nut with a wrench, and pre-tighten the engine
captive bolt from the upper side of the engine mount with
an air gun, connecting rod and socket wrench.
According to the removal and installation requirements
and steps of the transmission, re-tighten the
transmission captive bolt with a torque wrench.
9. Tighten the engine captive bolt with a torque wrench
having the torque of 305 ± 25N.m \ 225 ± 18lbf·ft. (Open-
end wrench 16#and 24#)
P2TP00024
10.Insert the coolant outlet pipe into the engine coolant
outlet, insert the coolant inlet pipe into the engine
coolant inlet, and hold the pipes tightly with clamps.
(Open-end wrench 10#)
P2TP00022
2-33

11.Insert the exhaust pipe into the engine exhaust port and
fix it tightly with a clamp. Insert the exhaust steel pipe
into the exhaust hose and fix it tightly with a clamp.
P2TP00021
12.Insert the air intake pipe into the engine air intake and fix
it tightly with a clamp. Insert the air intake steel pipe into
the air intake hose and fix it tightly with a clamp. (Open-
end wrench 10#)
P2TP00020
13.Insert the intercooler steel pipe into the silicone tube on
the engine and radiator, and fix it tightly with a clamp. Fix
the intercooler steel pipe bracket on the intake and
exhaust bracket, and pre-tighten it with a bolt. Fix the
intercooler steel pipe on the bracket with a U-clamp, and
tighten it with a nut. Tighten the mounting bolt of
intercooler steel pipe bracket. (Open-end wrench
10#and 16#)
P2TP00019
2-34

14.Fix the diesel joint to the engine fuel pump with a screw
and gasket. The oil pipe connected to the oil-water
separator is an oil inlet pipe, which is connected to the
oil inlet of the fuel pump. The oil inlet is marked with "in".
P2TP00018
15.According to the installation requirements and steps of
the air conditioning system, install the air conditioning
compressor, air conditioning pipe and warm air pipe to
the engine.
16.According to the installation steps of muffler, install the
muffler and connecting pipe to the intake and exhaust
bracket.
17.According to the installation steps of the air filter, install
the air filter on the heat insulation bracket.
18.According to the removal and installation requirements
and steps of the electrical system, install the electrical
connector and wiring to the engine, muffler and air filter.
19.Install the heat dissipation pump to the engine according
to the removal and installation requirements and steps of
the heat dissipation pump.
20.Install the lower engine hood and top cover according to
the requirements and steps for the “removal and
installation of the engine hood”.
21.Open the engine hood and fill up it with antifreeze.
22.Close the engine hood and remove the "No Operation"
warning sign.
2-35
DW90A Disassembling, check and assembling of air filter
Disassembling, check and assembling of air filter
Disassembling of air filter

1. Open the lock catch and remove the end cover of the air
filter.
P2TP00028
2. Take out the main filter element by rotation along the
housing.
P2TP00029
3. Take out the safety filter element along the direction of
the housing. Use the handle on the surface of the safety
filter element to pull the filter element toward the center
of the housing and remove it.
P2TP00030
2-36
Disassembling, check and assembling of air filter DW90A
Inspection of air filter
Check the main filter element and the safety filter element before installation. Visually check the sealing
surface for cuts, tears, or indentations. Do not install the filter element if there is any visible damage.
Assembling of air filter

1. Use the handle on the safety filter element to slide the
filter element obliquely into the outlet side and push it to
the position until the filter element is firmly and flatly
seated in place in the housing.
P2TP00030
2. Insert main filter element. Insert the filter element
vertically until it hits the end of the housing.
P2TP00051
3. Install the cover of the air filter and firmly lock the catch.
If the cover cannot be closed, remove the cover and
recheck the filter element position. If the filter element is
not installed correctly, the cover will be difficult to be
installed.
P2TP00028
2-37
DW90A Removal and installation of intake and exhaust assem-
Removal and installation of intake and exhaust assembly
Requirements for the removal and installation of intake and exhaust system
Precautions for removal of peripheral connectors of engine turbocharger.
When installing the intake and exhaust pipes, do not pull or pry the turbocharger.
Do not perform the thermal insulation treatment for the exhaust manifold and turbocharger housing.
Covering the exhaust manifold or turbocharger with a thermal insulation blanket will cause the
temperature of these components to rise, resulting in:
● Reduction in strength of exhaust manifold, thus causing the exhaust manifold to deform under the
gravity of the turbocharger.
● Reduction in strength of turbocharger housing, thus causing damage to the turbocharger impeller.
● Oxidization and falling of exhaust manifold and turbocharger.
Two clamps are needed to fix the intercooler steel pipe.
Two clamps
P2TP00031
2-38
Removal and installation of intake and exhaust assembly DW90A
Air intake pipe
P2TP00032
Exhaust pipe
P2TP00033
2-39
DW90A Removal and installation of fuel tank
Removal and installation of fuel tank
Removal of fuel tank
Tools Required
1 Open-end wrenches 7#, 24# 2
2 Sleeve 24# 1
3 Socket wrench 1
4 Oil drum 1
Load-bearing tool or
5 1
tooling

1. Discharge diesel:
Clean the oil discharge outlet of the fuel tank; put a clean oil
container under the fuel tank and remove the oil drain plug.
After the fuel is discharged, install the oil drain plug back on
the fuel tank. The fuel discharged shall be well sealed to
prevent contamination. (24# socket wrench, socket wrench,
and oil drum)
P2TP00034
2. Remove the fuel pipes at the suction and return ports:
After the fuel is discharged, remove the screw and pipe
clamp on the fuel tank end of the fuel pipe, remove the fuel
pipe on that end, and install the screw back to the oil return
port of the fuel tank. Shield the fuel pipes with clean plastic
bags. (open-end wrench 7#, plastic sealing bag, and plastic
sealing film)
P2TP00035
2-40
Removal and installation of fuel tank DW90A

3. Remove the fuel sensor and harness:
Take out the fuel sensor harness connector of fuel tank.
P2TP00036
4. Remove the fuel filter pipe and harness;
Remove the fuel inlet and outlet pipes of the fuel filter.
Remove the fuel filter harness connector that is connected
to the coolant sensor and fuel pump. (Open-end wrench
7#)
P2TP00037
5. Remove the fuel tank:
Remove 3 mounting bolts on the bottom of the fuel tank.
(open-ended wrench 24#, bearing tool or tooling)
P2TP00038
When the mounting bolts are loosened, the fuel tank will be separated from the frame.Therefore,
before removal,put a reliable tool with adequate bearing capacity (such as forklifts) under the fuel
tank to support the tank.
Before performing the operation in step 5, the operator must ensure that the operations in steps
2 to 4 have been completed; otherwise the relevant parts will be damaged and even accidents will
occur.
2-41
DW90A Removal and installation of fuel tank
Installation of fuel tank
Tools Required
Load-bearing tool or
2 1
tooling

1. Use a bearing tool to move the diesel tank under the
rear frame so that the diesel tank hole is aligned to the
diesel tank mounting hole on the rear frame. Use a bolt
and hardened washer to fix the diesel tank on the
bracket. The tightening torque of fuel tank mounting
bolts is 166 ± 26N.m \ 122 ± 19lbf·ft. (open-ended
wrench 24#, bearing tool or tooling)
P2TP00038
2. Install the fuel filter pipe and harness:
Install the fuel inlet and outlet pipes of the fuel filter.
Connect the fuel filter harness connector that is connected
to the coolant sensor and fuel pump. (Open-end wrench
7#)
P2TP00037
3. Install the fuel sensor and harness:
Connect the fuel sensor harness connector of fuel tank.
P2TP00036
2-42
Removal and installation of fuel tank DW90A

4. Install the fuel pipes at the suction and return ports
(open-ended wrench 7#)
P2TP00035
5. Fill up it with diesel.
P2TP00035
Cleaning
Unscrew the oil drain plug on the bottom of the fuel tank to drain the fuel (collect the fuel with a suitable
vessel), remove the cleaning port of the fuel tank, repeatedly flush the inner surface of the fuel tank with
clean fuel until the drained fuel is clean, and then reinstall the oil drain plug on the bottom of the fuel
tank.
2-43
DW90A Removal and installation of radiator assembly
Removal and installation of radiator assembly
Removal of radiator assembly
Tools Required
1 Open-end wrenches 7#, 10#, 17#, 18#, 24#, 25# 6
3 Bucket 1
4 Oil drum 1
6 Traveling crane 1
7 Steel wire rope 1

warning sign.
P2TP00016
P2TP00017
2. Remove the engine hood and top cover according to the
requirements and steps for the “removal and installation
of the engine hood”.
2-44
Removal and installation of radiator assembly DW90A

3. Unscrew the drain connector and drain out the engine
cooling water. (Open-end wrench 25#)
P2TP00039
4. Loosen the intercooler steel pipe clamp, pull out the
silicone tube on the radiator end, and seal each port with
a plastic sealing film. (open-end wrench 10#, and plastic
sealing film)
P2TP00019
5. Loosen the water pipe clamp and pull out the water pipe
from the radiator. Seal each port with a plastic sealing
film. (open-end wrench 10#, and plastic sealing film)
P2TP00022
2-45

6. Remove the condensate inlet and outlet connectors of
air conditioner radiator, and seal each port with a plastic
sealing film. (open-end wrench 17#, 24#, and plastic
sealing film)
P2TP00040
7. Remove the breather pipe joint and seal each port with a
plastic sealing film. (open-end wrench 7#, and plastic
sealing film)
P2TP00041
P2TP00042
8. Remove the engine according to the requirements and
steps for the “removal and installation of the engine”.
2-46

9. Slowly operate the traveling crane, hook the lifting point
with the steel wire rope, and tighten the rope, but do not
lift it. (Traveling crane and steel wire rope)
10.Unscrew fixing bolts of radiator assembly. (open-ended
wrench 18#, and traveling crane)
P2TP00043
11.When operating the traveling crane, slowly lift the
radiator assembly out and place it on a flat ground.
(Traveling crane)
Installation of radiator assembly
Tools Required
1 Open-end wrenches 7#, 10#, 17#, 18#, 24#, 25# 6
6 Traveling crane 1
7 Steel wire rope 1

1. Install the engine according to the requirements and
steps for the “removal and installation of the engine”.
2. Screw the lifting eye into the lifting lug of the radiator
assembly and screw in at least three turns. Use the hook
on the steel wire rope to hang the lifting eye. Slowly
operate the traveling crane, lift the radiator to the frame,
and align the mounting hole on the radiator to the
mounting hole on the frame. (traveling crane, steel wire
rope, and lifting eye)
2-47

3. Tighten the radiator mounting bolts with the tightening
torque of 66 ± 9N.m \ 48 ± 7lbf·ft. (Open-end wrench
18#)
P2TP00043
4. Install the breather pipe joint. (open-end wrench 7#, and
plastic sealing film)
P2TP00042
P2TP00041
2-48

5. Install the condensate inlet and outlet connectors of air
conditioner radiator. (Open-end wrench 17#and 24#)
P2TP00040
6. Insert the water inlet and outlet pipes into the water
radiator port, and fix the water pipes tightly with clamps.
P2TP00022
7. Connect the intercooler steel pipe to the air-to-air
intercooler with a silicone tube, and fix the silicone tube
tightly with a clamp. (Open-end wrench 10#)
P2TP00019
2-49

8. Tighten the radiator drain switch. (Open-end wrench
25#)
P2TP00039
9. Supplement coolant as required. (Plastic sealing film)
10.Install the engine hood and top cover according to the
requirements and steps for the “removal and installation
of the engine hood”.
Inspection of radiator assembly
Check the radiator passage pipe wall for cracks. Repair welding or replacement of radiator is required if
there are cracks.
Check the radiator fins. If a large area of fins are bent over and the air duct is blocked, the fins need to be
leveled along the air flow direction or the radiator needs to be replaced.
Check whether the radiator air duct is blocked by debris or impurities. If there is any blockage,
compressed air is required to blow the blockage. Note that the direction of compressed air shall be
reverse to the direction of air flowing through the radiator during normal operation of the machine.
2-50
Removal and installation of fan DW90A
Removal and installation of fan
Removal of Fan
Tools Required
1 Open-end wrenches 10# 1

warning sign.
P2TP00016
P2TP00017
2. Open the engine hood.
3. Unscrew the fan mounting bolt, hold the root of the fan
blade, gently shake it to separate the fan from the flange
and remove the fan. (Open-end wrench 10#)
P2TP00044
2-51
DW90A Removal and installation of fan
Installation of Fan
Tools Required
2 Plastic sealing film

1. Insert the fan into the flange with the inside of the fan arc
surface (concave surface) facing the rear of the whole
machine.
P2TP00045
2. Fix the fan to the flange block with a bolt. (Open-end
wrench 10#)
P2TP00044
2-52
Removal and installation of fan DW90A

3. Measure the clearance between the fan and the shroud
with a steel ruler. The clearance between the fan and the
shroud shall be greater than 10 mm (0.39In). (Steel
ruler)
4. Install the protective cover to the hood and fasten it with
a bolt. (Open-end wrench 16#)
5. Measure the clearance between the fan and the
protective cover with a steel ruler. The clearance
between the fan and the protective cover shall be
greater than 20 mm (0.79In). (Steel ruler)
P2TP00013
Inspection of fan
Check whether the fan blades are damaged or scratched. Check whether the fan blades and the
connection between the fan and the hub are cracked. Replace the fan with a new one if it is damaged.
2-53
June 9, 2020 Troubleshooting
DW90A Precautions for Fault Diagnosis
Troubleshooting
Precautions for Fault Diagnosis
Park the machine on level ground and check that the locking pins, cushion blocks, and parking brake are
firmly secured.
When two or more workers operate, they must strictly observe the signals agreed in advance and cannot
allow any unauthorized personnel to approach.
If the radiator cover is removed when the engine is hot, the hot coolant will spray out and cause burns,
so the fault diagnosis shall be performed after the engine is cooled down.
Be especially careful not to touch any hot parts or get stuck by any rotating parts.
When disconnecting the wires, make sure to disconnect the negative (-) of the battery first.
When the plug screw or cover is removed from the place with oil pressure, water pressure or air
pressure inside, the internal pressure must be released first. When installing the measuring device,
make sure to connect it correctly.
1. It is a careful job to judge the cause of diesel engine failure. Before the cause is basically found
out, the diesel engine shall not be disassembled randomly. Otherwise, the failure will not be
eliminated, but more serious failure will be caused by improper assembling after disassembling.
2. For a high-pressure oil pump, turbocharger and other related parts, repair and inspection shall
not only be performed with special instruments and equipment, but also be performed by
maintenance personnel with certain experience. Therefore, customers without experience and
conditions shall not disassemble or adjust them at will.
2-54
Troubleshooting June 9, 2020
Common Faults and Troubleshooting DW90A
Common Faults and Troubleshooting
Failure in starting diesel engine
The starter fails to work.

The starter is controlled by ECU. During the normal operation, the ECU outputs a current drive relay.
After the relay is turned on, the battery drives the starter to start. When a fault occurs, it is mainly to
check the neutral position.
Several check factors: include neutral switch, starting relay, battery and off-board parking switch.
◆ Check whether the neutral gear is engaged.
Before starting a vehicle, check whether the transmission shift lever is in the neutral position at first.
◆ Check the position of the off-board parking switch (in the OFF state)
The off-board parking switch is made into inching type and can be automatically reset. Check whether
the switch is normal.
If the switch cannot reset automatically, check whether the switch is on.
◆ Check whether the neutral switch and its wires are in good condition, and try to perform the
emergency starting (the ignition switch is continuously pressed for more than 5s).
For the engine of which the starter is controlled by ECU, the ECU determines whether the neutral gear is
engaged based on the signals from the neutral switch when the starter is started. When the neutral
switch is damaged or the wire connection is not good, the ECU cannot receive the neutral signals and
the starter does not work.
◆ Check whether the battery voltage is too low to drive the starter.
Generally, the battery voltage is 24V. If it is too low, the starter cannot be driven to work. The operator
can check it with the voltage position of a multimeter or read the actual value of "battery voltage" with a
fault diagnosis tester.
◆ Check whether the starter relay and its wires are in good condition.
Check whether there are too many oxides on the terminal surface and whether the bolt on the terminal
surface is loose or broken.
◆ Check whether the starter is burnt out
Use a multimeter to check whether the starter relay is normal.
◆ Check whether the ignition switch and starting switch are damaged.
Turn the ignition key to the ON position and check if the dashboard lamp is on or not:
Turn the ignition key to the starting position, and check whether the starter works (other reasons have
been eliminated at this time).
The rail pressure cannot be established (the starter works normally but cannot be started).
2-55
DW90A Common Faults and Troubleshooting
◆ Check whether the fuel level in the fuel tank is too low
This reason is easy to ignore and shall be noticed.
Check whether the hand fuel pump works normally.
Press the hand fuel pump manually to check if it is normal.
◆ Check whether there is air in the low-pressure oil line and exhaust the air (sometimes the leakage of
the low-pressure oil line is not obvious and a careful inspection is needed).
Exhaust method: It is mainly to exhaust the air in the coarse filter. Loosen the bleed screw on the coarse
filter, and press the hand pump on the coarse filter manually until oil continues to flow from the bleed
screw.
If the diesel engine cannot be started after the air in the low-pressure oil line is completely exhausted, it
means that there is air in the high-pressure oil line, and the air also needs to be exhausted.
Exhaust method: Loosen the high-pressure oil pipe of a certain cylinder, and use the starter to drive the
diesel engine to run until oil continues to flow from the high-pressure oil pipe. (Frequently removing the
high-pressure oil pipe joint is not recommended!)
◆ Check whether there is leakage in the high-pressure oil line.
This situation is generally obvious. Check whether the nut of the high-pressure oil pipe joint is loose.
Tighten the nut if loose.
◆ Check whether the oil line is unobstructed and whether the diesel filter is blocked. It is recommended
that the diesel filter element should be replaced in time.
Check method: Loosen the fine filter outlet bolt and use the starter to drive the diesel engine to run.
Check if there is any diesel oil ejecting or flowing out. If there is only a small amount of diesel oil flowing
out, the filter element can be determined as blocked, and the filter element needs to be replaced at this
time.
◆ Check whether the initial voltage of rail pressure sensor is about 500 mV, and check whether the set
rail pressure is 30-50MPa.
◆ Check whether the flow metering unit is in good condition, remove its connector, and try to restart it.
First of all, observe whether there is obvious hardware damage and whether the connectors are firmly
connected.
Connect a fault diagnosis tester for the Meter-unit test.
After the test, confirm whether the fuel metering unit is normal.
The connectors of both engine harness and finished machine harness are improperly inserted, or the
harness is subject to open or short circuit.
◆ Check the installation of connectors. Use a multimeter (preferably connected to a "circuit tester") to
check the on/off of the lines according to the definition of wiring diagram.
Loss of crankshaft and camshaft signals
Two speed sensors are installed on the diesel engine, which are located outside the flywheel housing
and the high-pressure oil pump respectively. They are: crankshaft position sensor and cylinder judging
sensor respectively. The injection timing of electronically controlled engines depends on these two
sensors. When the diesel engine fails to start, both signals are lost.
2-56
◆ Possible reasons for the loss of both signals

The sensors are damaged, or the harness is subject to open or short circuit.
The sensor is not fixed firmly, causing the clearance between the sensor and the sensing teeth to be too
large or too small (generally 1±0.5 mm).
Troubleshooting: Check whether the sensor is damaged, whether the harness is connected well, and
whether the sensor is loose.
◆ The installation after disassembling and assembling of high-pressure oil pump and flywheel shall be
carried out in strict accordance with the relevant process documents, to ensure the signal
synchronization.
Hard to start
Causes of engine difficult to be started and their elimination methods

◆ Diesel engine not running for a long time: The oil return pipe shall extend below the diesel level.
◆ A small amount of air in the low-pressure pipeline: Exhaust the air.
◆ Too weak crankshaft speed signal and camshaft signal, and relatively long synchronous judgment
duration: Find out the specific reasons and readjust.
◆ Failure of preheating device due to extremely low ambient temperature: Check whether the heating
flange connection is normal or replace the preheating device.
◆ Poor quality of diesel and engine oil (unqualified): Replace them with the standard oil products.
◆ Collision of starter or flywheel gear ring: Replace the starter and flywheel gear ring.
◆ Wear of piston ring and cylinder bushing or loose valve seal: Replace the piston ring, cylinder
bushing, or valve seat and valve.
◆ Unsuccessful exhaust due to blocked exhaust brake butterfly valve: Replace the butterfly valve.
Underpower of the engine
Limp home mode: It is a mode in which the engine can run with failures. The ECU detects that the
engine has failures, but it will not stop the engine immediately. Instead, it will limit the engine power so
that the engine speed can only be increased to 1,500 r/min. The driver can drive the vehicle to the
nearest repair station for repair.
1. Failure of injector
The fuel injector failures generally consist of mechanical and wiring failures.
Mechanical failure: The needle valve gets stuck. Due to a relatively large amount of dirt in diesel oil or
water corrosion, the needle valve gets stuck in the fuel injector and cannot operate. (Note: The ECU may
not report an error!)
Wiring failure: Due to vibration, abrasion and other reasons, the harness is disconnected or directly
connected to the cylinder head and short-circuited to the ground. The ECU will report an error.
2-57
2. The water temperature, oil temperature and air inlet temperature are too high
When the water temperature, engine oil temperature and intake air temperature are too high, the ECU
will enable the overheat protection function to limit the engine power. Before the failures are eliminated,
the incorrect indications of sensors and meters shall be eliminated at first.
◆ Causes of high water temperature and their elimination methods
(1) Extremely low water level in tank: Check for leaks and add water.
(2) Extremely low fan speed or failure to run: Check the fan for its drive parts.
(3) Blockage of water tank: Check the water tank, and clear or repair it as appropriate.
(4) Loose water pump belt of: Adjust the tensile force of belt as required.
(5) Damaged water pump gasket and abraded water pump impeller: Check and repair or replace them.
(6) Thermostat fault: replace it
(7) Air invasion due to damaged water pipe seal: Check the water pipe, joint, gasket and the like, and
then replace the damaged parts.
◆ Causes of high engine oil temperature and their elimination methods
(1) Low oil level in oil pan or lack of oil: Check the oil level and oil leakage position, and then repair and
add oil.
(2) High water temperature: Check the above causes of high water temperature and eliminate them.
(3) Poor circulation of engine oil cooler: Check and clear it.
◆ Causes of extremely high intake temperature and their elimination methods
Check the cooling capacity of intercooler.
3. Synchronizing signal error
In case of this problem, it usually means that the signals of one sensor fail.
Read the flash code through the flash code lamp, review the flash code table to find out the specific
causes, and eliminate them.
4. Flow measuring unit fault
The flow metering unit is the actuator for controlling the rail pressure. It is installed on the high-pressure
oil pump. After this problem occurs, the high-pressure oil pump will supply oil to the common rail pipe
with its maximum capacity. At this time, the pressure relief valve on the common rail trim will be opened
in general, and the diesel oil will have a "click" noise. The rail pressure sensor will have a similar
phenomenon when a problem occurs.
Elimination method: Check the lines to confirm whether the flow metering unit or the rail pressure sensor
fails. Then, notify the office to handle it.
5. The rail pressure fluctuates abnormally due to leakage of fuel pipeline.
When a vehicle is running, its speed will be unstable and the vehicle will run at high and low speeds
alternately.
Troubleshooting method:
At first, power off the engine for one minute and then restart it. If the problem still exists, check the
tightness of the fuel line and eliminate the problem.
2-58
6. Sensor fault
The intake pressure sensor is a sensor (installed on the intake pipe) used by the ECU to estimate the
intake air amount. The water temperature sensor is a sensor (installed on the water pump) used to judge
the thermal load of the engine. The rail pressure sensor (installed on the common rail pipe) is used to
detect the fuel pressure of the common rail pipe.
Troubleshooting method
Check the intake air temperature and pressure, water temperature, and rail pressure sensor to see if the
connectors are firm or not.
When the faults 1, 3, 4, 5 and 6 occur, the diesel engine enters the "limp home" mode!
The engine is always running at 1,000 r/min.
At this time, the accelerator fails. The ECU determines the load through the signal given by the pedal
potentiometer. When the pedal fails, the ECU will control the diesel engine to automatically return to the
idle speed of 1,000 r/min for safety reasons.
◆ Loose or incorrectly connected electronic accelerator pedal wire
Remove and install or check the accelerator pedal wire for correct connection. If not, reconnect it.
◆ Water invasion of electronic accelerator connector
Blow-dry the connector with a tool before starting.
A new throttle with the same model is needed for replacement of an old one!
2-59
Engine idle hunting
◆ Causes of engine idle hunting and their elimination methods

(1) Improper operation of engine oil extractor: Check each cylinder for their injector and harness.
(2) Vehicle speed signal input detected for a finished machine with a speed sensor stopped: Check the
speedometer, speed sensor signal and wiring.
(3) Poor fuel quality (with water or wax): Clean the fuel system and replace the fuel filter.
(4) Air invasion of low-pressure oil line of fuel system: Check the tightness of oil pipe and joint, and
exhaust the air.
(5) Unstable atomization of fuel injection nozzle: Check and repair.
Idle speed rise caused by low water temperature is a normal function of ECU!
When there are other loads (like when the air conditioner is started), the idle speed will naturally
rise by 100 r/min!
2-60
Engine Fault Code Table DW90A
Engine Fault Code Table
DTC for DTC for DTC DTC

English Blink Model
Index DFC Name J1939 J1939 for for Class DisblMsk CtlMsk
Description Code Name
SPN FMI UDS 15031
Exhaust brake
DFC_ECRVl valve inside the DOP_100
001 571 3 P00C1 P0478 2 315 32771 3072
vSCBat cylinder short- ms
circuited to ground
Exhaust brake
valve inside the
DFC_ECRVl DOP_100
002 cylinder short- 571 4 P00C2 P0477 2 315 32771 0
vSCGnd ms
circuited to the
power supply
Open circuit of
DFC_ECRVl exhaust brake DOP_100
003 571 5 P00C3 P0475 2 315 32771 0
vOpenLoa d valve inside the ms
cylinder
Unreliable
DFC_AccPe
004 accelerator pedal 91 7 P0013 P2299 2 225 0 0 IO20ms
dBrkPlaus
and brake signal
Air mass flow
DFC_AFSS sensor voltage
005 132 3 P009F P0103 0 234 32768 0 IO20ms
RCRawMax exceeding upper
limit
Air mass flow
DFC_AFSS sensor voltage
006 132 4 P009B P0102 0 234 32768 0 IO20ms
RCRawMin exceeding lower
limit
DFC_AirHtS Intake heating
007 2898 7 P0014 P2609 3 322 0 0 STRT
tickOn stuck-open
Unreliable double
signal relationship
DFC_APP1 between
008 520252 2 P000C P2135 2 221 0 0 IO20ms
2Plaus accelerator pedal 1
and accelerator
pedal 2
Voltage value of
accelerator pedal 1
DFC_APP1
009 greater than the 91 3 P000A P0123 2 221 0 0 IO20ms
SRCMax
upper threshold
value
Voltage value of
DFC_APP1 accelerator pedal 1
010 91 4 P000B P0122 2 221 0 0 IO20ms
SRCMin less than the lower
threshold value
Unreliable 1/2
signal relationship
DFC_APP2 between
011 1 0 P000F P2135 2 221 32768 0 IO20ms
1Plaus accelerator pedal 2
and accelerator
pedal 1
Voltage value of
accelerator pedal 2
DFC_APP2
012 greater than the 29 3 P000D P0223 2 221 0 0 IO20ms
SRCMax
upper threshold
value
Voltage value of
DFC_APP2 accelerator pedal 2
013 29 4 P000E P0222 2 221 0 0 IO20ms
SRCMin less than the lower
threshold value
Unreliable
DFC_APSC atmospheric
014 102 2 P0012 P006D 1 231 0 0 IO100ms
DNPL pressure sensor
signal
2-61
DW90A Engine Fault Code Table

English Blink Model
SPN FMI UDS 15031
Voltage of
barometric
DFC_APSC pressure sensor
015 108 3 P0010 P2229 2 232 0 0 IO100ms
DSRCMax greater than the
upper threshold
value
Voltage of
barometric
DFC_APSC
016 pressure sensor 108 4 P0011 P2228 2 232 0 0 IO100ms
DSRCMin
less than the lower
threshold value
DFC_ArHt1 Open circuit of DOP_100
017 2898 5 P001B P0110 3 321 263 0
OpenLoad intake heater ms
Short circuit of
DFC_ArHt1 DOP_100
018 intake heater to 2898 3 P0019 P0113 3 321 263 3072
SCBat ms
power supply
Short circuit of
DFC_ArHt1 DOP_100
019 intake heater to 2898 4 P001A P0112 3 321 263 0
SCGnd ms
ground
Original value of
DFC_BattC battery voltage less
020 168 4 P0020 P0562 2 124 0 0 IO10ms
DSRCMax than the lower
threshold
Original value of
DFC_BattC battery voltage
021 168 3 P001F P0563 2 124 0 0 IO10ms
DSRCMin greater than the
upper threshold
Unreliable intake
DFC_BPSC
022 pressure sensor 1 0 P001E P006D 1 231 32768 0 IO100ms
DNPL
signal
Voltage of air
intake pressure
DFC_BPSC
023 sensor greater than 102 3 P001C P0238 2 231 0 0 IO10ms
DSRCMax
the upper threshold
value
Voltage of air
intake pressure
DFC_BPSC
024 sensor less than 102 4 P001D P0237 2 231 0 0 IO10ms
DSRCMin
the lower threshold
value
The fault lamp is
normally on due to
DFC_Brk1S the identification
025 597 11 P00DF P0504 1 223 32768 0 IO20ms
wtCrCtllmp error of cruise
control
requirements
The cruise control
DFC_Brk1S inhibition is wrong
026 597 7 P00DE P0504 1 223 32768 0 IO20ms
wtCrCtlRls before stepping on
the brake pedal
DFC_BrkCD Unreliable brake
027 597 2 P0022 P0504 3 223 0 0 IO20ms
Npl signal
DFC_BrkCD
028 Brake signal error 597 19 P0021 P0571 1 223 32768 0 IO20ms
Sig
The rising range of
cooling water
DFC_Clg_D temperature in a
029 110 18 P002A P0116 1 242 0 0 IO100ms
ynTst certain period of
time does not
reach the minimum
2-62

English Blink Model
SPN FMI UDS 15031
The cooling water
temperature does
DFC_ClgAb not reach the
030 110 17 P0029 P0116 1 242 0 0 IO100ms
sTst minimum in a
certain period of
time
DFC_ComC
Unavailable water
031 TSCDUnA 1 0 P00FE P140D 8 242 32768 0 FrmMng
temperature signal
vail
DFC_ComE
Unavailable engine
032 ngSpdUnA 190 2 P00FD P140B 6 224 32768 0 FrmMng
speed signal
vail
DFC_ConvC Unreliable clutch
033 598 2 P002C P0704 1 222 0 0 IO20ms
DNpl status signal ?
DFC_CoVeh OBD torque limiting
034 520198 11 P00E6 P1007 0 511 0 0 PrfmLim
PrfmLimA ct activation error
Open circuit of
DFC_CSLp DOP_100
035 cold-start indicator 626 5 P0025 P0381 2 332 263 0
CDNoLoad ms
lamp
Short circuit of
DFC_CSLp DOP_100
CDSCBat ms
to power supply
Short circuit of
DFC_CSLp DOP_100
CDSCGnd ms
lamp to ground
The signals of
cooling water
DFC_CTSC temperature and
038 110 2 P0028 P0116 1 241 0 0 IO100ms
DNpl engine oil
temperature are
incredible
The water
temperature
sensor works
DFC_CTSC
039 normally but the 110 15 P00DD P0217 2 242 0 0 IO100ms
DOvrTemp
water temperature
exceeds the
threshold value
Voltage of coolant
DFC_CTSC temperature
040 110 3 P0026 P0118 2 241 0 0 IO100ms
DSRCMax sensor greater than
the upper threshold
The voltage of
cooling water
DFC_CTSC
041 temperature 110 4 P0027 P0117 2 241 0 0 IO100ms
DSRCMin
sensor is less than
the lower threshold
Off-vehicle start/
DFC_ECBtC
042 stop button getting 520203 5 P002F P2536 1 343 0 0 IO20ms
DPlausLoc k
stuck
DFC_EngM Camshaft signal
DOP_20
043 BackUpLi only, limp home 4203 13 P0030 P0335 2 114 32768 0
ms
mp mode activated
DFC_EngM Camshaft signal DOP_20
044 4201 12 P0033 P0340 1 123 0 0
CaS1NoSig loss ms
DFC_EngM Camshaft cycle DOP_20
045 4201 2 P0031 P0341 1 123 0 0
CaSPer error ms
Camshaft
DFC_EngM DOP_20
046 synchronization 4201 11 P0032 P0341 1 123 0 0
CaSSyn ms
error
2-63

English Blink Model
SPN FMI UDS 15031
Camshaft and
DFC_EngM crankshaft DOP_20
047 4201 13 P0035 P0340 1 123 0 0
CaSSynCrS synchronization ms
error
DFC_EngM Crankshaft signal DOP_20
048 4203 12 P0036 P0335 2 122 0 0
CrS1NoSig loss ms
Crankshaft
DFC_EngM DOP_20
049 synchronization 4203 3 P0039 P0336 2 122 0 0
CrSSyn ms
error
DFC_EngM Error in number of DOP_20
050 4203 4 P0038 P0336 2 122 0 0
CrSToothN r crankshaft teeth ms
DFC_EngM
Crankshaft teeth DOP_20
051 CrSToothP 4203 2 P003A P0336 2 122 0 0
cycle error ms
er
Error between
DFC_EngM crankshaft signal
DOP_20
052 OfsCaSCrS and camshaft 4201 14 P003B P0340 1 123 0 0
ms
SRCMax signal out of
threshold value
DFC_EngPrt Engine speed out
053 1769 11 P003C P0219 2 513 0 0 TSL
OvrSpd of limit
Open circuit of
DFC_EngSp DOP_100
054 engine speed 1623 5 P003F P100A 1 344 33031 0
dOpenLoad ms
signal
Short circuit of
DFC_EngSp engine speed DOP_100
055 1623 3 P003D P100C 1 344 33031 3072
dSCBat signal to power ms
supply
Short circuit of
DFC_EngSp DOP_100
056 engine speed 1623 4 P003E P100D 1 344 33031 0
dSCGnd ms
signal to earth
Open circuit of
DFC_ExFlC DOP_100
057 exhaust brake 520208 5 P0042 P0475 3 311 263 0
DOpenLoa d ms
butterfly valve
Short circuit of
DFC_ExFlC exhaust brake DOP_100
058 520208 3 P0040 P0478 3 311 263 3072
DSCBat butterfly valve to ms
power supply
Short circuit of
DFC_ExFlC exhaust brake DOP_100
059 520208 4 P0041 P0477 3 311 263 0
DSCGnd butterfly valve to ms
earth
DFC_FanC Open circuit of fan
DOP_100
060 D1OpenLoa actuator (PWM 4815 7 P0047 P0481 2 312 263 0
ms
d wave)
Fan actuator (PWM
DFC_FanC DOP_100
061 wave) short to 4815 9 P0045 P0694 2 312 263 3072
D1SCBat ms
power supply
Fan actuator (PWM
DFC_FanC DOP_100
062 wave) short- 4815 10 P0046 P0693 2 312 263 0
D1SCGnd ms
circuited to ground
DFC_FanC Open circuit of fan
DOP_100
063 D2OpenLoa actuator (digital 4815 5 P004A P0480 2 312 263 0
ms
d signal)
Fan actuator
DFC_FanC (digital signal) DOP_100
064 4815 3 P0048 P0692 2 312 263 3072
D2SCBat short-circuited to ms
power supply
Short circuit of fan
DFC_FanC DOP_100
065 actuator (digital 4815 4 P0049 P0691 2 312 263 0
D2SCGnd ms
signal) to earth
2-64

English Blink Model
SPN FMI UDS 15031
Cooling fan speed
DFC_FanC greater than the
066 1639 3 P004B P0495 2 316 0 0 IO10ms
DSpMax upper threshold
value
Cooling fan speed
DFC_FanC
067 less than the lower 1639 4 P004C P0494 2 316 0 0 IO10ms
DSpMin
threshold value
Fuel heating relay
DFC_FlFltHt (digital signal) DOP_100
068 520261 5 P0003 P1032 3 216 32768 0
1OpenLoa d subject to open ms
circuit
Fuel heating relay
069 520261 3 P0001 P1034 3 216 32768 3072
1SCBat short-circuited to ms
power supply
Fuel heating relay
070 520261 4 P0002 P1035 3 216 32768 0
1SCGnd short-circuited to ms
ground
Fuel heating
DFC_FlFltHt actuator (PWM) DOP_100
071 520261 10 P0008 P1035 3 216 32768 0
2OpenLoa d short-circuited to ms
ground
Fuel heating
072 520261 9 P0007 P1034 3 216 32768 3072
2SCBat short-circuited to ms
power supply
Fuel heating
073 520261 7 P0009 P1032 3 216 32768 0
2SCGnd subject to open ms
circuit
Fuel boosting
DFC_FlIncP DOP_100
074 actuator subject to 95 5 P0006 P1017 3 217 32768 0
OpenLoad ms
open circuit
Fuel boosting
DFC_FlIncP actuator short- DOP_100
075 95 3 P0004 P1015 3 217 32768 3072
SCBat circuited to power ms
supply
Fuel boosting
DFC_FlIncP DOP_100
076 actuator short- 95 4 P0005 P1016 3 217 32768 0
SCGnd ms
circuited to ground
Water in oil
DFC_FlSys condition detected
077 520264 11 P0056 P2269 16 211 0 0 WIF
WtDet by water-in-oil
sensor
The accelerator
DFC_FrmM
signal received by
078 ngAPPMax 522064 19 U0007 U0107 0 426 505 0 FrmMng
the bus exceeds
Err
the limit
CAN receiving
DFC_FrmM
079 frame CM1 data 522056 14 U004C U0136 0 561 505 0 FrmMng
ngCM1DL C
volume error
CAN receiving
DFC_FrmM
080 frame CM1 timeout 522056 19 U004D U0136 0 562 505 0 FrmMng
ngCM1TO
error
DFC_FrmM CAN receiving
081 ngDashDsp frame DashDspl 522052 14 U0044 U0132 0 561 505 0 FrmMng
lDLC data volume error
082 ngDashDsp frame DashDspl 522052 19 U0045 U0132 0 562 505 0 FrmMng
lTO timeout error
2-65

English Blink Model
SPN FMI UDS 15031
083 ngDEC1DL frame DEC1 data 522062 14 U003F U0101 0 561 505 0 FrmMng
C volume error
DFC_FrmM DEC1 message
084 522062 19 U0005 U0107 0 437 505 0 FrmMng
ngDEC1TO receiving timeout
085 ngEBC1DL frame EBC1 data 522013 14 U0016 U0103 0 228 505 0 FrmMng
C length error
CAN receiving
DFC_FrmM
086 frame EBC1 522013 19 U0015 U0129 0 413 505 0 FrmMng
ngEBC1TO
timeout error
DFC_FrmM
087 ngEBC2DL Data length error 522015 14 U0018 U0130 0 228 32768 0 FrmMng
C
DFC_FrmM
088 Timeout error 522015 19 U0019 U0129 0 413 505 0 FrmMng
ngEBC2TO
089 ngEGF1DL frame EGF1 data 522053 14 U0046 U0133 0 561 505 0 FrmMng
C volume error
CAN receiving
DFC_FrmM
090 frame EGF1 522053 19 U0047 U0133 0 562 505 0 FrmMng
ngEGF1TO
timeout error
091 ngEngTem frame EngTemp2 522020 14 U0029 U0100 0 561 505 0 FrmMng
p2DLC data volume error
092 ngEngTem frame EngTemp2 522020 19 U002A U0100 0 562 505 0 FrmMng
p2TO timeout error
093 ngERC1DR frame ERC1DR 522021 14 U002D U0100 0 561 505 0 FrmMng
DLC data volume error
094 ngERC1DR frame ERC1DR 522021 19 U002E U0100 0 562 505 0 FrmMng
TO timeout error
DFC_FrmM
ETC1 message
095 ngETC1DL 522022 14 U0002 U0103 0 425 505 0 FrmMng
data length error
C
DFC_FrmM ETC1 message
096 522022 19 U0001 U0103 0 425 505 0 FrmMng
ngETC1TO receiving timeout
097 ngETC2DL frame ETC2 data 522023 14 U002B U0291 0 425 505 0 FrmMng
C volume error
CAN receiving
DFC_FrmM
098 frame ETC2 522023 19 U002C U0291 0 425 505 0 FrmMng
ngETC2TO
timeout error
099 ngETC7DL frame ETC7 data 522063 14 U003E U0102 0 561 505 0 FrmMng
C volume error
DFC_FrmM ETC7 message
100 522063 19 U0006 U0108 0 425 505 0 FrmMng
ngETC7TO receiving timeout
101 ngHRVDD frame HRVD data 522051 14 U0042 U0131 0 561 505 0 FrmMng
LC volume error
CAN receiving
DFC_FrmM
102 frame HRVD 522051 19 U0043 U0131 0 562 505 0 FrmMng
ngHRVDT O
timeout error
The remote
DFC_FrmM
accelerator signal
103 ngRemAPP 522065 19 U0008 U0107 0 427 505 0 FrmMng
received by the bus
MaxErr
exceeds the limit
2-66

English Blink Model
SPN FMI UDS 15031
DFC_FrmM
RxCCVS message
104 ngRxCCVS 522030 14 U0004 U0100 0 478 505 0 FrmMng
data length error
DLC
DFC_FrmM
RxCCVS message
105 ngRxCCVS 522030 19 U0003 U0104 0 460 505 0 FrmMng
receiving timeout
TO
106 ngTRF1DL frame TRF1 data 520217 14 U004A U0135 0 561 505 0 FrmMng
C volume error
CAN receiving
DFC_FrmM
107 frame TRF1 520217 19 U004B U0135 1 562 376 0 FrmMng
ngTRF1TO
timeout error
108 ngTSC1AE frame TSC1AE 522035 14 U0027 U0121 0 414 505 0 FrmMng
109 ngTSC1AE frame TSC1AE 522035 19 U0028 U0121 0 414 505 0 FrmMng
TO timeout error
110 ngTSC1AR frame TSC1AR 522036 14 U0023 U0121 0 414 505 0 FrmMng
111 ngTSC1AR frame TSC1AR 522036 19 U0024 U0121 0 414 505 0 FrmMng
TO timeout error
112 ngTSC1DE frame TSC1DE 522037 14 U0025 U0121 0 415 505 0 FrmMng
113 ngTSC1DE frame TSC1DE 522037 19 U0026 U0121 0 415 505 0 FrmMng
TO timeout error
114 ngTSC1DR frame TSC1DR 522038 14 U0021 U0121 0 415 505 0 FrmMng
115 ngTSC1DR frame TSC1DR 522038 19 U0022 U0121 0 415 505 0 FrmMng
TO timeout error
DFC_FrmM
CANTOTSC1PE
116 ngTSC1PE 522039 14 U0009 U0121 0 416 505 0 FrmMng
data volume error
DLC
DFC_FrmM CANTOTSC1PE
117 ngTSC1PE communication 522039 19 U000A U0121 0 416 505 0 FrmMng
TO error
DFC_FrmM
CANTOTSC1TE
118 ngTSC1TE 522040 14 U000B U0121 0 417 505 0 FrmMng
data volume error
DLC
DFC_FrmM
CANTOTSC1TE
119 ngTSC1TE 522040 19 U000C U0121 0 417 505 0 FrmMng
timeout error
TO
DFC_FrmM
CANTOTSC1TR
120 ngTSC1TR 522041 14 U000D U0121 0 417 505 0 FrmMng
data volume error
DLC
DFC_FrmM
CANTOTSC1TR
121 ngTSC1TR 522041 19 U000E U0121 0 417 505 0 FrmMng
timeout error
TO
DFC_FrmM
CANTOTSC1VE
122 ngTSC1VE 522042 14 U000F U0121 0 418 505 0 FrmMng
data volume error
DLC
DFC_FrmM
CANTOTSC1VE
123 ngTSC1VE 522042 19 U0010 U0121 0 418 505 0 FrmMng
timeout error
TO
2-67

English Blink Model
SPN FMI UDS 15031
DFC_FrmM
CANTOTSC1VR
124 ngTSC1VR 522043 14 U0011 U0121 0 418 505 0 FrmMng
data volume error
DLC
DFC_FrmM
CANTOTSC1VR
125 ngTSC1VR 522043 19 U0012 U0121 0 418 505 0 FrmMng
timeout error
TO
Voltage of fuel
temperature
DFC_FTSC
126 sensor exceeding 174 3 P0043 P0183 3 215 32768 0 IO100ms
DSRCMax
the upper threshold
value
Voltage of fuel
temperature
DFC_FTSC
127 sensor exceeding 174 4 P0044 P0182 3 215 32768 0 IO100ms
DSRCMin
the lower threshold
value
The interval time of
DFC_Gearb
128 gear ascension is 520221 2 P0069 U0404 1 227 0 0 Gearbx
xIncMax
too long
DFC_Gen1F (Water-in-oil lamp)
DOP_100
129 lSysWtOpe open circuit of 624 12 P006C P1625 1 334 263 0
ms
nLoad indicator lamp
(Water-in-oil lamp)
DFC_Gen1F
short circuit of DOP_100
130 lSysWtSC 624 3 P006A P1623 1 334 263 3072
indicator lamp ms
Bat
power supply
(Water-in-oil lamp)
DFC_Gen1F
indicator lamp DOP_100
131 lSysWtSC 624 4 P006B P1624 1 334 263 0
short-circuited to ms
Gnd
ground
High-pressure test
132 DFC_HpTst 520223 20 P00C4 P160C 1 522 0 0 HpTst
error
DFC_HWE
EEPROM read DOP_20
133 MonEEPRO 2802 14 P006D P062F 0 117 0 0
error ms
MRdErr
DFC_HWE
EEPROM write DOP_20
134 MonEEPRO 2802 12 P006E P062F 0 117 0 0
error ms
MWrtErr
Voltage of air
intake temperature
DFC_IATSC
135 sensor greater than 105 3 P006F P0098 2 233 0 0 IO20ms
DSRCMax
the upper threshold
value
Voltage of air
intake temperature
DFC_IATSC
136 sensor less than 105 4 P0070 P0097 2 233 0 0 IO20ms
DSRCMin
the lower threshold
value
Abrasion degree of
spray hole
DFC_InjDia
137 exceeding 20% for 520210 16 P00F6 P1012 2 324 32768 0 InjDia
QOC
continuous 20
times
Abrasion degree of
DFC_InjDia spray hole ranging
138 520210 15 P00F7 P1013 2 324 32768 0 InjDia
QOCfactor from 5% to 20% for
continuous 500 ms
INJdriverIC
DFC_InjIniA initialization DOP_10
139 507 9 P009C P1131 2 147 0 0
sicErr version number ms
error
2-68

English Blink Model
SPN FMI UDS 15031
Initialization error
DFC_InjIniE DOP_10
140 after powering on 507 10 P009D P1132 2 147 0 0
naErr ms
INJdriverIC
Spray hole
DFC_InjNDi abrasion resulting
141 520210 14 P0099 P1011 2 324 32768 0 InjNDia
a in over 20% failure
rates
Spray hole
DFC_InjNDi abrasion resulting
142 520210 13 P0092 P1014 2 324 32768 0 InjNDia
afactor in 0~20% failure
rates
DFC_InjPwr INJdriverIC power- DOP_10
143 507 11 P009E P1133 2 147 0 0
DrvDis on error again ms
Short circuit on
DFC_InjVlv
high side of fuel DOP_10
144 Cyl1AHSS 1413 15 P0076 P0286 2 141 0 3072
injector 1 to power ms
CBat
supply
DFC_InjVlv Short circuit on
DOP_10
145 Cyl1AHSS high side of fuel 1413 17 P0077 P02A4 2 141 32768 0
ms
CGnd injector 1 to earth
Short circuit
DFC_InjVlv
between low side DOP_10
146 Cyl1ALSS 1413 16 P0074 P0280 2 141 0 3072
of fuel injector 1 ms
CBat
and power supply
DFC_InjVlv Short circuit on low
DOP_10
147 Cyl1ALSS side of fuel injector 1413 18 P0075 P029E 2 141 32768 0
ms
CGnd 1 to earth
DFC_InjVlv
Open circuit of fuel DOP_10
148 Cyl1BNoL 1413 5 P007A P0201 2 141 0 0
injector 1 ms
oad
DFC_InjVlv Fuel injector error DOP_10
149 1413 11 P0057 P0292 2 141 0 0
Cyl1ERR of cylinder 1 ms
Open circuit with
DFC_InjVlv cylinder 1 in Bank
DOP_10
150 Cyl1MNoL and other cylinders 1413 6 P0177 P02AA 2 141 0 0
ms
oad or short circuit to
the weak power
Short circuit of fuel
DFC_InjVlv DOP_10
151 injector of cylinder 1413 3 P0058 P0298 2 141 32768 3072
Cyl1SCB ms
1 to power supply
DFC_InjVlv DOP_10
Cyl1SCG ms
1 to earth
Short circuit on
DFC_InjVlv DOP_10
153 high and low sides 1413 4 P0078 P0261 2 141 0 0
Cyl1SCL ms
of fuel injector 1
Short circuit on
DFC_InjVlv
154 Cyl2AHSS 1414 15 P007D P0287 2 142 0 3072
CBat
supply
DOP_10
155 Cyl2AHSS high side of fuel 1414 17 P007E P02A5 2 142 32768 0
ms
Short circuit
DFC_InjVlv
156 Cyl2ALSS 1414 16 P007B P0281 2 142 0 3072
CBat
and power supply
DOP_10
157 Cyl2ALSS side of fuel injector 1414 18 P007C P029F 2 142 32768 0
ms
CGnd 2 to earth
2-69

English Blink Model
SPN FMI UDS 15031
DFC_InjVlv
158 Cyl2BNoL 1414 5 P0080 P0202 2 142 0 0
injector 2 ms
oad
159 1414 11 P005A P0293 2 142 0 0
Open circuit with
DOP_10
160 Cyl2MNoL and other cylinders 1414 6 P0178 P02AB 2 142 0 0
ms
the weak power
DFC_InjVlv DOP_10
161 injector of cylinder 1414 3 P005B P0299 2 142 32768 3072
Cyl2SCB ms
2 to power supply
DFC_InjVlv DOP_10
162 injector of cylinder 1414 7 P005C P0265 2 142 0 0
Cyl2SCG ms
2 to earth
Short circuit on
DFC_InjVlv DOP_10
163 high and low sides 1414 4 P007F P0264 2 142 0 0
Cyl2SCL ms
of fuel injector 2
Short circuit on
DFC_InjVlv
164 Cyl3AHSS 1415 15 P0083 P0288 2 143 0 3072
CBat
supply
DOP_10
ms
Short circuit
DFC_InjVlv
166 Cyl3ALSS 1415 16 P0081 P0282 2 143 0 3072
CBat
and power supply
DOP_10
167 Cyl3ALSS side of fuel injector 1415 18 P0082 P0282 2 143 32768 0
ms
CGnd 3 to earth
DFC_InjVlv
168 Cyl3BNoL 1415 5 P0086 P0203 2 143 0 0
injector 3 ms
oad
169 1415 11 P005D P0294 2 143 0 0
Open circuit with
DOP_10
170 Cyl3MNoL and other cylinders 1415 6 P0179 P02AC 2 143 0 0
ms
the weak power
DFC_InjVlv DOP_10
171 injector of cylinder 1415 3 P005E P029A 2 143 32768 3072
Cyl3SCB ms
3 to power supply
DFC_InjVlv DOP_10
172 injector of cylinder 1415 7 P005F P0268 2 143 0 0
Cyl3SCG ms
3 to earth
Short circuit on
DFC_InjVlv DOP_10
Cyl3SCL ms
of fuel injector 3
Short circuit on
DFC_InjVlv
174 Cyl4AHSS 1416 15 P0089 P0289 2 144 0 3072
CBat
supply
DOP_10
175 Cyl4AHSS high side of fuel 1416 17 P008A P02A7 2 144 32768 0
ms
2-70

English Blink Model
SPN FMI UDS 15031
Short circuit
DFC_InjVlv
176 Cyl4ALSS 1416 16 P0087 P0283 2 144 0 3072
CBat
and power supply
DOP_10
177 Cyl4ALSS side of fuel injector 1416 18 P0088 P02A1 2 144 32768 0
ms
CGnd 4 to earth
DFC_InjVlv
178 Cyl4BNoL 1416 5 P008C P0204 2 144 0 0
injector 4 ms
oad
179 1416 11 P0060 P0295 2 144 0 0
Open circuit with
DOP_10
180 Cyl4MNoL and other cylinders 1416 6 P017A P02AD 2 144 0 0
ms
the weak power
DFC_InjVlv DOP_10
181 injector of cylinder 1416 3 P0061 P029B 2 144 32768 3072
Cyl4SCB ms
4 to power supply
DFC_InjVlv DOP_10
Cyl4SCG ms
4 to earth
Short circuit on
DFC_InjVlv DOP_10
183 high and low sides 1416 4 P008B P0270 2 144 0 0
Cyl4SCL ms
of fuel injector 4
Short circuit on
DFC_InjVlv
184 Cyl5AHSS 1417 15 P008F P0290 2 145 0 3072
CBat
supply
DOP_10
ms
Short circuit
DFC_InjVlv
186 Cyl5ALSS 1417 16 P008D P0284 2 145 0 3072
CBat
and power supply
DOP_10
187 Cyl5ALSS side of fuel injector 1417 18 P008E P02A2 2 145 32768 0
ms
CGnd 5 to earth
DFC_InjVlv
188 Cyl5BNoL 1417 5 P0093 P0205 2 145 0 0
injector 5 ms
oad
189 1417 11 P0063 P0296 2 145 0 0
Open circuit with
DOP_10
190 Cyl5MNoL and other cylinders 1417 6 P017B P02AE 2 145 0 0
ms
the weak power
DFC_InjVlv DOP_10
191 injector of cylinder 1417 3 P0064 P029C 2 145 32768 3072
Cyl5SCB ms
5 to power supply
DFC_InjVlv DOP_10
Cyl5SCG ms
5 to earth
Short circuit on
DFC_InjVlv DOP_10
Cyl5SCL ms
of fuel injector 5
2-71

English Blink Model
SPN FMI UDS 15031
Short circuit on
DFC_InjVlv
194 Cyl6AHSS 1418 15 P0096 P0291 2 146 0 3072
CBat
supply
DOP_10
ms
Short circuit
DFC_InjVlv
196 Cyl6ALSS 1418 16 P0094 P0285 2 146 0 3072
CBat
and power supply
DOP_10
197 Cyl6ALSS side of fuel injector 1418 18 P0095 P02A3 2 146 32768 0
ms
CGnd 6 to earth
DFC_InjVlv
198 Cyl6BNoL 1418 5 P009A P0206 2 146 0 0
injector 6 ms
oad
199 1418 11 P0066 P0297 2 146 0 0
Open circuit with
DOP_10
200 Cyl6MNoL and other cylinders 1418 6 P017C P02AF 2 146 0 0
ms
the weak power
DFC_InjVlv DOP_10
201 injector of cylinder 1418 3 P0067 P029D 2 146 32768 3072
Cyl6SCB ms
6 to power supply
DFC_InjVlv DOP_10
Cyl6SCG ms
6 to earth
Short circuit on
DFC_InjVlv DOP_10
Cyl6SCL ms
of fuel injector 6
DFC_MeUn Open circuit of fuel DOP_100
204 1442 7 P00C5 P0251 2 133 0 3072
CDNoLoad meter ms
DFC_MeUn Power short circuit DOP_100
205 1442 9 P00C6 P0254 2 133 0 3072
CDSCBat of fuel meter ms
DFC_MeUn Short circuit of fuel DOP_100
206 1442 10 P00C7 P0253 2 133 0 3072
CDSCGnd meter to earth ms
The cruise signal is
DFC_MFLv unreliable (invalid
207 596 2 P00A0 P0575 1 341 0 0 CrCtl
CrCtlMode switch
combination)
DFC_MILNo Open circuit of DOP_100
208 520219 5 P00A3 P0650 2 331 263 0
Load OBD lamp ms
Short circuit of
DFC_MILSC DOP_100
209 OBD lamp to 520219 3 P00A1 P0650 2 331 263 3072
Bat ms
power supply
DFC_MILSC Short circuit of DOP_100
210 520219 4 P00A2 P0650 2 331 263 0
Gnd OBD lamp to earth ms
DFC_MisFir
211 Cylinder 1 is on fire 1323 3 P00E7 P0301 2 512 32768 0 MisDect
eCyl1
DFC_MisFir Cylinder 10 is on
212 1332 3 P00F0 P0310 2 515 32768 0 MisDect
eCyl10 fire
213 1333 3 P00F1 P0311 2 524 32768 0 MisDect
eCyl11 fire
214 1334 3 P00F2 P0312 2 534 32768 0 MisDect
eCyl12 fire
2-72

English Blink Model
SPN FMI UDS 15031
DFC_MisFir
eCyl2
DFC_MisFir
eCyl3
DFC_MisFir
217 Cylinder 4 is on fire 1326 3 P00EA P0304 2 521 32768 0 MisDect
eCyl4
DFC_MisFir
218 Cylinder 5 is on fire 1327 3 P00EB P0305 2 522 32768 0 MisDect
eCyl5
DFC_MisFir
219 Cylinder 6 is on fire 1328 3 P00EC P0306 2 523 32768 0 MisDect
eCyl6
DFC_MisFir
220 Cylinder 7 is on fire 1329 3 P00ED P0307 2 531 32768 0 MisDect
eCyl7
DFC_MisFir
221 Cylinder 8 is on fire 1330 3 P00EE P0308 2 532 32768 0 MisDect
eCyl8
DFC_MisFir
222 Cylinder 9 is on fire 1331 3 P00EF P0309 2 533 32768 0 MisDect
eCyl9
The number of
DFC_MisFir cylinders being on
223 1322 3 P00F3 P0300 2 544 32768 0 MisDect
eTot fire exceeds the
limit
The multi-state
DFC_MSSC
224 switch signal is 976 19 P00A6 P253E 3 345 0 0 IO20ms
DNpl
incredible
The multi-state
DFC_MSSC switch voltage
225 976 3 P00A4 P251C 3 345 0 0 IO20ms
DSRCMax exceeds the upper
limit
The multi-state
DFC_MSSC switch voltage
226 976 4 P00A5 P251B 3 345 0 0 IO20ms
DSRCMin exceeds the lower
limit
DFC_OLSC Unreliable oil level
227 98 2 P00A9 P250B 7 246 32768 0 IO100ms
DNpl sensor signal
Voltage of oil level
DFC_OLSC
228 sensor exceeding 98 3 P00A7 P250D 7 246 32768 0 IO100ms
DSRCMax
the upper limit
Voltage of oil level
DFC_OLSC
229 sensor being less 98 4 P00A8 P250C 7 246 32768 0 IO100ms
DSRCMin
than the lower limit
DFC_OPSC Too low oil
230 100 17 P00AD P0524 2 243 391 0 IO100ms
DLow pressure
The engine oil
pressure is too
DFC_OPSC
231 high or the engine 100 15 P00AC P0523 2 243 0 0 IO100ms
DNpl
oil temperature
signal is incredible
Voltage of oil
DFC_OPSC pressure sensor
232 100 16 P00AA P0523 3 243 0 0 IO100ms
DSRCMax exceeding the
upper limit
Voltage of oil
DFC_OPSC pressure sensor
233 100 18 P00AB P0522 3 243 0 0 IO100ms
DSRCMin being less than the
lower limit
The engine oil
DFC_OTSC temperature
234 175 15 P00B1 P0196 1 244 0 0 IO100ms
D1Npl sensor signal is
incredible
2-73

English Blink Model
SPN FMI UDS 15031
Voltage of oil
temperature
DFC_OTSC
235 sensor exceeding 175 3 P00AE P0198 3 244 0 0 IO100ms
DSRCMax
the upper threshold
value
Voltage of oil
temperature
DFC_OTSC
236 sensor being less 175 4 P00AF P0197 3 244 0 0 IO100ms
DSRCMin
than the lower
threshold value
Unreliable oil
temperature and
DFC_OTSC
237 cooling water 1 0 P00B0 P0217 1 242 32768 0 IO100ms
DSRCNpl
temperature
signals
DFC_PCVO Open circuit of
238 1443 7 P017D P0255 2 134 32768 0 DOP_100
L PCV valve
PCV valve short-
DFC_PCVS DOP_100
239 circuited to power 1443 9 P017F P0257 2 134 32768 3072
CB ms
supply
DFC_PCVS PCV valve short- DOP_100
240 1443 10 P017E P0256 2 134 32768 0
CG circuited to ground ms
While the pressure
fluctuation, the
DFC_PRVM
241 common rail 523470 21 P00CA P0089 2 138 32768 0 RPD
onPresShc k
pressure release
valve is not opened
The opening times
of common rail
DFC_PRVM pressure release
242 onwearNu valve exceeds the 520241 11 P00CB P0089 1 134 0 0 RPD
mMax maximum times
required by
technology
Common-rail blow-
DFC_PRVO
243 off valve being 520241 14 P00C8 P0089 2 135 0 3072 RPD
pn
open
The opening time
DFC_PRVTi of pressure limiting
244 520241 0 P00C9 P0089 1 136 0 0 RPD
OpnMax valve exceeds the
limit
The voltage of rail
DFC_RailC
pressure sensor
245 DOfsTstSR 157 15 P00CE P0191 1 132 32768 0 IO10ms
exceeds the
CMax
maximum deviation
The voltage of rail
DFC_RailC
pressure sensor is
246 DOfsTstSR 157 17 P00CF P0191 1 132 32768 0 IO10ms
less than the
CMin
minimum deviation
Voltage of rail
pressure sensor
DFC_RailC
247 exceeding the 157 3 P00CC P0193 2 131 0 3072 IO10ms
DSRCMax
upper threshold
value
The voltage of rail
pressure sensor in
DFC_RailC
the interruption
248 DSRCMaxS 157 3 P0184 P0193 2 131 0 3072 ETCal
acquisition mode
op
exceeds the upper
threshold value
2-74

English Blink Model
SPN FMI UDS 15031
Voltage of rail
pressure sensor
DFC_RailC
249 being less than the 157 4 P00CD P0192 2 131 0 3072 IO10ms
DSRCMin
lower threshold
value
The voltage of rail
pressure sensor in
DFC_RailC
the interruption
250 DSRCMinS 157 4 P0185 P0192 2 131 0 3072 ETCal
acquisition mode is
op
less than the lower
threshold value
Rail pressure
DFC_RailM deviation
251 eUn0OfsM exceeding the 520243 16 P00D0 P0251 2 251 32768 0 RPD
ax upper threshold
value
Fuel quantity in the
DFC_RailM
fuel meter
252 eUn10MeU 520243 7 P00D8 P0251 2 252 0 0 RPD
exceeding the
nQHi
threshold value
The rail pressure
deviation exceeds
DFC_RailM
the threshold
eUn12Ofs
253 value, and the fuel 520243 5 P00D9 P0251 2 254 32768 0 RPD
Max
quantity in the fuel
MeUnQHi
meter exceeds the
threshold value
Rail pressure
deviation
DFC_RailM exceeding the
254 eUn1OfsM upper threshold 520243 0 P00D1 P0251 2 251 0 0 RPD
axQHi value and fuel
injection quantity
exceeding the limit
Rail pressure
deviation being
less than the lower
DFC_RailM
threshold value
255 eUn2OfsMi 520243 1 P00D2 P0251 2 255 0 0 RPD
and fuel injection
nQLo
quantity being less
than the threshold
value
Rail pressure peak
DFC_RailM being less than the
256 520243 20 P00D3 P0087 2 256 0 0 RPD
eUn3PkLo lower threshold
value
Rail pressure peak
DFC_RailM exceeding the
257 520243 21 P00D4 P0088 2 271 0 0 RPD
eUn4PkHi upper threshold
value
DFC_RailM The rail pressure is
258 520243 18 P00D5 P0090 2 253 32768 0 RPD
eUn6Rmp dropped rapidly
The fuel metering
DFC_RailM
unit setting is
259 eUn7MeUn 520243 23 P00D6 P1050 2 273 0 0 RPD
incredible in the
SetPlaus
overspeed mode
DFC_RailM
Fuel metering unit
eUn8LowId
260 monitor error in the 520243 24 P00D7 P0251 2 274 0 0 RPD
lMeUn
low idle condition
Montr
Output voltage
value of remote
DFC_RmtAp
261 accelerator pedal 1 520277 3 P00E0 P1501 2 229 0 0 IO20ms
p1SRCMa x
exceeding the
upper limit
2-75

English Blink Model
SPN FMI UDS 15031
Output voltage
value of remote
DFC_RmtAp
p1SRCMi n
being less than the
lower limit
Output voltage
value of remote
DFC_RmtAp
p2SRCMa x
exceeding the
upper limit
Output voltage
value of remote
DFC_RmtAp
p2SRCMi n
being less than the
lower limit
Voltage of sensor
DFC_SSpM power supply 1
265 on1SRCMa exceeding the 3509 3 P00B2 P0643 2 112 0 0 IO20ms
x upper threshold
value
The voltage of
sensor power
DFC_SSpM
266 supply 1 is less 3509 4 P00B3 P0643 2 112 0 0 IO20ms
on1SRCMi n
than the lower
threshold value
Voltage of sensor
x upper threshold
value
The voltage of
sensor power
DFC_SSpM
on2SRCMi n
than the lower
threshold value
Voltage of sensor
x upper threshold
value
The voltage of
sensor power
DFC_SSpM
on3SRCMi n
than the lower
threshold value
DFC_stAirFl Replacement of air
271 107 7 P0072 P1051 3 564 32768 0 TI
tFoul filter
DFC_stFuel Replacement of
272 520289 11 P0071 P1048 3 563 32768 0 TI
Foul fuel filter
DFC_STGP Lock the vehicle
273 RSLCKMO and execute the 522014 1 P00F4 U1001 1 412 0 0 GPRS
D1 locking mode 1
DFC_STGP Lock the vehicle
274 RSLCKMO and execute the 522014 2 P00F5 U1002 1 413 0 0 GPRS
D2 locking mode 2
Replacement of
275 DFC_stOil 99 11 P0073 P1053 3 565 32768 0 TI
engine oil
DFC_stOilFl Replacement of oil
276 99 7 P0079 P1052 3 566 32768 0 TI
t filter
Power short circuit
DFC_StrtCD DOP_100
277 on low side of start 1675 3 P00DA P0617 2 121 0 3072
LSSCBat ms
motor relay
2-76

English Blink Model
SPN FMI UDS 15031
Short circuit on low
DFC_StrtCD DOP_100
278 side of start motor 1675 4 P00DB P0616 2 121 0 0
LSSCGnd ms
relay to earth
DFC_StrtCD Open circuit of start DOP_100
279 1675 5 P00DC P0615 2 121 0 0
NoLoad motor relay ms
DFC_T50C T50 turn-on time
280 520253 11 P00B8 P2530 1 345 0 0 IO20ms
DTimeOut exceeding the limit
The voltage of ECU
temperature
DFC_TECU
281 sensor is less than 1136 4 P002E P0668 1 119 0 0 IO100ms
SRCMax
the lower threshold
value
The voltage of ECU
temperature
DFC_TECU
282 sensor exceeds the 1136 3 P002D P0669 1 119 0 0 IO100ms
SRCMin
upper threshold
value
Adblue return pipe
(pump to tank)
DFC_UHtrB Not used
283 heating relay 4346 5 P00F8 P3021 9 461 32768 0
LOL at present
subject to open
circuit
Adblue return pipe
(pump to tank)
DFC_UHtrB Not used
284 heating relay short- 4346 3 P00F9 P3023 9 461 32768 3072
LSCB at present
circuited to power
supply
Adblue return pipe
DFC_UHtrB (pump to tank) Not used
285 4346 4 P00FA P3022 9 461 32768 0
LSCG heating relay short- at present
circuited to ground
Adblue pressure
pipe (pump to
DFC_UHtrP Not used
286 nozzle) heating 4344 5 P0055 P3024 9 462 32768 0
LOL at present
relay subject to
open circuit
Adblue pressure
pipe (pump to
DFC_UHtrP nozzle) heating Not used
287 4344 3 P0053 P3027 9 462 32768 3072
LSCB relay short- at present
circuited to power
supply
Adblue pressure
pipe (pump to
DFC_UHtrP Not used
288 nozzle) heating 4344 4 P0054 P3026 9 462 32768 0
LSCG at present
relay short-
circuited to ground
Adblue heating
DFC_UHtrRl Not used
289 main relay subject 523003 5 P0186 P3043 9 463 32768 0
yOL at present
to open circuit
Adblue heating
DFC_UHtrRl main relay short- Not used
290 523003 3 P0187 P3045 9 463 32768 0
ySCB circuited to power at present
supply
Adblue heating
DFC_UHtrRl Not used
291 main relay short- 523003 4 P0188 P3046 9 463 32768 0
ySCG at present
circuited to ground
Adblue suction
pipe (tank to pump)
DFC_UHtrS Not used
292 heating relay 4340 5 P004F P3028 9 464 32768 0
LOL at present
subject to open
circuit
2-77

English Blink Model
SPN FMI UDS 15031
Adblue suction
pipe (tank to pump)
DFC_UHtrS Not used
293 heating relay short- 4340 3 P004D P3032 9 464 32768 3072
LSCB at present
circuited to power
supply
Adblue suction
DFC_UHtrS pipe (tank to pump) Not used
294 4340 4 P004E P3031 9 464 32768 0
LSCG heating relay short- at present
circuited to ground
Adblue pot water
DFC_UHtrT heating solenoid Not used
295 3363 5 P0052 P3016 9 466 32768 0
nkOL valve subject to at present
open circuit
Adblue pot water
heating solenoid
DFC_UHtrT Not used
296 valve short- 3363 3 P0050 P3020 9 466 32768 3072
nkSCB at present
circuited to power
supply
Adblue pot water
DFC_UHtrT heating solenoid Not used
297 3363 4 P0051 P3019 9 466 32768 0
nkSCG valve short- at present
circuited to ground
The vehicle speed
DFC_VSSC 1 is greater than
298 84 0 P00B9 P0279 1 224 0 0 IO20ms
D1Max the maximum
threshold value.
The vehicle speed
1, fuel injection
DFC_VSSC
299 quantity and 84 2 P00BA P0501 3 224 0 0 IO20ms
D1Npl
engine speed are
incredible
Speed 3 signal
DFC_VSSC pulse width
300 1624 3 P00BB P2158 3 225 32768 0 IO20ms
D3Max exceeding upper
threshold
Speed 3 signal
DFC_VSSC pulse width below
301 1624 4 P00BC P2160 3 225 32768 0 IO20ms
D3Min the lower threshold
value
Vehicle speed
DFC_VSSC signal average
302 1624 8 P00BD P2161 3 225 32768 0 IO20ms
D3Sig period less than
threshold value
DFC_WrnO Open circuit of DOP_100
303 520250 5 P00C0 P1604 2 333 263 0
penLoad alarm lamp ms
DFC_WrnS Power short circuit DOP_100
304 520250 3 P00BE P1606 2 333 263 3072
CBat of alarm lamp ms
DFC_WrnS Short circuit of DOP_100
305 520250 4 P00BF P1607 2 333 263 0
CGnd alarm lamp to earth ms
The original value
of voltage of water
DFC_WtLvS
306 sensor in the oil 520264 3 P00E4 P2267 3 214 0 0 IO100ms
RClMax
exceeds the upper
threshold
The original value
of voltage of water
DFC_WtLvS
307 sensor in the oil is 520264 4 P00E5 P2266 3 214 0 0 IO100ms
RClMin
less than the lower
threshold
CAN
DFC_NetMn J1939DS
308 communication 522000 12 U0017 U0073 3 411 0 0
gCANAOf f M
error
2-78

English Blink Model
SPN FMI UDS 15031
The double
DFC_RmtA relationship of
309 520253 2 P0190 P1505 2 229 0 0 IO20ms
PP12Plaus remote accelerator
is incredible
DFC_RmtAc Credibility check of
310 cPedBrkPl remote accelerator 520277 7 P0191 P2299 2 226 0 0 IO20ms
aus and brake
Inconsistency
between key
DFC_ComG
311 message received 520218 14 U0056 U0138 0 561 0 0 GPRS
PSKeyErr
and key computed
by ECU
DFC_ComG key message
312 520218 19 U0057 U0138 0 562 0 0 GPRS
PSMsgTo timeout
DEC1 message
DFC_ComT
313 T50 signal 14161 31 U0059 U0107 1 234 32768 0 FrmMng
50StMaxEr r
reception error
Duration in which
engine speed
DFC_ComG
being 0 with T15
314 PSDrvCycl 520218 0 U0058 P0000 2 000 0 0 GPRS
not powered off
Idle
exceeding a certain
value
DFC_FrmM TCO1 message
315 522032 14 U005A U0100 1 236 505 3584 FrmMng
ngTCO1TO timeout
DFC_FrmM
TCO1 message
316 ngTCO1DL 522032 19 U005B U0100 1 468 505 3584 FrmMng
data length error
C
DFC_BrkNpl Unreliable brake
317 597 14 P0192 P0504 3 223 32768 3584 IO20ms
SngSwt signal
DFC_ClthSi Clutch signal from
318 598 19 P0193 PD400 3 222 32768 3584 IO20ms
g CAN error
DFC_GbxN Neutral CAN input
319 59 19 P0194 PD402 1 227 32768 3584 IO20ms
PosSig signal error
Improper operation
DFC_GearD of idle-sleep switch
320 520202 5 P0195 PD403 1 342 0 3072 IO20ms
etErr during ECU
powered on
CCVS message
DFC_FrmM
error during brake
321 ngRxCCVS 522030 17 U005C U0104 0 460 505 0 FrmMng
signal sent through
BrkCD
message path
CCVS message
DFC_FrmM
error during clutch
322 ngRxCCVS 522030 18 U005D U0104 0 460 505 0 FrmMng
signal sent through
ConvCD
message path
ETC1 message
DFC_FrmM
error during clutch
323 ngETC1Co 522022 18 U005E U0103 0 425 505 0 FrmMng
signal sent through
nvCD
message path
ETC1 message
DFC_FrmM
error during neutral
324 ngETC1Ge 522022 17 U005F U0103 0 425 505 0 FrmMng
signal sent through
arCD
message path
ETC2 message
DFC_FrmM
325 ngETC2Ge 522023 18 U0060 U0291 0 425 505 0 FrmMng
signal sent through
arCD
message path
2-79

English Blink Model
SPN FMI UDS 15031
DEC1 message
DFC_FrmM
326 ngDEC1Ge 522062 18 U0061 U0107 0 437 505 0 FrmMng
signal sent through
arCD
message path
DEC1 message
DFC_FrmM
error during T50
327 ngDEC1T5 522062 17 U0062 U0107 0 437 505 0 FrmMng
signal sent through
0CD
message path
DFC_AFWV High generator
328 523471 25 P0196 P0505 0 567 0 3072 AFW
ltgHigh generating voltage
DFC_AFWV Low generator
329 523471 26 P0197 PD405 0 567 0 3072 AFW
ltgLow generating voltage
DFC_BattVlt Battery voltage
330 523472 27 P0198 PD406 0 568 0 3072 AFW
gHigh high
DFC_BattVlt
331 Low battery voltage 523472 28 P0199 PD407 2 568 0 3072 AFW
gLow
2-80
3-1
June 9, 2020 Drive system
DW90A
Drive system
Basic information ...............................................................................................................3-3
Safety .....................................................................................................................................................3-3
Composition and location of drive system..............................................................................................3-4
Transmission system.........................................................................................................3-5
Double-intermediate-shaft Series Transmission Assembly....................................................................3-5
Main Section of Double-intermediate-shaft Series Transmission Assembly......................................3-5
Main performance parameters of ten-gear large-center-distance series transmission ......................3-5
Disassembling and assembling of double-intermediate-shaft series transmission ............................3-6
Single-box double-intermediate-shaft transmission assembly .............................................................3-47
Main Section of Single-box Double-intermediate-shaft Transmission Assembly .............................3-47
Main technical parameters of the eighth gear transmission assembly.............................................3-47
Disassembling and assembling of single-box double-intermediate-shaft transmission ...................3-48
Front, Intermediate and Rear Axle System .....................................................................3-71

Schematic Diagram of Front, Intermediate and Rear Axle System Assembly .....................................3-71
Bearing Axle System............................................................................................................................3-71
Front Axle Parameters .....................................................................................................................3-71
Nameplate........................................................................................................................................3-72
Assembly of the Front Axle ..............................................................................................................3-72
Drive axle system.................................................................................................................................3-88
Composition and location of drive axle system ................................................................................3-88
Parameters of Drive Rear Axle ........................................................................................................3-89
Identification instruction of drive axle assembly ...............................................................................3-89
Removal, installation and maintenance of drive axle hub ................................................................3-90
Removal, installation and maintenance of drive axle main reducer assembly...............................3-104
List of General Tools and Toolings ....................................................................................................3-117
List of Special Tools and Tooling ...................................................................................................3-117
Models and filling amounts of recommended lubricating oil and lubricating grease ..........................3-118
Balanced suspension assembly ....................................................................................3-119

Schematic Diagram of Balanced Suspension Assembly ...................................................................3-119
Main technical parameters of balanced suspension assembly ..........................................................3-120
Composition of balanced suspension assembly ................................................................................3-120
Assembling List of Balanced Suspension Assembly..........................................................................3-121
3-2
Drive system June 9, 2020
DW90A
Removal, installation and adjustment of balanced suspension assembly .........................................3-122

Removal of balanced suspension assembly ..................................................................................3-122
Assembling of balanced suspension assembly..............................................................................3-124
Installation and adjustment of balance shaft casing assembly ......................................................3-127
3-3
DW90A Safety
Basic information
Safety
Many accidents related to operation, maintenance and repair are caused by failure to observe basic
safety rules and safety precautions. These accidents are usually avoidable if potential hazards can be
fully observed. Operating personnel must pay attention to potential hazards, and must acquire
corresponding skills through necessary training to operate, maintain and repair the machine in a safe
and correct manner.
● Improper operation, maintenance and repair of the machine may cause hazards and personal injury
and even death.
● Before operation, maintenance and repair of the machine, operating personnel must read and
understand relevant safety precautions and notes.
● In the process of operation, maintenance and repair of the machine, please strictly observe safety
warning information listed in this Manual and on the machine; otherwise, major casualty accidents
may occur. The safety warning information in this Manual is marked with the following symbols:
It indicates an immediate hazard that will, if not avoided, lead to death or serious personal injury.
It indicates a potential hazard that will, if not avoided, lead to death or serious personal injury.
It indicates a potential hazard that will, if not avoided, lead to minor or moderate injury.
"Caution" is also used in this manual to indicate safety information relating to unsafe operations which
may cause personal injuries. "Danger" represents the most dangerous of conditions. The "Danger" or
"Warning" safety sign is set at a specific dangerous place. General notice information is included under
the safety sign"Caution.”
In addition, some other "Cautions" are also listed in this Manual. Please observe these cautions;
otherwise, your machine will suffer from great damage. The company does not list all possible hazards
(including potential ones). Warning information listed in this Manual and on the product does not cover
all hazardous matters. If you use tools, operation steps, operation methods or operation techniques
other than those specifically recommended by Liugong, you must ensure the safety of yourself and
others and ensure no harm to the machine.
This Manual is prepared based on the current situation of the machine at the time of preparation. Any
product is in the process of continuous improvement and the machine is no exception. Modifications will
affect the operation, maintenance and repair of the machine. For this reason, before operation,
maintenance and repair of the machine, please contact Liugong's dealer for the latest and most
comprehensive service information.
3-4
Composition and location of drive system DW90A
Composition and location of drive system
The transmission system, as the heart of DW90A, is of great importance. It is located between the
engine and the tire as their power transfer device. It ensures the traction force and speed required by the
vehicle under various driving conditions, as well as the coordination and change functions between
traction force and speed, so that the vehicle has good power performance and fuel economy. As shown
in the following figure, the bold part of the diagram of the transmission system position shows that the
transmission system is mainly composed of the gearbox and the front, intermediate and rear axle system
and the green part indicates the engine.
P2TT00001
3-5
June 9, 2020 Transmission system
DW90A Double-intermediate-shaft Series Transmission Assembly
Transmission system
Double-intermediate-shaft Series Transmission Assembly
Main Section of Double-intermediate-shaft Series Transmission Assembly
P2TT00002
Main performance parameters of ten-gear large-center-distance series transmission
Maximum
Transmissi Rated input Rated input Weight Weight Overall
input speed
on model power KW torque N.m (Kg) (Kg) length (mm)
rpm
10JSD220
380 2200 2600 310 14 873.4
(A, B)
3-6
Transmission system June 9, 2020
Double-intermediate-shaft Series Transmission Assembly DW90A
Disassembling and assembling of double-intermediate-shaft series transmission
Disassembling and assembling of gear shifting mechanism (double H assembly)
Disassembling of double H assembly

1. Left-handed single-lever double H assembly
P2TT00003
2. Remove three air ducts and two air filter bolts.
P2TT00004
3. Remove the four nuts on the double H assembly.
P2TT00005
4. Knock the double H assembly housing with a copper rod
to loosen it.
P2TT00006
3-7

5. Take down the double H control assembly from the
transmission, and remove the double H air valve and air
duct with an Allen wrench.
P2TT00007
6. Remove the reverse gear, neutral switch and pin
P2TT00008
7. Remove the gear shifting rocker arm, dust cover and
breather plug
P2TT00009
8. Remove the side plate and spring seats on both sides,
and take out the spring, positioning plunger and other
parts.
P2TT00010
3-8

9. Remove the bowl-shaped plug and the locking wire on
the fork head.
P2TT00011
10.Knock and remove the cylindrical pin with a tool.
P2TT00012
11.Remove the elastic pin on the reverse gear control block
P2TT00013
12.Remove the stop screw and take out the other set of
springs and spring seats in the double H housing to
prevent the springs from popping.
P2TT00014
3-9

13.Main components in the double H control assembly:
Fork head, reverse gear control block, spring, spring seat,
spacer bush and transverse shift lever
Note: One of the two springs near the inside of

the housing is slightly shorter.
P2TT00015
Assembling of double H assembly

1. Install the oil seal and apply grease to the cutting edge.
P2TT00016
2. Assemble the spring, spring seat and spacer bush in the
double H housing and lock them with stop screws.
P2TT00017
3. Assemble the spring pin on the locating ring and pay
attention to the orientation of the locating ring.
P2TT00018
3-10

4. Install the transverse shift lever into the housing and
assemble the elastic pin on the reverse gear control
block.
P2TT00019
5. Assemble the cylindrical pin on the fork head and lock it
with iron wires.
P2TT00020
6. Install the plungers, springs and spring seats on both
sides and lubricate the plungers initially.
P2TT00021
7. Assemble the spring seat and spring and install the side
plate.
P2TT00022
3-11

8. Assemble dust cover and shift rocker arm.
Note: Make sure that the rocker arm and the fork
head are in a straight line
P2TT00023
9. Install reverse gear and neutral gear switches and pins.
P2TT00024
10.Assemble the two set screws of double H valve with an
Allen wrench.
P2TT00025
3-12
Disassembling and assembling of upper transmission cover assembly
Disassembling of upper transmission cover assembly

1. Remove the bolts from the upper cover assembly.
P2TT00026
2. Tap the upper cover with a copper rod to separate it from
the bushing.
Note: Block the spring by hand to prevent it from

falling into the box.
P2TT00027
3. Remove the upper cover assembly from the
transmission and take out the shift self-locking steel ball
and spring.
P2TT00028
4. Remove the four studs.
P2TT00029
3-13

5. Turn over the upper cover assembly and remove the 3rd/
4th shift fork shaft, guide block and the 3rd/4th shift fork.
P2TT00030
6. Remove the 1st/2nd shift fork shaft, guide block, the 1st/
2nd shift fork and interlocking pin.
P2TT00031
7. Remove the reverse shift fork shaft and low reverse shift
fork.
P2TT00032
8. Fork shaft, interlocking steel ball and interlocking pin
P2TT00033
3-14
Assembling of upper transmission cover assembly

1. Assemble the reverse shift fork and fork shaft, tighten
bolts and bind them with iron wires.
P2TT00034
2. Install an interlocking steel ball
P2TT00035
3. Install the 1st/2nd shift fork shaft, guide block and the 1st/
2nd shift fork, tighten bolts and bind them with iron wires;
install interlocking pins and interlocking steel balls.
P2TT00036
4. Install the 3rd/4th shift fork shaft, guide block and the 3rd/
4th shift fork, tighten the bolts and bind them with iron
wires.
P2TT00037
3-15

5. Move the fork to the neutral position and assemble the
upper cover assembly.
P2TT00038
6. Assemble four studs and install self-locking steel balls
and springs.
Note: The spring inside the 3/4 shift fork shaft

hole is slightly thick
P2TT00039
Disassembling and assembling of auxiliary transmission assembly
Disassembling of Auxiliary Transmission Assembly

1. Mesh two sliding sleeves with the main transmission
gear.
P2TT00040
3-16

2. Remove the flange nuts of the flange with a dedicated
wrench.
P2TT00041
3. Remove the nuts from the rear cover housing.
P2TT00042
4. Push the auxiliary transmission assembly out for about
10mm with three bolts
P2TT00043
5. Pick up the auxiliary transmission assembly and move it
back to separate it from the main transmission.
P2TT00044
3-17

6. Remove the output flange and the odometer driving
gear.
P2TT00045
7. Remove the extended intermediate shaft cover and take
down the snap ring on the extended intermediate shaft
with a tool.
P2TT00046
8. Tap the extended intermediate shaft with a copper rod to
separate it from the bearing.
P2TT00047
9. Cut off the iron wires and remove the bolts on the fork of
the auxiliary transmission.
P2TT00048
3-18

10.Remove the bolts connecting the shift cylinder and the
rear cover, and take down the shift cylinder assembly.
P2TT00049
11.Remove auxiliary transmission synchronizer
P2TT00050
12.Knock the output shaft to remove it from the rear cover
housing
P2TT00051
13.Knock the output shaft to separate it with the bearing
P2TT00052
3-19

14.Remove the output bearing cover and tap it with a soft
rod to remove the outer bearing hole in the rear cover
housing hole.
Note: The assembly positions of the output

combination bearing are not interchangeable; the
bearing assembly shall be replaced if any part is
damaged.
P2TT00053
Disassembly and Assembly of Auxiliary Transmission Synchronizer

1. Auxiliary transmission synchronizer and its components
P2TT00054
2. Place the low-gear ring of the auxiliary transmission
synchronizer on a plane and put it into the synchronizer
sliding sleeve.
P2TT00055
3. Put the three springs into the high-gear ring holes and
apply a rotating force to match them with other parts of
the synchronizer.
P2TT00056
3-20
Disassembling of gear shifting cylinder of auxiliary transmission

1. Remove the four bolts on the cylinder head and remove
the cylinder head.
P2TT00057
2. Remove the self-locking nut from the piston.
P2TT00058
3. Piston of shift cylinder and three O-rings
P2TT00059
4. The piston plane shall face outwards during the
assembling of cylinder assembly.
P2TT00060
3-21
Assembling of auxiliary transmission assembly

1. Put the synchronizer on a wood block that is 50mm high,
with the low-gear ring upward, and insert the output
shaft
P2TT00061
2. Install the spindle washer and the spindle gear gasket of
the auxiliary transmission.
P2TT00062
3. Insert the convex surface of the reduction gear gasket
downward into the output shaft and lubricate the gasket
initially.
P2TT00063
4. Install the bearing inner ring into the extended
intermediate shaft of the auxiliary transmission.
P2TT00064
3-22

5. Make fitting marks on the shaft gear marked with "O" on
the extended intermediate shaft of the auxiliary
transmission.
P2TT00065
6. Make fitting marks on the reduction gear of the auxiliary
transmission in the direction of adjacent 180°, as shown
in the figure.
P2TT00066
7. Install the rear cover housing.
Note: If there is only one spline on the extended

intermediate shaft, the shaft shall be installed in the
lower right of the rear cover housing.
P2TT00067
8. Assemble the combination bearing and roller bearings
on the two extended intermediate shafts.
P2TT00068
3-23

9. Assemble stop rings on the two extended intermediate
shafts.
P2TT00069
10.Assemble output cover, odometer driven gear and
odometer connector.
P2TT00070
11.Assemble the two extended intermediate shaft covers.
P2TT00071
12.Assemble the cylinder housing.
P2TT00072
3-24

13.Assembling of cylinder piston
Note: The piston plane shall face upwards.
P2TT00073
14.Insert the shift fork of the auxiliary transmission into the
synchronizer sliding sleeve, assemble the bolts on the
fork shaft, and lock them with iron wires.
P2TT00074
15.Assemble the shift cylinder head, flange and flange nut.
P2TT00075
16.Place the auxiliary transmission synchronizer at the low-
gear area
P2TT00076
3-25

17.Grease the bearing holes of the front axle of the two
extended intermediate shafts. This step is crucial to the
assembly of the auxiliary transmission.
P2TT00077
18.Turn the flange by hand, push the auxiliary transmission
assembly forward to assemble the auxiliary transmission
assembly in place, and tighten the rear cover bolts.
Note: It is forbidden to forcibly assemble it via

knocking or other means.
P2TT00078
Disassembling and assembling of main transmission parts
Remove the clutch housing assembly
P2TT00079
3-26
Disassembling and assembling of auxiliary transmission drive gear assembly

1. Remove the stop ring at the rear end of the auxiliary
transmission drive gear, cut off the iron wire binding the
six bolts, and remove the six bolts of the positioning
plate.
P2TT00080
2. Push out the drive gear assembly with three bolts.
P2TT00081
3. Remove the retainer fixing ring and stop ring on the
auxiliary transmission drive gear, and knock the gear to
separate it from the bearing.
P2TT00082
4. Assembling of drive gear assembly
5. Place the drive gear horizontally and install the
positioning plate and bearing.
P2TT00083
3-27

6. Assemble the stop ring of the drive gear.
P2TT00084
7. Assemble the retainer fixing ring of the drive gear.
P2TT00085
Disassembling of reverse gear idle pulley assembly

1. Remove the stop ring inside the second shaft reverse
gear
P2TT00086
2. Offset the reverse gear with the low-speed gear of the
second shaft.
P2TT00087
3-28

3. Remove the bearing at the rear end of the reverse gear
idle pulley shaft with a professional tool
P2TT00088
4. Remove the reverse gear and offset it with the low-
speed gear of the second shaft.
P2TT00089
5. Remove the self-locking nut on the reverse gear idle
pulley shaft
P2TT00090
6. Pull out the reverse gear idle pulley shaft with a special
tool
P2TT00091
3-29

7. Reverse gear idle pulley assembly
P2TT00092
Disassembling and assembling of second shaft assembly

1. Remove the intermediate shaft brake assembly
P2TT00093
2. Remove the bearing baffle at the front end in the middle
of the main transmission.
P2TT00094
3. Remove the stop ring on the rear bearing of the
intermediate shaft of the main transmission
P2TT00095
3-30

4. Remove the rear bearing of the intermediate shaft with a
soft rod.
P2TT00096
5. Tap the intermediate shaft to move it back by about 10
mm.
P2TT00097
6. Knock the intermediate shaft from the rear to the front to
expose the bearing stop ring by at least 5 mm from the
housing, and remove the intermediate front bearing with
special tools.
P2TT00098
7. Take out the second shaft assembly from the main
transmission housing
P2TT00099
3-31

8. Remove the stop ring at the end of the second shaft
P2TT00100
9. Pull out the elastic pin on the second shaft.
P2TT00101
10.Pull out the long key.
P2TT00102
11.Remove each gear from the second shaft in turn.
P2TT00103
3-32

12.Assembling: Place the second shaft vertically upwards,
insert the adjusting pad into the second shaft with the
convex surface upwards, and put the long key after
turning of one pitch.
P2TT00104
13.Install the low-gear/reverse sliding sleeve, with the place
of missing gears facing the groove of the second shaft
with holes.
Note: The three sliding sleeves on the second

shaft are interchangeable.
P2TT00105
14.Install an adjusting pad with the convex surface
downwards and push the long key after the turning of
one pitch and put a spline pad.
P2TT00106
15.Install the low-speed gear into the second shaft, with the
engaging teeth downwards.
P2TT00107
3-33

16.Assemble the first gear onto the second shaft, with the
combined gear upward as well as a spline pad
P2TT00108
17.Install an adjusting pad with the convex surface upwards
and push the long key after the turning of one pitch.
P2TT00109
18.Install the sliding sleeve for the 1st/2nd gear, with the
place of missing gears facing the groove of the second
shaft with holes.
P2TT00110
19.Install an adjusting pad with the convex surface
downwards and push the long key after the turning of
one pitch and put a spline pad.
P2TT00111
3-34

20.Install the second gear into the second shaft, with the
P2TT00112
21.Assemble the three gear onto the second shaft, with the
combined gear upward as well as a spline
P2TT00113
22.Install an adjusting pad with the convex surface upwards
and push the long key after the turning of one pitch.
P2TT00114
23.Knock the elastic pin into the small hole on the second
shaft and install the sliding sleeve for the 3rd/4th gear.
P2TT00115
3-35

24.Place the second shaft horizontally and install the
reverse gear and spline pad of the second shaft; install a
stop ring at the rear end of the second shaft, with the
opening of the stop ring staggered with the groove with
long keys.
P2TT00116
25.Inspection of the axial clearance of the second shaft:
Place the second shaft vertically, install the stop ring of
the reverse gear, assemble the drive gear assembly of
the upper auxiliary transmission and stop ring and check
the clearance (0.3-0.9 mm) between the reverse gear
and the drive gear with a feeler gauge.
P2TT00117
26.Check the axial clearance (0.13-0.3 mm) between the
low-speed and reverse gears of the second shaft and
the second and third gears.
P2TT00118
3-36
Disassembling of main transmission parts

1. Loosen the six bolts on the bearing cover of the first
shaft and take down the first shaft cover.
P2TT00119
2. Remove the stop ring on the first shaft bearing, knock
the shaft head, and take out the first shaft assembly from
the housing.
P2TT00120
3. Remove the nuts of the first shaft with special tools
P2TT00121
4. Remove the intermediate shaft assembly from the main
transmission housing.
P2TT00122
3-37
Assembling of main transmission parts

1. Assemble the reverse gear idle pulley (with its convex
side facing forwards) together with the thrust washer of
the reverse gear shaft into the housing
P2TT00123
2. Assemble the idle pulley shaft of the reverse gear.
Note: The cup-shaped washer hole is eccentric,

with the assembly direction unique. Do not knock it.
P2TT00124
3. Assemble the gasket and tighten the self-locking nut at
the front end of the idle pulley shaft of the reverse gear.
P2TT00125
4. Mark the teeth that are directly facing the key grooves of
the constant meshing gear of the intermediate shaft
assembly
P2TT00126
3-38

5. Place the assembly of the two intermediate shafts into
the main transmission housing.
Note: The size of the power take-off gear on the

two intermediate shafts is different, and the
intermediate shaft with smaller power take-off gear is
installed on the upper right side of the housing.
P2TT00127
6. Install the guide sleeve of the second shaft into the inner
hole of the first shaft.
P2TT00128
7. Install the stop ring of the first shaft.
P2TT00129
8. Insert the first shaft gear into the first shaft and install the
gear spacer of the first shaft.
P2TT00130
3-39

9. Assemble the first shaft bearing in place with the side of
the oil baffle disc facing upwards.
P2TT00131
10.Apply anaerobic adhesive to the threads of the first shaft
nut, tighten the first shaft nut and tie it to prevent
loosening.
P2TT00132
11.Select two sets of teeth for fitting marking in the 180°
direction of the first shaft gear.
P2TT00133
12.Place the first shaft assembly into the main transmission
housing.
P2TT00134
3-40

13.Insert the teeth with marks of the intermediate shaft into
the tooth grooves with marks of the first shaft gear, and
assemble the rear bearing of the intermediate shaft
position it with the stop ring
P2TT00135
14.Assemble the front bearing of the intermediate shaft
P2TT00136
15.Assemble the stop ring on the first shaft bearing
P2TT00137
16.Grease the inner hole of the first shaft (initial
lubrication).
P2TT00138
3-41

17.Place the second shaft assembly into the main
transmission, and position the rear end initially with drive
gear.
P2TT00139
18.Insert the other teeth with marks of the intermediate
shaft into the tooth grooves with marks of the first shaft
gear
P2TT00140
19.Assemble the bearing at the rear end of the
intermediate shaft and position it with stop ring.
P2TT00141
20.Assemble the bearing at the front end of the
intermediate shaft and assemble the pressure plate of
the intermediate shaft.
Note: Fastening bolts of the pressure plate shall

be coated with anaerobic adhesive.
P2TT00142
3-42

21.Assemble the other idle pulley assembly of the reverse
gear and tighten the self-locking nut.
P2TT00143
22.Pull back the reverse gear of the second shaft to mesh it
with the idle pulley of the reverse gear, remove the drive
gear assembly and assemble the stop ring of the
reverse gear.
P2TT00144
23.Assemble the drive gear and the front bearing of the two
intermediate shafts of the auxiliary transmission. The six
screws on the positioning plate shall be tied with iron
wires.
P2TT00145
24.Assemble the intermediate shaft brake assembly
P2TT00146
3-43
Method of removing the main transmission and replacing the first shaft

1. Mesh the two sets of gears in the main transmission with
the sliding sleeve.
P2TT00147
2. Remove the nuts of the first shaft with special tools(left-
handed rotation)
P2TT00148
3. Knock the first shaft inward with copper rod
P2TT00149
4. Tap the first shaft from side to side with a copper bar to
separate the first shaft bearing from the first shaft.
P2TT00150
3-44

5. Remove the first shaft gear spacer
P2TT00151
6. Pull out the stop ring in the first shaft gear with a ball
screwdriver.
P2TT00152
7. Take out the first shaft for corresponding inspection.
P2TT00153
8. Assembling: Take the new first shaft and install it into the
guide sleeve of the second shaft and grease the hole.
P2TT00154
3-45

9. Install the first shaft into the first shaft gear hole and
assemble a stop ring.
P2TT00155
10.Assemble the first shaft gear spacer
P2TT00156
11.Mesh the sliding sleeve for the 3rd/4th gear of the second
shaft with the teeth of the first shaft, and counter it with a
soft rod.
P2TT00157
12.Assemble the first shaft bearing in place
P2TT00158
3-46

13.Apply anaerobic adhesive to the threads of the first shaft
nut.
P2TT00159
14.Tighten the first shaft nut with a special tool (left-handed
rotation).
P2TT00160
15.Rivet the first shaft nut at the thread groove of the first
shaft firmly
P2TT00161
16.Install the six bolts of the first shaft cover.
P2TT00162
3-47
DW90A Single-box double-intermediate-shaft transmission assembly
Single-box double-intermediate-shaft transmission assembly
Main Section of Single-box Double-intermediate-shaft Transmission Assembly
P2TT00163
Main technical parameters of the eighth gear transmission assembly
Transmission model Maximum input torqueN.m Maximum input speed rpm

8DS240A 2400 2600
3-48
Single-box double-intermediate-shaft transmission assembly DW90A
Disassembling and assembling of single-box double-intermediate-shaft

transmission
Disassembling and assembling of gear shifting mechanism
Disassembling of gear shifting mechanism

1. Gearbox assembly
P2TT00164
2. Remove the four bolts on the double H assembly and
remove the double H assembly.
P2TT00165
3. Remove the reverse and neutral switches and the
breather plug.
P2TT00166
4. Remove the gear selector fork head assembly.
P2TT00167
3-49

5. Remove the three screws on the shift rocker arm and
joint.
P2TT00168
6. Remove the spline sleeve, joint and shift joint.
P2TT00169
7. Remove the four bolts on the side plate and take out the
spring and spring seat.
P2TT00170
8. Remove the stop screw from the double H housing.
P2TT00171
3-50

9. Remove the fastening wire from the fork head.
P2TT00172
10.Knock and remove the cylindrical pin on the fork head.
P2TT00173
11.Remove the elastic cylindrical pin on the reverse gear
control block
P2TT00174
12.Remove the elastic cylindrical pin on the limit sleeve of
the transverse shift lever, take out the transverse shift
lever, and take out the spring and spring seat in the
housing.
P2TT00175
3-51
Installation of gear shifting mechanism

1. Assembling: Install the spring and spring seat into the
housing in sequence.
P2TT00176
2. Install the spacer bush and tighten it with stop screws.
P2TT00177
3. Insert the reverse gear control block and the fork head
sequentially into the transverse shift lever, and install the
elastic cylindrical pin of the limit sleeve of the transverse
shift lever.
P2TT00178
4. Install the elastic cylindrical pin on the reverse gear
control block.
P2TT00179
3-52

5. Install the cylindrical pin on the fork head and fasten it
with iron wires.
P2TT00180
6. Install the side cover on the side and the spring and
spring seat in the housing.
P2TT00181
7. Assemble the four bolts on the end cover.
P2TT00182
8. Assemble the gear selector fork head assembly.
Note: The gear selector fork head shall be

installed in the groove of the gear shift fork head.
P2TT00183
3-53

9. Tighten the four bolts on the cover of the gear selector
fork head assembly.
Note: The position of the black bolt with guide

part is fixed.
P2TT00184
10.Place the double H assembly vertically and install it into
the spline sleeve.
Note: The position of the side with holes shall be

aligned with the neutral switch hole.
P2TT00185
11.Assemble the joint, shift joint and shift rocker arm.
P2TT00186
12.Assemble the reverse and neutral switches and the
breather plug.
P2TT00187
3-54
Disassembling and assembling of upper transmission cover assembly
Disassembling of upper transmission cover assembly

1. Remove the fastening bolts of the upper cover.
P2TT00188
2. Knock the upper cover housing and remove the upper
cover assembly.
Note: Block the spring by hand to prevent it from

popping.
P2TT00189
3. Take out the spring and steel ball of the upper cover
housing hole.
P2TT00190
4. Turn over the upper cover and remove the reverse shift
fork shaft, guide block and reverse shift fork.
P2TT00191
3-55

5. Remove the 2nd/3rd shift fork shaft and the 2nd/3rd shift
fork, and take out the interlocking steel ball and
interlocking pin.
P2TT00192
6. Remove the 4th/5th shift fork shaft, 4th/5th shift fork and
guide block, and take out the interlocking steel ball and
interlocking pin.
P2TT00193
7. Remove the 6th/7th shift fork shaft, 6th/7th shift fork and
guide block, and take out the interlocking steel ball.
P2TT00194
3-56
Assembling of upper transmission cover assembly

1. Install the 6th/7th shift fork shaft, the 6th/7th shift fork and
the guide block, tighten the bolts on the shift fork, bind
them with iron wires, and put the interlocking steel balls.
P2TT00195
2. The position of the interlocking pin on the4/5 shift fork
shaft
P2TT00196
3. Install the 4th/5th shift fork shaft, the 4th/5th shift fork and
P2TT00197
4. Install the 2nd/3rd shift fork shaft, the 2nd/3rd shift fork and
P2TT00198
3-57

5. Install the reverse shift fork shaft, guide block and
reverse shift fork, tighten the bolts on the shift fork and
guide block, and bind them with iron wires.
P2TT00199
6. Assemble the upper cover assembly and tighten the
bolts on the upper cover.
P2TT00200
7. Install the four locating springs and steel balls on the
upper cover.
P2TT00201
3-58
Disassembling of main transmission parts

1. Take down the bolts on the clutch housing, and remove
the clutch housing
P2TT00202
2. Remove the first shaft cover.
P2TT00203
3. Mesh the two sets of teeth in the main transmission
respectively with the sliding sleeve (the lever is pushed
into two gear positions).
P2TT00204
4. Remove the bolts of the front baffle of the two
intermediate shafts.
P2TT00205
3-59

5. Take out the first shaft assembly from the front (refer to
the disassembly and assembly part of the double-
intermediate-shaft transmission for the structure of the
first shaft).
P2TT00206
6. Remove the flange nut on the output shaft with a special
labor-saving spanner
P2TT00207
7. Remove the flange and the flange nut.
P2TT00208
8. Remove the two extended intermediate shaft covers.
P2TT00209
3-60

9. Remove the output bearing cover and the spacer bush
on the output shaft, and disassemble the output bearing
cover assembly.
P2TT00210
10.Remove the stop ring on the output bearing.
P2TT00211
11.Remove the bolts on the rear cover housing
P2TT00212
12.Push out the rear cover housing with two jack screws.
P2TT00213
3-61

13.Remove the rear cover housing, loosen the self-locking
nut on the idle pulley of the reverse gear and remove the
idle pulley assembly of the reverse gear.
P2TT00214
14.Remove the bearings at the end of the two intermediate
shafts
P2TT00215
15.Move the second shaft assembly backward and take the
second shaft assembly out of the housing.
P2TT00216
16.Remove the bearing and spacer bush at the rear end of
the second shaft.
P2TT00217
3-62

17.Pull out the long key from the rear end of the second
shaft.
P2TT00218
18.Pull out the elastic pin at the front end of the second
shaft and remove the parts on the second shaft.
P2TT00219
19.Remove the two bearings at the front end of the
intermediate shaft and take out the two intermediate
shafts from the housing.
P2TT00220
3-63

1. Install the two reverse gear intermediate shafts into the
holes of the housing.
P2TT00221
2. Mark the teeth that are directly facing the key grooves of
the two intermediate shafts and mark in the rear groove
respectively
P2TT00222
3. Place the two intermediate shaft assemblies into the
housing and assemble the front bearing.
P2TT00223
4. Select two sets of teeth in the 180° direction of the first
shaft gear assembly for fitting marking.
P2TT00224
3-64

5. Assemble the first shaft assembly and align the teeth.
P2TT00225
6. Assemble the second shaft assembly. Place the second
shaft vertically on the workbench and install it into the
adjusting pad of the reverse gear with the convex
surface upwards, and insert the long key into a selected
groove after the turning of one pitch.
P2TT00226
7. Install the sliding sleeve of the first/reverse gear, with the
notch aligned with the groove with a long key; install the
adjusting pad and spline pad of the first gear tooth, and
put the long key upwards after the turning of one pitch.
P2TT00227
8. Install the first gear teeth of the second shaft with the
P2TT00228
3-65

9. Install the 2nd/3rd gear spacer bush with the notch
aligned with the groove with a long key.
P2TT00229
10.Assemble the second gear teeth of the second shaft
with the engaging teeth upwards, assemble the
adjusting pad and the spline pad of the second gear
teeth, and penetrate the long key upwards after the
turning of one pitch
P2TT00230
11.Install the sliding sleeve for the 2nd/3rd gear, with the
notch aligned with the groove with a long key; install the
2nd/3rd gear baffle with the convex face downwards.
P2TT00231
12.Install the third gear teeth of the second shaft with the
P2TT00232
3-66

13.Install the fourth gear teeth of the second shaft with the
engaging teeth upwards, install the adjusting pad and
spline pad of the fourth gear tooth, penetrate the long
key upwards into the groove with holes after the turning
of one pitch and then pull out the long key.
P2TT00233
14.Install the sliding sleeve for the 4th/5th gear, with the
notch aligned with the groove with holes; install the
adjusting pad and spline pad of the fifth gear tooth,
penetrate the long key downwards after the turning of
one pitch and then pull out the long key.
P2TT00234
15.Install the fifth gear teeth of the second shaft with the
P2TT00235
16.Install the sixth gear teeth of the second shaft with the
engaging teeth upwards, put the adjusting pad and the
spline, and penetrate the long key into the groove with
holes after the turning of one pitch.
P2TT00236
3-67

17.Install an elastic cylindrical pin in the small hole at the
front end of the second shaft.
P2TT00237
18.Install the 6th/7th gear spacer bush with the notch

aligned with the groove with a long key.
P2TT00238
19.Place the second shaft horizontally, and install the spline
pad of the reverse gear of the second shaft, the reverse
gear and the reverse gear baffle of the second shaft
from the rear end.
P2TT00239
20.Move the second shaft assembly forwards from the rear
end of the housing in parallel and align the teeth (for the
convenience of assembly, fitting marks are usually made
on the first gear teeth of the second shaft to match with
the marks in the groove at the rear end of the
intermediate shaft).
P2TT00240
3-68

21.Assemble two idle pulley assemblies of the reverse
gear.
P2TT00241
22.Assemble the rear bearings of the two intermediate
shafts and the rear bearing of the second shaft
respectively.
P2TT00242
23.Assemble the rear cover housing in place and install the
stop ring on the rear bearing of the second shaft.
P2TT00243
24.Tighten the bolts on the rear cover housing
P2TT00244
3-69

25.Assemble the rear bearing covers of the two
intermediate shafts
P2TT00245
26.Install the rear bearing cover of the second shaft and
place the driven gear of the odometer.
P2TT00246
27.Assemble the odometer joint
P2TT00247
28.Install the flange and the flange nut
P2TT00248
3-70

29.Apply anaerobic adhesive to the baffle bolt of the
intermediate shaft.
P2TT00249
30.Assemble the baffles of the two intermediate shafts.
P2TT00250
31.Install the bearing cover of first shaft
P2TT00251
32.Install the clutch housing
P2TT00252
3-71
June 9, 2020 Front, Intermediate and Rear Axle System
DW90A Schematic Diagram of Front, Intermediate and Rear Axle System Assembly
Front, Intermediate and Rear Axle System
Schematic Diagram of Front, Intermediate and Rear Axle System

Assembly
P2TT00253
Bearing Axle System
Front Axle Parameters
The front axle of DW90A wide-body vehicle mainly plays the role of bearing and steering. The schematic
diagram and system technical parameters are as follows:
P2TT00254
S/N Item Parameter

1 Rated axle load (kg) 20000
2 Toe-in 2-5
3 Kingpin inclination 5
4 Kingpin caster 2.5
5 Front wheel camber 1
6 Brake specifications Φ500X220
7 Wheel installation method 12-M25X1.5; pitch diameter: Φ450
3-72
Front, Intermediate and Rear Axle System June 9, 2020
Bearing Axle System DW90A
Identification instruction of front shaft assembly
P2TT00255
Nameplate
The nameplate shall contain the following information:

1. Axle No.: for example, HDZ20T04002**** means the front axle assembly No.;
2. Shaft load: like 20,000 kg, representing the rated load of the axle assembly;
3. Production sequence number: like X140907108, composed of 1 capital letter and 9 digits;
Note: The capital letters represent the assembly line code of the axle assembly, the first 4 digits
represent the manufacturing year and month of the axle assembly, and the last 5 digits represent the
serial number of the axle assembly.
Assembly of the Front Axle
Disassembling of front shaft assembly

1. Remove the tie rod:
1) Remove the cotter pin with the copper rod;
P2TT00256
3-73
DW90A Bearing Axle System

2) Remove the hexagon slotted nut with spanner and
take out the steering tie rod.
P2TT00257
2. Remove the brake:
1) Remove the cross recessed countersunk head screw
fastening the brake drum with a cross head
screwdriver.
P2TT00258
2) Push out the brake drum diagonally with two M12×1.5
bolts.
Requirement: Check the brake drum for cracks and
excessive wear.
P2TT00259
3. Remove the hub:
1) Remove the bolts on the hub end cover with a wrench;
P2TT00260
3-74

2) Loosen the hexagon socket head cap screw with an
internal hexagonal wrench;
P2TT00261
3) Remove the locking nut with the tool XZ-783-160015;
P2TT00262
4) Remove the thrust washer
P2TT00263
5) Remove the hub assembly with tools BM-783-150254
and XZ-783-160654;
P2TT00264
3-75

6) Remove the inner ring of the inner bearing of the hub
with tools BZ-783-151722 and XZ-783-160654.
P2TT00265
7) Remove the outer ring of the outer bearing of the hub
P2TT00266
8) Remove the outer ring of the inner bearing of the hub
P2TT00267
4. Disassemble the brake assembly:
1) Remove the bolts on the braking plate with a wrench;
2) Remove the brake assembly and the shaft head.
P2TT00268
3-76

3) Remove the brake assembly and the shaft head.
P2TT00269
5. Disassemble the steering knuckle:
1) Remove the bolts on the steering knuckle arm
assembly and steering actuation cylinder arm with a
wrench;
P2TT00270
2) Remove the bolts under the tie rod arm with a wrench
and remove the tie rod arm.
P2TT00271
3) Remove the bolts on the steering knuckle assembly
with a wrench, and remove the steering knuckle
assembly and shaft sleeve.
Requirement: Check the bushing for excessive wear.
P2TT00272
3-77
Installation of steering knuckle assembly

1. Press the bushing into the tie rod arm in place with tool
BZ-783-150089.
P2TT00273
2. Press the bushing into the shaft sleeve in place with tool
BZ-783-150089.
P2TT00274
3. Install the protection sheet and sealing ring into the
steering knuckle to distinguish the left and right of the
steering knuckle according to the traveling direction,
remove the bearing cover from the steering knuckle
assembly, install the shaft sleeve and apply grease, and
then install the steering knuckle onto the king pin.
P2TT00275
4. Install the seal ring and protection sheet at the steering
knuckle hole.
P2TT00276
3-78

5. Install the steering knuckle assembly on the kingpin in a
complete set, and initially pretighten the steering knuckle
bearing cap with the fastening bolt.
P2TT00277
6. Apply grease to the circumference of the inner hole of
the thrust bearing and install the tapered roller thrust
bearing below the king pin. Note: During the pressing
and mounting, the tension ring of the thrust bearing shall
face the front axle assembly.
P2TT00278
7. Install the locating sleeve on the tie rod arm assembly,
and then install it under the steering knuckle. Apply
thread locking agent to the threaded surface of the
toothed bolt of the hexagonal flange face and tighten it in
place.
Requirement: tightening torque (500±30) Nm
P2TT00279
8. Clean the cover mating face, and apply a layer of
sealant to the face.
P2TT00280
3-79

9. Fasten the cover plate to the track rod arm.
P2TT00281
10.Install appropriate adjusting shims on the upper end
face of the shaft sleeve assembly to adjust the axial
clearance of the steering knuckle.
P2TT00282
11.Initially pretighten the steering knuckle arm (left side) or
steering booster cylinder arm (right side) with hexagon
head bolts.
P2TT00283
12.Use a feeler gauge to detect the clearance between the
axle sleeve assembly and the front axle with the
required clearance of ≤ 0.2 mm. if the clearance is not
proper, the required clearance can be realized by
changing the adjusting shim thickness.
P2TT00284
3-80

13.Remove fastening bolts of steering knuckle arm (left
side) or steering booster cylinder arm (right side).
P2TT00285
14.Apply thread locking agent to the threaded surface of
the bolt and tighten it in place. Requirement: tightening
torque (500±30) Nm
P2TT00286
15.Tighten the steering knuckle arm assembly and steering
actuation cylinder arm on the steering knuckle
respectively with hexagon-head bolts coated with thread
locking agent.
Requirement: tightening torque (500±30) Nm
P2TT00287
3-81
Installation of wheel side assembly

1. Assembly of spindle head and brake:
1) After aligning the shaft head with the steering knuckle
hole, install the shaft head in place;
P2TT00288
2) Tighten the brake bottom plate bolt with the tightening
torque of 500 Nm;
P2TT00289
3) Clean the camshaft S-surface, and install the
additional shim and the O-ring in a complete set at the
side of camshaft closer to S-surface.
P2TT00290
4) After the camshaft support assembly is padded and
the hexagon-head bolt is coated with thread locking
agent, tighten the camshaft support assembly to the
steering knuckle;
Requirement: tightening torque (240±20) Nm;
P2TT00291
3-82

5) Support the brake shoe on the brake shoe supporting
pin, and hang the brake return spring. Use a crow bar
to hang the brake return spring, and thread in the
brake return spring pin;
P2TT00292
6) Install the roller, install 2 brake return spring supporting
pins into the slot, and ensure that installation is in
place
P2TT00293
7) Install the roller snap spring
P2TT00294
8) Set the gap adjusting arm onto the brake camshaft,
and then install the washer, adjusting shim and the
spring collar for shaft use in place in sequence;
P2TT00295
3-83

9) Measure axial clearance of the adjustment arm as 0.5-
1.0 mm. The axial clearance can be adjusted by
changing the thickness of the adjusting shim.
P2TT00296
2. Installation of hub brake drum and hub:
1) Align the outer ring of the tapered roller bearing on the
outer side of the hub with the hole position and press
and mount it in place with tool XZ-783-160013;
P2TT00297
2) Align the inner ring of the tapered roller bearing on the
oil seal side of the hub with the hole position and press
and mount it in place with tool XZ-783-160012;
P2TT00298
3) Apply a layer of sealant to the mounting hole of hub oil
seal, align the oil seal with the hole position, and press
and mount it in place with tool XZ-783-160014; press
and amount 12 wheel bolts in place in sequence.
Note: The bolt shall be aligned with the hub seam

allowance, and the hub shall be fitted to the wheel bolt
mounting plane.
P2TT00299 P2TT00300
3-84

4) Grease the outer rings of the two bearings, and apply
grease to the inner ring rollers of the bearings and the
cavities of the retainer respectively and place them in
the outer rings;
Requirement: Grease the inner ring and outer ring of the
wheel bearing on each side.
P2TT00301
5) Clean the steering knuckle journal and evenly apply a
layer of lubricating oil; install the spacer in place;
P2TT00302
6) Heat the inner ring of the hub inner bearing and install
it on the steering knuckle shaft head, and apply
lubricating oil on the raceway and ball of the inner
bearing ring.
P2TT00303
7) Align the assembled hub assembly with the hole
position and install the inner ring of the tapered roller
bearing in place with tool XZ-783-160011.
P2TT00304
3-85

8) Install a thrust washer on the spindle head.
P2TT00305
9) Tighten the locking nut with the tool of XZ-783-160015.
At the same time, turn the hub by 2~3 rounds and
tighten the locking nut again. After tightening, loosen
the locking nut by 60°~90°.
Requirement: Tightening torque: (275±25) Nm.
P2TT00306
10) Tighten the hexagon socket head cap screws to the
specified torque with an internal hexagonal wrench;
P2TT00307
11) Pull the wheel bolts at a constant speed
perpendicular to the radial direction of the hub with a
spring balance, measure at least three bolts at about
120°, and measure the pre-tightening force of the hub
bearing to determine whether it is within 70~90N. If it
does not meet the requirements, make adjustment by
tightening or loosening the locking nut.
P2TT00308
3-86

12) Wipe the hub and the mounting surface of the end
cover with cotton cloth dipped in gasoline, and apply
sealant to the mating surface of the hub mounting end
cover.
Requirement: The sealant shall be applied evenly and
continuously in a closed way.
P2TT00309
13) Screw the hub end cover into the hub and tighten it.
P2TT00310
3. Adjustment of brake clearance:
1) After cleaning the connection surface between the hub
and the brake drum, align the hole, install the brake
drum in a complete set on the hub, and tighten the
brake drum with the cross recessed countersunk head
screw.
P2TT00311
2) Use a S12 wrench to adjust the brake clearance,
tighten the adjustment arm adjusting screw clockwise
till it is to the extreme position, and loosen the
adjustment arm for 3 threads anticlockwise.
P2TT00312
3-87

3) Open the sealing plug and measure the clearance
between the shoe and drum with a feeler gauge;
Requirement: the clearance between the shoe and drum:
(0.3-1.1)mm; the difference between maximum clearance
and minimum clearance on one side of the hub: ≤0.30mm.
P2TT00313
Installation of steering tie rod

1. Apply a proper amount of grease to the taper hole of the
steering tie rod arm, install the steering tie rod assembly
on the steering tie rod arm, and tighten it with hexagonal
slotted nuts.
Requirement: tightening torque: (400±40)Nm.
Adjust toe-in requirements by rotating the tie rod: The toe-in
value shall be adjusted according to vehicle parameters.
P2TT00314
2. Tighten the clamp locking bolts.
Note: The clamp opening should be consistent

with the slotting direction of the rod. The required bolt
tightening torque is 165 N·m.
P2TT00315
3-88
Drive axle system DW90A
Drive axle system
Composition and location of drive axle system
The drive axle system of DW90A wide body vehicle is mainly composed of the intermediate axle and the
rear axle. Through the main drive and hub deceleration, the speed input from the transmission is
reduced and the torque is increased, so as to meet the requirements of the driving and working speed as
well as traction of the main engine. Meanwhile, the drive axle converts the movement in the straight-line
direction to the movement in the longitudinal/transverse directions through the main drive, thus driving
the drive wheels to rotate. As a result, the vehicle can run in the straight-line direction. In addition, a
speed difference between left and wheel tires is obtained via differential, to ensure that the vehicle can
still run properly when the resistance on both sides is different.
In addition to completing its basic functions, the drive axle of DW90A wide body vehicle is also the load-
bearing device of the engine, the supporting device of traveling wheels, the installation and supporting
device of service brake. The drive axle system is mainly composed of the intermediate axle and rear axle
as well as its brake pipelines.
The schematic diagram and technical parameters of the drive axle system are as follows.
The schematic diagram of the intermediate axle of the drive axle system and the technical parameters of
the system are as follows:
P2TT00316
Item Parameter
Rated axle load (kg) 35000
Speed ratio 10.723, 11.70, 12.87, 14.298, 16.086
Hub speed ratio 3.478
Brake specification (mm) Φ500X200
Wheel installation method Tire bolt:12-M24X1.5; pitch diameter: Φ425
3-89
DW90A Drive axle system
Parameters of Drive Rear Axle
The schematic diagram of the rear axle of the drive axle system and the technical parameters of the
system are as follows:
P2TT00317
Item Parameter
Rated axle load (kg) 35000
Speed ratio 10.723, 11.70, 12.87, 14.298, 16.086
Hub speed ratio 3.478
Brake specification (mm) Φ500X200
Wheel installation method Tire bolt:12-M24X1.5; pitch diameter: Φ425
Identification instruction of drive axle assembly
P2TT00318
The nameplate shall contain the following information:

1. Axle No.: For example, HDZ35T7314860** indicates the number of the through-type single-stage
reduction drive axle assembly; HDZ35T7315860** indicates the number of the single-stage reduction
drive axle assembly;
2. Speed ratio: total transmission ratio of axle assembly;
3. Shaft load: like 35,000kg, representing the rated load of the axle assembly;
4. Production sequence number: like X141200379, composed of 1 capital letter and 9 digits;
Note: The capital letters represent the assembly line code of the axle assembly, the first 4 digits
represent the manufacturing year and month of the axle assembly, and the last 5 digits represent the
serial number of the axle assembly.
3-90
Removal, installation and maintenance of drive axle hub
Removal and installation of brake drum
Remove the brake drum.

1. Remove the 3 sunk screws with a cross screwdriver.
P2TT00319
2. Push the brake drum out at the jackscrew hole (2) with a
fastening screw.
P2TT00320
3. Remove the brake drum.
P2TT00321
3-91
Install the brake drum.

1. Check the brake drum for cracks and excessive wear.
P2TT00322
2. Install the brake drum, and tighten it with 3 sunk screws.
P2TT00323
Removal and installation of hub reducer assembly
Remove the hub reducer

1. Turn the oil drain port to the right below. Remove the
drain plug with a wrench to drain out the hub lubricating
oil.
P2TT00324
3-92

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.
P2TT00325
3. Take out the sun gear, and pull out the axle shaft.
P2TT00326
4. Remove connecting bolts of the hub reducer with a
cross screwdriver.
P2TT00327
5. Diagonally push out the hub reducer at the jackscrew
hole (1) with fastening screws, and remove the hub
reducer assembly.
P2TT00328
3-93

6. Remove the 5 connecting bolts of the hub reducer with a
socket wrench.
P2TT00329
7. Knock out the 5planetary shafts evenly distributed on the
hub reducer with a copper rod, and remove the planet
carrier.
P2TT00330
8. 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.
Note: Guarantee that the joint surface is not damaged.
P2TT00331
Sub-assembling and installation of hub reducer assembly

1. Press to install 5 planet shafts with the opening of the
hub reducer shell facing upward.
P2TT00332
3-94

2. Assemble 5 planet gear gaskets on the planet shaft.
P2TT00333
3. Assemble the needle bearing assembly and the planet
gears on the planet shaft in turn.
P2TT00334
4. Take 5 washers (with oil groove facing downward) and
respectively assemble them on the planet shaft. Put one
thrust washer on the middle.
P2TT00335
5. Take one matching planet carrier and align it to the hub
reducer shell. Press to install it in place. The planet
carrier and the hub reducer shell must be matched for
installation and replaced in pair.
P2TT00336
3-95

6. Tighten with bolts coated with thread locking agent. The
tightening torque of bolts is 300±30Nm. The planetary
gears are required to rotate flexibly.
P2TT00337
7. Assemble the sub-assembled hub reducer assembly
with the hub, and tighten with sunk screws.
P2TT00338
Removal and Installation of Gear Ring Support and Hub
Remove the gear ring bracket and hub

1. Remove the cross recessed countersunk flat head
screws (4), and remove the outer shaft head nut (3),
thrust washer (2) and inner shaft head nut (1) in order.
P2TT00339
3-96

2. Remove the shaft head nuts with a special tool.
P2TT00340
3. Remove the gear ring and gear ring bracket, and take
out the circlip with circlip pliers.
P2TT00341
4. Remove the hub assembly from the axle housing shaft
head.
P2TT00342
5. Hub assembly
P2TT00343
3-97

6. Pull out the inner ring and space ring of the inner hub
bearing.
P2TT00344
Installation of gear ring bracket and hub assembly

1. Assemble the gear ring with the gear ring bracket, and
install the circlip in place with circlip pliers.
P2TT00345
2. Press to install the outer rings of the hub inner and outer
bearings.
P2TT00346
3. Press to install the combination oil seal of the hub.
P2TT00347
3-98

4. Press to install the oil drip pan.
Note: For 35-ton axles, the left and right hub oil seals are
the same.
P2TT00348
5. Press to install the tire bolts.
P2TT00349
6. Press to install the space ring to the axle housing shaft
head.
P2TT00350
7. Press to install the inner ring of the hub inner bearing to
the axle housing shaft head.
P2TT00351
3-99

8. Install the assembled hub assembly to the axle housing
spindle head, and install the inner ring of the hub outer
bearing.
P2TT00352
9. Install the gear ring and its bracket.
P2TT00353
10.Tighten the shaft head nuts, and adjust the pre-
tightening force of the hub bearing. Tighten the shaft
head inner nut 1 with a torque wrench; the tightening
torque is 1,000 Nm. While tightening the locking nut,
rotate the hub and vibrate it axially with a copper rod.
Loosen the shaft head inner nut for 1/6 thread, and
install the stop washer 2. Tighten the shaft head outer
nut 3; the tightening torque is 1,000 Nm.
P2TT00354
11.Rotate the hub. Pull the tire bolts with a spring scale
along the tangential direction of the hub. The pre-
tightening force is required to be 120-140 N. If suitable,
align the outer locking nut hole to the stop washer hole,
and screw the locking bolt 4 in the outer locking nut,
making the bolt head clamped into the stop washer hole.
If not suitable, properly change the looseness angle of
the shaft head inner locking nut for adjustment.
P2TT00355
3-100
Removal and installation of brake assembly
Remove the brake assembly

1. Remove the snap spring from the roller.
P2TT00356
2. Pry up the brake shoe assembly downward, and take
out the roller.
P2TT00357
3. Pull out the brake return spring pin.
P2TT00358
4. Take down the brake assembly, and check to confirm
that the friction plate thickness is not less than 8mm.
P2TT00359
3-101

5. Take down the cotter pin and cylindrical pin from the
brake air chamber U-shaped fork, and then use circlip
pliers to take down the circlip. Remove the adjustment
arm, adjusting shim and washer successively.
P2TT00360
6. Remove the clamp ring and washer on the camshaft
with clamp pliers, and take out the camshaft.
P2TT00361
7. Remove the connecting bolts of the brake bottom plate,
and take down the brake bottom plate.
P2TT00362
Installation of brake assembly

1. Install the brake bottom plate, and tighten it with
connecting bolts. The tightening torque is 430Nm.
P2TT00363
3-102

2. Clean the camshaft S-surface, and install the additional
shim and the “O-ring” in a complete set at the side of
camshaft closer to “S”-surface.
P2TT00364
3. Support the brake shoe on the brake shoe supporting
pin, and hang the brake return spring.
P2TT00365
4. Install the return spring pin and the return spring.
P2TT00366
5. Apply lubricant on the roller, pry up the brake shoe and
install the roller in place.
P2TT00367
3-103

6. Install the roller snap spring.
P2TT00368
7. Install a washer on the camshaft, and use a circlip for
axial positioning.
P2TT00369
8. Install the adjustment arm, gasket and adjusting shim.
Use a spring for axial positioning.
Note: Make sure that the axial clearance of the adjustment
arm is 0.5-1.0mm. It can be adjusted through the adjusting
shim.
P2TT00370
9. Connect the adjustment arm and the air chamber with a
cylindrical pin. Rotate the adjusting screw of the
adjustment arm clockwise to the extreme position, and
loosen the adjusting screw for 3 threads
counterclockwise.
P2TT00371
3-104

10.Measure the clearance between the brake shoe and the
brake drum. The brake clearance is required to be 0.7-
1.2mm.
P2TT00372
Removal, installation and maintenance of drive axle main reducer assembly
Installation of driving bevel gear

1. Press to install the inner rings of the conical bearing and
cylindrical bearing on the driving gear.
P2TT00373
2. Press to install the upper and lower bearing outer rings
in the bearing seat.
P2TT00374
3-105

3. Assemble the main cone with the bearing seat.
P2TT00375
4. Install the adjusting shim on the driving gear.
P2TT00376
5. Install the upper bearing of the main cone in place.
P2TT00377
6. Press to install the oil seal set in the bearing seat (an oil
seal installed in the oil seal seat).
P2TT00378
3-106

7. Install the flange and flange nut. The tightening torque
for the flange nut is 950Nm. Lock the flange nut with a
clasp.
P2TT00379
8. Measure the pre-tightening force of the bearing with a
spring scale. The force is required to be 6-10 Nm. Note:
It can be adjusted by changing the thickness of the
adjusting shim between the two bearings. The thicker
the shim, the smaller the pre-tightening force; the thinner
the shim, the bigger the pre-tightening force.
P2TT00380
Installation of driving bevel gear assembly and main reducer housing

1. Install the outer ring of the cylindrical roller bearing on
the main reducer housing, and apply sealant on the
junction surface.
P2TT00381
2. Install an adjusting shim on the junction surface, and
connect the driving bevel gear assembly with the main
reducer housing with bolts. The tightening torque of the
bolts is 370Nm.
Note: The shim is used to adjust the engagement mark of
the driving and driven bevel gears.
P2TT00382
3-107
Sub-assembling of inter-wheel differential

1. Put the axle shaft gear gasket on the axle shaft gear,
and install in the differential housing.
P2TT00383
2. Insert the planet gear, spider and planet gear gasket in
the differential housing.
P2TT00384
3. Install the second axle shaft gear and axle shaft gasket
in the differential housing.
P2TT00385
4. Install the second axle shaft gear and axle shaft gasket
in the differential housing.
P2TT00386
3-108

5. Connect the two halves of the differential housing and
the driven gear with fastening bolts, whose tightening
torque is required to be 570 Nm. Measure that the
backlash between the axle shaft gear and the planet
gear shall be 0.25mm-0.55mm. The backlash can be
adjusted by adjusting the thickness of the axle shaft gear
gasket.
P2TT00387
Installation of inter-wheel differential

1. The circular hole and the inner thread hole inside the
main reducer housing assembly are machined in pair
and shall be assembled and replaced in pair.
P2TT00388
2. Support the assembled inter-wheel differential with
driven bevel gear assembly on the main reducer
housing with 2conical roller bearings. Screw in the left
and right adjusting nuts. The nuts shall be rotated freely.
P2TT00389
3. Install the left and right bearing caps in pair on the
reducer housing. Pre-tighten the connecting bolts of the
bearing caps. Preliminarily adjust the backlash between
the driving and driven gears to be 0.25~0.40mm by
tightening the left and right adjusting nuts.
P2TT00390
3-109

4. Tighten the bearing cap bolts on the driving bevel gear
side to the specified torque 630Nm with a wrench.
P2TT00391
5. Take a set of magnetic stand with dial indicator. Suck the
magnetic stand on the bearing cap on the driven bevel
gear side, with the head put against on the back of the
driven bevel gear and the pointer with certain pressure.
Tighten the adjusting nut on the driven bevel gear side
till the dial indicator pointer rotates, and then completely
loosen the adjusting nut. Finally, tighten the adjusting nut
to make the pointer rotate for 0.40±0.05mm. Tighten the
bearing cap bolts on the driven bevel gear side with a
torque of 630 Nm.
P2TT00392
6. Re-check that the backlash of the bevel gear shall be
0.25-0.4mm. The backlash can be achieved by screwing
in or out the left and right adjusting nuts of the differential
synchronously.
P2TT00393
7. Adjustment of engagement marks of driving and driven
bevel gears:
Apply "Sudan Red" (pigment) to the surface of the driven
bevel gear, and then rotate the driven bevel gear to check
the meshing marks. 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
P2TT00394 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.
3-110

8. Lock the adjusting nut with a locking plate.
P2TT00395
Installation of driving bevel gear assembly in intermediate axle main reducer

1. Install the adjusting shim. Put in the driving bevel gear
with bearing seat, and make sure that the oil return port
is corresponding. The adjusting shim is used to adjust
the engagement mark of the driving and driven bevel
gears.
P2TT00396
2. Tighten the connecting bolts of the bearing seat with the
tightening torque of 370Nm.
P2TT00397
3. Install the driven cylindrical gear and locking nuts. The
tightening torque of the locking nut is 950Nm. Lock the
nut with a clasp.
P2TT00398
3-111
Installation of inter-axle differential

1. Press to install the bearing outer ring in the inner hole of
the main reducer housing.
P2TT00399
2. Press to install the bush in the inner hole of the rear axle
shaft gear.
P2TT00400
3. Press to install the bearing inner ring on the rear axle
shaft gear.
P2TT00401
4. Install the rear axle shaft gear in the main reducer
housing.
P2TT00402
3-112

5. Put a washer on the rear axle shaft gear.
P2TT00403
6. Install the spider and planet gear in the inter-axle
differential housing.
P2TT00404
7. Press to install the oil-collecting hood on the differential
housing.
P2TT00405
8. Install the inter-axle differential assembly in the main
reducer housing.
P2TT00406
3-113

9. Press to install the bush in the inner hole of the driving
cylindrical gear.
P2TT00407
10.Install the driving cylindrical gear, and place an adjusting
shim.
P2TT00408
11.Install the main axle. Measure that the axial clearance of
the driving cylindrical gear is 0.5-0.8mm If the clearance
is improper, it can be adjusted by adjusting the thickness
of the adjusting shim. Install the sliding mesh sleeve,
shifting fork and return spring.
P2TT00409
12.Install the pass-axle box cap, and apply sealant on the
junction surface. Tighten the connecting bolts with the
tightening torque of 150Nm. Install the conical roller
bearing in the pass-axle box cap.
P2TT00410
3-114

13.Press to install the oil seal in the inner hole of the
adjusting nut, and apply lubricating grease on the oil
seal edge.
P2TT00411
14.Apply plane sealant on the adjusting nut thread
tightened, and screw the nut in the pass-axle box cap
with tightening torque of 250Nm Then, loosen the nut for
40-50°.
P2TT00412
15.Lock the locknut with a locking plate. The tightening
torque for fixing the locking plate bolt is 25 Nm.
P2TT00413
16.Install the flange, and apply sealant on the flange inner
spline. Lock the flange nut with tightening torque of
950Nm. Lock the flange bolt with a clasp.
P2TT00414
3-115

17.Apply plane sealant evenly on the junction surface of
the axle housing. Assemble the main reducer assembly.
The tightening torque of the bolt is 370 Nm.
P2TT00415
Installation of intermediate axle through shaft assembly

1. Press to install the oil seal in the inner hole of the
adjusting nut, and apply lubricating grease on the oil
seal edge.
P2TT00416
2. Install the adjusting nuts on the through shaft, and press
to install the four-point contact bearing in place.
P2TT00417
3. Lock the four-point contact bearing with slotted nuts. The
tightening torque of the slotted nut is 950Nm. Knock the
nut edge into the through shaft key slot.
P2TT00418
3-116

4. Install the through shaft assembly in the axle housing,
and apply sealant on the threads of the adjusting nut.
The tightening torque of the nut is 950Nm.
P2TT00419
5. Lock the adjusting nut with a locking plate. The
tightening torque of the locking plate nut is 25 Nm.
P2TT00420
3-117
DW90A List of General Tools and Toolings
List of General Tools and Toolings
Refer to torque converter-gearbox system, drive axle system and transmission shaft system in this
manual for the detailed list of general tools and tooling.
List of Special Tools and Tooling
S/N Part description Part No. Figure
Flange nut socket S65

1 XM-783-160106
(dodecagonal)
P2TT00421
Intermediate axle input

2 XZ-783-160170
adjusting nut socket
P2TT00422
Differential adjusting nut

3 XZ-783-160173
socket
P2TT00423
Through shaft bearing lock

4 XM-783-160122
nut socket
P2TT00424
Through shaft adjusting nut

5 XM-783-160335
socket
P2TT00425
6 Spindle head lock nut socket BZ-783-150014A
P2TT00426
3-118
Models and filling amounts of recommended lubricating oil and lubricating grease DW90A
Models and filling amounts of recommended lubricating oil and

lubricating grease
Type of
Lubricating point Lubricant Type of Lubricant Quantity Remarks
Axle
First rear Main reducer 28L
Select lubricating oil
axle Hub reducer as per different 6.3L Single side
Gear oil
Second Main reducer seasons and regions 18L
Drive axle (remarks)
rear axle Hub reducer 6.3L Single side
Lubricating 2# lithium-based
Lubricating grease nozzle Fill up
grease grease
Note:
Regions with temperature above -12°C: 85W/90 GL-5 gear oil for heavy duty vehicle;
Regions with temperature above -26°C: 80W/90 GL-5 gear oil for heavy duty vehicle;
Regions with temperature above -40°C: 75W/90 gear oil for heavy duty vehicles (severe cold regions);
3-119
June 9, 2020 Balanced suspension assembly
DW90A Schematic Diagram of Balanced Suspension Assembly
Balanced suspension assembly
Schematic Diagram of Balanced Suspension Assembly
The mine equalizing suspension assembly is used as an equalizing and bearing system on double-rear-
axle series heavy trucks. 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. The drawing is as
follows
P2TT00427
For this structural form, the locking method of left-handed and right-handed rotation nuts is shown in the
following figure:
P2TT00428
3-120
Balanced suspension assembly June 9, 2020
Main technical parameters of balanced suspension assembly DW90A
Main technical parameters of balanced suspension assembly
Connection Dimension Diagram of Equalizing Suspension
P2TT00429
Composition of balanced suspension assembly
Analytical Drawing of Balanced Suspension Assembly
14 15
7 12 13
6
11
10
8 9 16 17
18
5 6
2 3 4
P2TT00430
3-121
DW90A Assembling List of Balanced Suspension Assembly
Assembling List of Balanced Suspension Assembly
Detailed List of Assembling

S/N Description Qty. Remarks
1 Balance shaft with support assembly 1 Assembly
Bracket 2
Balance shaft 1
Cylindrical pin 2
2 Type ring 2
3 O-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
3-122
Removal, installation and adjustment of balanced suspension assembly DW90A
Removal, installation and adjustment of balanced suspension assembly
Removal of balanced suspension assembly

1. Remove bolts of balance shaft casing cover
P2TT00431
2. Use a flat spade to pry up or remove the tongue (12 mm
in length) of the stop gasket
P2TT00432
3. Remove the slotted nut (right)
P2TT00433
4. Remove the lock gasket
P2TT00434
3-123
DW90A Removal, installation and adjustment of balanced suspension assembly

5. Remove the thrust washer (left)
P2TT00435
6. Remove the shaft casing
P2TT00436
7. Remove bushing and adjust gasket and outer ring of the
bearing
P2TT00437
3-124
Assembling of balanced suspension assembly

1. Assemble bearing outer ring and adjust gasket and
bushing
P2TT00438
2. Install the shaft casing, bearing outer ring and space
washer
P2TT00439
3. Screw the thrust washer (left) to the bottom with a torque
of 1200-1300N/m
P2TT00440
4. Install the lock gasket
P2TT00441
3-125

5. Screw the slotted nut (right) and the lock gasket to the
bottom with a torque of 900-1000N/m
P2TT00442
6. Adjust the bearing clearance to be 0.1-0.3mm
P2TT00443
7. Lock the lock gasket
P2TT00444
8. Apply silicone sealant HZ1213 on the end face
P2TT00445
3-126

9. Install the end cover
P2TT00446
10.Add GL-5.8W-90heavy duty gear oil of 0.8-1L
P2TT00447
11.Tighten the oil plug
P2TT00448
3-127
Installation and adjustment of balance shaft casing assembly

1. Press the bearing outer ring into the press machine
P2TT00449
2. Press the shaft sealing ring
P2TT00450
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.
3-128
4-1
June 9, 2020 Hydraulic System
DW90A
Hydraulic System
Overview of hydraulic system............................................................................................4-3
Composition of hydraulic lifting system ..................................................................................................4-3
Operating principle of hydraulic lifting system .......................................................................................4-4
Structure and Function of Working Hydraulic Lifting System ............................................4-5

Installation of hydraulic oil tank ..............................................................................................................4-5
Hydraulic fuel tank assembly ............................................................................................................4-5
Implement pump ....................................................................................................................................4-6
Main technical specification of working pump ....................................................................................4-6
Structure and operating principle of working pump ...........................................................................4-6
Container lifting cylinder.........................................................................................................................4-8
Main technical parameters of lifting cylinder ......................................................................................4-8
Structure of Lifting Cylinder................................................................................................................4-8
Main control valve ..................................................................................................................................4-9
Structure and operating principle of main control valve .....................................................................4-9
Pilot valve.............................................................................................................................................4-11
Structure and operating principle of pilot valve ...............................................................................4-11
Pneumatic control valve .......................................................................................................................4-12
Structure of pneumatic control valve ...............................................................................................4-12
Operating principle of pneumatic control valve ................................................................................4-12
Lifting operation ...............................................................................................................4-13

Lifting ...................................................................................................................................................4-13
Lifting suspension ................................................................................................................................4-13
Lowering ..............................................................................................................................................4-13
Maintenance of Hydraulic Lifting System ........................................................................4-15

Common faults of hydraulic lifting system and troubleshooting.......................................4-17
Repair of Key Components of Hydraulic Lifting System..................................................4-21
Replace hydraulic oil filter element ......................................................................................................4-21
Structure and Principle of Steering System.....................................................................4-23

Structure of Steering System ..............................................................................................................4-23
Principle of steering system .................................................................................................................4-24
Steering operation ...........................................................................................................4-25

4-2
Hydraulic System June 9, 2020
DW90A
Precautions for steering...................................................................................................4-26

Maintenance of Hydraulic Steering System.....................................................................4-27
Maintenance ........................................................................................................................................4-27
Maintenance ........................................................................................................................................4-27
Common faults of hydraulic steering system and troubleshooting ..................................4-28

Repair of Key Components of Hydraulic Steering System ..............................................4-32
4-3
June 9, 2020 Overview of hydraulic system
DW90A Composition of hydraulic lifting system
Overview of hydraulic system
Composition of hydraulic lifting system
The working hydraulic lifting system is mainly composed of hydraulic oil tank, working pump, lifting oil
cylinder, main control valve, pilot valve, pneumatic limit valve and hydraulic hose, with the structure
shown in the figure below:
1
6
2
3
P2TH00001
1. Lifting cylinder 5. Duplicate gear pump

2. Lifting valve 6. Hydraulic fuel tank assembly
3. Pneumatic control valve 7. Hydraulic hose assembly
4. Pilot valve
4-4
Overview of hydraulic system June 9, 2020
Operating principle of hydraulic lifting system DW90A
Operating principle of hydraulic lifting system
P2TH00002
1. Oil cylinder 4. Oil return filter 7. Limit valve

2. Lifting valve 5. Hydraulic oil tank 8. Pneumatic control valve for lifting
3. Oil pump 6. Converging valve block
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 priority 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.
4-5
June 9, 2020 Structure and Function of Working Hydraulic Lifting System
DW90A Installation of hydraulic oil tank
Structure and Function of Working Hydraulic Lifting System
Installation of hydraulic oil tank
Hydraulic fuel tank assembly
2
5
4 P2TH00003
1. Oil filler 3. Oil tank 5. Cable tie

2. Liquid level gauge 4. Rack 6. Return oil filter
1. The hydraulic oil tank is installed between the right-side cab and the dump body.
2. Oil return filter: Filtering oil to ensure cleanliness of oil.
3. Air 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.
4-6
Structure and Function of Working Hydraulic Lifting System June 9, 2020
Implement pump DW90A
Implement pump
Main technical specification of working pump
Technical parameters Front pump Rear pump

Theoretical displacement 83.6 41.8
Direction of rotation Right-handed rotation
Rated/maximum speed (r/min) 2200/2500
Rated/maximum pressure (MPa) 23/28
Volume efficiency (≥%) 92
Structure and operating principle of working pump
P2TH00004
1. Retainer ring 72 7. Ear-shaped stopper 13. Bearing 33×37×35

2. Set 8. Ear-shaped seal 14. Rectangle sealing ring
3. Rotary shaft lip seal 9. Side plate 15. Pump body I
4. Front cover 10. Driving gear shaft 16. Driving gear shaft II
5. Nameplate (for Liugong only) 11. Driven gear shaft 17. Rear cover body
6. Locating sleeve 12. Axle sleeve 18. M16 bolt
4-7
DW90A Implement pump
Operating principle
P2TH00005
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.
Installation location
Duplicate gear pump is located at PTO output port at the rear end of diesel engine.
Function
To supply power hydraulic oil to the oil cylinder.

4-8
Container lifting cylinder DW90A
Container lifting cylinder
Main technical parameters of lifting cylinder
Overall volume (L) 105

Maximum pressure (bar) 250
Installation distance (mm) 343
Total stroke (mm) 4700
All-level sleeve diameter (mm) Ø196/Ø172/Ø150/Ø129
Sleeve travel at all levels (mm) 1200/1205/1210/1205
Sleeve thrust at all levels (KN) 603/465/353/261
Structure of Lifting Cylinder
120
121
30 40
20
0
130
122
101
41
123
21 31
1
124
102
103
41
102
32 42
22
33 43
2 23
32 44
3 22
4 34
5 24
6 P2TH00006
0. Seal kit MN 202 21. Middle cylinder barrel 34. Lifting ring MN 157 103.Sliding block MN 118
1. Base cylinder MN2 202- MN2 179-1440-HD 40. Double seal kit MN137 120.Top nut M48×3
1491-4/4BSAE-190- 22. External stop collar MN 41. Middle cylinder barrel 121.Gasket M48
C273-HD 179 MN2137-1440-HD 122.External sleeve 273-
2. Seal ring of baseplate 23. Sliding block MN 179 42. External stop collar 1255 SPH LOCKED
202 24. Lifting ring MN 179 MN137 123.Bolt M12×30×1.75
3. Baseplate 202 30. Double seal kit 157 43. Sliding block MN137 124.O-ring D273 of external
4. Lock plate 202 31. Middle cylinder barrel 44. Lifting ring MN 137 sleeve
5. Spring washer M12 MN2 157-1440-HD 101.Piston rod MN2 118- 130.Dust cover 273
6. Bolt M12× 1.25×25 32. External stop collar MN 1452-HD
20. Double seal kit MN179 157 102.External stop collar MN
33. Sliding block MN 157 118
4-9
DW90A Main control valve
Main control valve
Structure and operating principle of main control valve
2
1 3
4
5
P2TH00007
1. Pressure gauge interface 5. Pneumatic control valve/lifting connector

2. Oil return port of oil tank (T) 6. Overflow valve
3. Hydraulic pump connector (P) 7. Oil tank connector (C)
4. Pneumatic control valve/lowering connector
4-10
Main control valve DW90A
P2TH00008
1. The lifting valve is installed directly at the SAE inlet of the cylinder.
2. Safety: HT valve is installed at the oil inlet of the cylinder, playing the role of safety performance of
explosion-proof valve.
3. The lifting valve is located at the oil inlet of the lifting cylinder. It is a three-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,
holding 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.
4-11
DW90A Pilot valve
Pilot valve
Structure and operating principle of pilot valve
P2TH00009
P2TH00010
1 - Inlet 21-Lowering air port (connected with the lifting valve)

3 - Exhaust port 22-Lifting air port (connected with the 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.
4-12
Pneumatic control valve DW90A
Pneumatic control valve
Structure of pneumatic control valve
P2TH00011
1. Air inlet (connected with the pneumatic control valve) 3. Discharge outlet
2. Air outlet (connected with the lifting valve)
Operating principle of pneumatic control 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.
4-13
June 9, 2020 Lifting operation
DW90A Lifting
Lifting operation
Lifting
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 oil pump,
and insufficient oil supply will cause damage to the oil cylinder and oil 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.
Lifting 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.
Lowering
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
elements will occur. The control lever shall not be used in high-gear position area and at a
reverse gear.
4-14
Lifting operation June 9, 2020
Lowering DW90A
Lowering 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.
1)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;
2)All removed sealing elements, such as O-ring, oil seal and sealing washer must be replaced
and not be reused.
3)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.
4-15
June 9, 2020 Maintenance of Hydraulic Lifting System
DW90A Lowering
Maintenance of Hydraulic Lifting System
1. For the first filling of hydraulic oil, fill the oil till the oil level reaches the middle position of oil level
gauge. 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.
2. During the process of driving, put the pneumatic control valve in the middle position and it is
forbidden to lift the dump body.
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.
4. High-pressure oil pipes shall be replaced periodically (every two years) to avoid the risk of aging and
blasting.
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.
6. Regularly (20h weekly) apply the lubricant to the oil cylinder support (pin shaft at the link joint)
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.
8. When the dump body is lifted for maintenance of components under the dump body, the dump body
support rod must be lowered to the position allowing safe support. After maintenance, the support
rod must be restored to its original position.
Maintenance and Inspection From
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 whether the
Once every day
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
4-16
Maintenance of Hydraulic Lifting System June 9, 2020
Lowering DW90A
Hydraulic System Maintenance Interval Schedule

Interval period
Maintenance 10 250 500 1000 2000

50 hours 100
item When hours or hours hours hours or hours
or every hours or
necessary every or every or 3 half a or 1
week 2 weeks
day month months 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 mark ★ indicates the first maintenance.

4-17
June 9, 2020 Common faults of hydraulic lifting system and troubleshooting
DW90A Lowering
Common faults of hydraulic lifting system and troubleshooting

Common fault diagnosis of double pump
Fault Phenomenon Possible cause Troubleshooting
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
The oil suction pipe is blocked
oil 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 Readjust the pressure of the overflow
is insufficient valve
The pump has slow or no 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 gear
The side plate has been damaged Replace the side plate or gear pump
pump
Oil leakage of gear pump Abrasion or damage of sealing ring Replace the sealing 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
4-18
Common faults of hydraulic lifting system and troubleshooting June 9, 2020
Lowering DW90A
Common fault diagnosis of lifting system

Fault Causes Solution
Check whether the main air supply
Without main air supply
pipeline is unobstructed
Start the engine to make the pressure
Air pressure is too low
reach over 7.5 kilograms
Internal fault of pneumatic control
Replace the pneumatic control valve
valve
The limit valve fails to work normally Replace the limit valve
Inner valve rod of the lifting valve is Clean and inspect the lifting valve body
clamped and rod
Wrong connection of gas circuit or oil Check whether the gas circuit or oil
The oil cylinder fails to be lifted
pipeline pipeline is connected correctly
No oil comes out from the gear pump Check the oil circuit and pump
Check whether the power take-off is
The power take-off is not engaged.
engaged.
Open the ball valve and check whether
The ball valve at the bottom of the oil
the hydraulic oil meets the
tank is not opened.
requirements.
Blow-by of air cavity of the lifting valve Replace the lifting valve repair kit
Check whether the limit valve stem is
The limit valve stem is stuck.
retracted flexibly.
Start the engine to make the pressure
Air pressure is too low
reach over 7.5 kilograms
Fault of gear pump Check or replace the gear pump
Replace air pipe and tighten the
Leakage of air pipe
connector
The air pipe is bent Rearrange the air pipe direction
The oil cylinder is lifted and lowered
too slowly Inner valve rod of the lifting valve is Clean and inspect the lifting valve body
clamped and rod
Blow-by of air cavity of the lifting valve Replace the lifting valve repair kit
The one-way valve inside the lifting Replace the one-way valve inside the
valve is damaged lifting valve
Viscosity coefficient of hydraulic oil is
Replace with appropriate hydraulic oil
too large
Excessive overload Manual unloading
Oil level of the tank is not enough Add hydraulic oil of the same grade
Fault of gear pump Check or replace the gear pump
The oil cylinder cannot be lifted Make the pressure reach over 7.5
completely Air pressure is too low
kilograms
The limit valve is not installed at a Readjust the installation position of the
correct position limit valve
The overflow valve fails. Replace the overflow valve
4-19
June 9, 2020 Common faults of hydraulic lifting system and troubleshooting
DW90A Lowering

The limit valve is not installed at a Readjust the installation position of the
Piston rod and head of the oil cylinder correct position limit valve
is pulled together Goods are of a large blocked structure Adjust the lifting angle to make the
and the lifting angle is too small stroke reach the maximum angle
Eccentric load Correct handling of goods
The clearance of cylinder support
bracket goes beyond the specified
Adjust the support clearance
tolerance zone and the cylinder is not
Damage of oil cylinder barrel mounted vertically
Operate and use in strict accordance
The roadbed was uneven at unloading
with the operation requirements
Replace the hydraulic oil and the filter
Hydraulic oil is dirty
element
Load goods correctly and replace the
Repeated unbalance loading
seal kit
Oil penetration and leakage of oil
Damage of cylinder barrel Replace the cylinder barrel and seal kit
cylinder
Installation position of the oil cylinder Replace the cylinder barrel and
fails to meet requirements readjust the oil cylinder position
Replace air pipe and tighten the
Leakage of air pipe
connector
Sudden failure of pneumatic control The air pipe is bent Rearrange the air pipe direction
valve There are impurities in pneumatic
control valve
The limit valve element acts up Replace the limit valve
The one-way valve inside the lifting Replace the check valve with a new
valve does not work one
Leakage in the lifting valve Replace the lifting valve
Cylinder slippage occurs during the Air leakage of pneumatic control valve Replace the pneumatic control valve
lifting process The lifting valve rod cannot be Clean the valve body and rod, and
reseated normally replace the seal kit
Replace the damaged cylinder barrel
Oil leakage of the oil cylinder
and seal kit
The limit valve element is obstructed Change the limit valve element
The gas circuit between the lifting
valve and pneumatic control valve is Check or replace the pipeline
obstructed
The dump body or stable frame is
The oil cylinder does not drop Rectify dump body or stable frame
deformed
The pneumatic control valve is not
ventilated
The lifting system has no main air
Check the main gas circuit
source
4-20
Common faults of hydraulic lifting system and troubleshooting June 9, 2020
Lowering DW90A

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
Replace the air filter element
dirty
The oil level in the tank has exceeded
Drain a little oil from the oil tank
the oil dipstick
Fail to operate correctly as required,
Oil spillage from air filter of oil tank Please operate correct by following the
and the oil cylinder is lowered during
requirements strictly
the driving process
The gear pump is damaged Replace the gear pump
Use the hydraulic oil meeting
The hydraulic oil grade is not correct
requirements
4-21
June 9, 2020 Repair of Key Components of Hydraulic Lifting System
DW90A Replace hydraulic oil filter element
Repair of Key Components of Hydraulic Lifting System
Replace hydraulic oil filter element
Step 1: Unscrew the four M10 bolts on the flange. See P2TH00012 for operation;
P2TH00012
Step 2: Remove the oil return flange and joint. See P2TH00013 for operation;
2
P2TH00013
4-22
Repair of Key Components of Hydraulic Lifting System June 9, 2020
Replace hydraulic oil filter element DW90A
Step 3: Unscrew the four M10 bolts fixing the hydraulic oil filter and the oil tank. See P2TH00014 for
operation;
P2TH00014
Step 4: Remove the hydraulic oil filter. See P2TH00015 for operation;
P2TH00015
Step 5: Replace the hydraulic oil filter element. After the replacement, replace the hydraulic oil filter
element in reverse according to the above steps.
4-23
June 9, 2020 Structure and Principle of Steering System
DW90A Structure of Steering System
Structure and Principle of Steering System
Structure of Steering System
1
5
4
3
2
P2TH00016
1. Steering gear 3. Hydraulic pump 5. Priority valve

2. Steering cylinder 4. Hydraulic oil tank
4-24
Structure and Principle of Steering System June 9, 2020
Principle of steering system DW90A
Principle of steering system
P2TH00017
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.
4-25
June 9, 2020 Steering operation
DW90A Principle of steering system
Steering operation
The steering system 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 steering 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.
4-26
Precautions for steering June 9, 2020
Principle of steering system DW90A
Precautions for steering
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.
The vehicle shall be stopped immediately when the steering system fails due to oil pump or oil
line.
4-27
June 9, 2020 Maintenance of Hydraulic Steering System
DW90A Maintenance
Maintenance of Hydraulic Steering System
Maintenance
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:
1. Fully tighten the positioning bolt that has been loose.
2. 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.
3. Adjust the other positioning bolt using the same method.
Maintenance
1. 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.
2. 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. 3-7.7. (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.)
3. Regularly (20h weekly) apply the lubricant to the oil cylinder support (pin shaft at the link joint).
4-28
Common faults of hydraulic steering system and troubleshooting June 9, 2020
Maintenance DW90A
Common faults of hydraulic steering system and

troubleshooting
Diagnosis of Common Faults of Steering System

Fault Phenomenon Causes Troubleshooting method
The junction surface
The junction surface is polluted. Check and clean the junction surface.
between parts leaks oil;
The front cover of steering
Oil leakage The shaft seal ring is damaged. Replace the seal ring
gear leaks oil;
The valve bolt (plug) leaks The tightening torque of bolt
Tighten the bolts(plug)
oil (plug) is insufficient
The steering wheel is heavy
Check the oil pump and the oil supply
when it is turned fast and The oil supplied is insufficient.
line.
light when it is turned slowly
The oil cylinder creeps, the
Discharge the air in the system. Check
oil contains bubble, and Air exists in the steering system.
the oil pump inlet for air leakage.
irregular sounds are heard
The steering is hard, and Check whether a steel ball is provided.
The manual steering one-way
the steering cylinder fails to Check whether the steel ball is
valve fails.
Hard steering work. cushioned by 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 combination
work.
internal leakage. valve.
The steering is easy at no The FK safety valve leaks or the
load and hard at heavy safety valve spring does not Replace the FK combination valve.
load. work.
The viscosity of hydraulic oil is
Hard steering
too high.
The steering wheel fails to
return to the middle The leaf spring fails. Replace the leaf spring.
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.
Steering When the steering wheel is The couple axle is incorrectly

malfunction turned, it immediately turns installed at the position of rotor,
Reassembling
to 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, The two-way overload valve is
and it does not make cushioned by pollutants or the Check the overload valve.
corrections when the spring fails.
steering wheel is turned.
4-29
June 9, 2020 Common faults of hydraulic steering system and troubleshooting
DW90A Maintenance

The steering column and the
The pressure drop in the
The steering valve element are not installed
middle position increases.
wheel cannot concentrically. The steering
When the steering wheel
get back to column tightly jacks the valve Carry out the troubleshooting as per
stops rotating, the steering
the middle element in the axial direction. the actual situations.
gear does not unload (the
position The steering resistance of
vehicle deviates from the
automatically. steering column is too strong so
driving direction).
the lead spring is broken.
Steering
wheel
The steering oil cylinder
incapable of
cannot be turned to the Appropriately increase the safety
being turned The safety valve pressure is low.
extreme position, and the valve pressure.
to the
steering is hard.
extreme
position
After the steering oil
cylinder is turned to its
extreme position, the
The overload valve pressure is Appropriately increase the overload
No end point steering wheel can be
low. valve pressure.
easily turned when a force
is applied (no sense of end
point).
In case of power steering,
the oil cylinder piston
reaches its extreme position
but the driver cannot The radial or axial clearance of
No manual The radial or axial clearance of the
obviously feel the end point. the stator and rotor pairs is too
steering stator and rotor pairs is too large.
In case of manual steering, large.
the steering wheel can
rotate but the oil cylinder
keeps still.
4-30
Common faults of hydraulic steering system and troubleshooting June 9, 2020
Maintenance DW90A

Remove the scratches with oil stone
The sliding surface of piston rod
and polish the sliding surface. If oil still
Piston rod has scratches and rust.
leaks, replace all piston rods.
The electroplated layer falls off. Seal
Pollutants get stuck on the seal, Remove the pollutants and replace the
thus abrading the seal. seal.
The seal is burnt out due to air Replace the seal and exhaust the oil
compression. cylinder.
The piston Replace the seal, check the hydraulic
rod leaks oil Seal - piston rod oil for its quality, check the causes of
(the piston The seal is subject to aging. abnormal high temperature, and
rod surface is replace the hydraulic oil when
accumulated necessary.
with oil
drops). The seal is deformed and
If necessary, replace the hydraulic oil.
squeezed out.
The seal is deformed and Replace the seal and check the
Seal - for buffering
squeezed out. causes of abnormal high pressure.
The dust ring is polluted. Remove the pollutants.
Seal - 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 The O-ring is polluted or Remove the pollutants, replace the O-
O-ring
surface damaged during assembling. ring, and check the fitting surface.
between
cylinder head
and tube Cylinder head threads The cylinder head is loose. Retighten the cylinder head.
leaks oil.
Remove the scratches by polishing.
The inner wall is subject to
Cylinder tube Replace the cylinder tube if it is
scratches or deformation.
impossible to repair.
The bending of piston rod
Piston rod Replace the piston rod.
The oil exceeds the allowable limit.
cylinder The seal inside cylinder head is Check and remove the pollutants.
Cylinder cap
extends and polluted. Check the lining.
contracts not The inner hole is deformed, the
smoothly. Replace the cylinder tube assembly
Cylinder tube piston has pits, and the cylinder
and the piston.
tube has scratches.
4-31
June 9, 2020 Common faults of hydraulic steering system and troubleshooting
DW90A Maintenance

The piston Replace the seal and check whether
rod extends Piston seal It is abraded. the piston and the cylinder tube inner
or contracts wall fail or not.
automatically Replace the cylinder tube assembly.
and does not Cylinder tube The inner wall is damaged. Attempt to repair if the scratches are
work at a not severe.
certain
Retighten the nut. Check the setscrew
working Piston nut It is loose.
and threads for damage.
speed.
The impact is Check whether the control valve is
The valve is subject to internal
strong when Control valve polluted or damaged. Replace the
leakage.
the oil valve if damaged.
cylinder Replace the pin shaft and bearing
extends or Pin shaft and bearing
It is excessively abraded. bushing. Apply the lubricant to ensure
contracts. bushing
full lubrication.
Abnormal The lubrication is insufficient or
noise can be the type of lubricant is incorrect.
Replace the pin shaft and bearing
heard when Pin shaft and bearing
bushing as needed. Apply the
the oil bushing
It is excessively abraded. lubricant to ensure full lubrication.
cylinder is
working.
4-32
Repair of Key Components of Hydraulic Steering System June 9, 2020
Maintenance DW90A
Repair of Key Components of Hydraulic Steering System
The main faulty component of the steering system is the steering cylinder, with its disassembly and
repair steps as follows:
1. Loosen the steering hose nuts shown in(1) and (2) in Fig. P2TH00018 with M26 torque wrench.
2
1
P2TH00018
After that, see Fig. P2TH00019:
P2TH00019
4-33
June 9, 2020 Repair of Key Components of Hydraulic Steering System
DW90A Maintenance
2. Loosen the hose joint nuts shown in (1), (2), (3) and (4) in Fig. P2TH00020 with M20 torque wrench,
and then remove the hose
1 2 3 4 P2TH00020
After that, see Fig. P2TH00021
P2TH00021
3. Loosen and remove the bolts shown in (1), (2), (3) and (4) in Fig. P2TH00022 with M12 wrench.
2 3
1
4 P2TH00022
4-34
Repair of Key Components of Hydraulic Steering System June 9, 2020
Maintenance DW90A
4. Remove the bearing of the steering cylinder hinged with the front axle bracket and remove the
steering cylinder, as shown in Fig. P2TH00023:
P2TH00023
5. After the disassembly and assembly of the steering cylinder, the dirt on the surface of the piston
cylinder and the seals on the piston rod shall be removed. When the piston cylinder of the steering
cylinder is seriously deformed, the cylinder barrel assembly and the piston assembly can be
replaced.
6. After the replacement, reverse the above steps to restore the replaced steering cylinder.
5-1
June 9, 2020 Air conditioning system
DW90A

General information ...........................................................................................................5-3
Safety .....................................................................................................................................................5-3
List of General Tools and Toolings ........................................................................................................5-3
List of Special Tools and Tooling ...........................................................................................................5-3
Structure, Function and Principle ......................................................................................5-4

Component Composition and Location ..................................................................................................5-4
Technical Parameters of the System .....................................................................................................5-7
Operating principle .................................................................................................................................5-7
Working process ................................................................................................................................5-7
Working Principle Diagram.................................................................................................................5-8
Test and Adjustment........................................................................................................5-10

Air conditioning system test .................................................................................................................5-10
Removal and installation of air conditioning components................................................5-12

Removal and Installation of Compressor .............................................................................................5-12
Discharging (recycling) of refrigerant in the air conditioning system................................................5-12
Remove the line connecting the compressor and the compressor. .................................................5-14
Installation Method ...........................................................................................................................5-15
Removal and Assembly of Belt and Tension Pulley.............................................................................5-16
Removal and installation of evaporator mounting assembly................................................................5-17
Replacement of A/C control panel .......................................................................................................5-20
Check and replacement of A/C fuse ................................................................................................5-20
Removal and replacement of reservoir ................................................................................................5-21
Removal of Liquid Storage Tank......................................................................................................5-21
Replacement of Liquid Storage Tank...............................................................................................5-22
Removal and installation of condenser ................................................................................................5-23
Removal and installation of pressure switch ........................................................................................5-24
Fault diagnosis and judgment..........................................................................................5-25

Common fault classification .................................................................................................................5-25
Diagnosis and removal of common faults in air conditioning system...................................................5-25
Doggerel for the Repair of Air Conditioner ...........................................................................................5-27
Precautions for Maintenance ...............................................................................................................5-28
How to judge whether there is enough refrigerant? .............................................................................5-29
5-2
Air conditioning system June 9, 2020
DW90A
System maintenance .......................................................................................................5-30

Regular Maintenance of Air-Conditioning System ...............................................................................5-30
Cleaning of Internal Air Filter Screen ...............................................................................................5-30
Adjustment of compressor belt.........................................................................................................5-30
Filling Method of Air Conditioner Refrigerant ..................................................................................5-31
Use and Maintenance of Air Conditioning Refrigerant Oil................................................................5-33
Accessory ............................................................................................................................................5-35
Tightening torque for each pipe joint of air conditioning system: .....................................................5-35
5-3
June 9, 2020 General information
DW90A Safety
General information List of General Tools and Toolings
Safety Specification
Main functions
of tools
Prior to the disassembly of the compressor, Used for the disassembly and
10# open-end
assembly of fixing bolts of pipes and
condenser, liquid storage tank, pressure switch, wrench
connector box cover plates
air conditioning pipe and other components, the
refrigerant in the air conditioning system shall be Used for the disassembly and
8# open-end
assembly of liquid storage tank on
discharged according to the requirements for wrench
condenser
"releasing (recovering) refrigerant in the air
14# open-end Used for the disassembly and
conditioning system". The disassembled pipe
wrench assembly of compressor fixing nuts
joints shall be sealed in a reliable method to
prevent moisture in the air from entering the air Used for the disassembly and
17# open-end
assembly of the pipeline from
conditioning system. wrench
evaporator to condenser
Used for the disassembly and
24# open-end
assembly of the pipeline from
wrench
compressor to condenser
Liquid refrigerant may cause blindness if 15# open-end Used for the disassembly and
splashed into eyes; spraying on the skin may wrench assembly of condenser fixing bolts
cause frostbite. In addition, containers 13# open-end Used for the disassembly and
storing refrigerants shall not be exposed to wrench assembly of condenser fixing bolts
the ambient temperature above 50°C, near Used for the disassembly and
heating devices or objects, or shall not be Electronic
assembly of evaporator mounting
runner
directly exposed to sunlight. It is easy to assembly
raise the temperature of the refrigerant, Used for the disassembly and
increasing the pressure in the container. Ratchet wrench assembly of fixing bolts of
When the pressure is high enough, the evaporator
container will leak or explode. Used for the disassembly and
15# sleeve assembly of fixing bolts of
The refrigerant itself is non-toxic, but it shall
evaporator
not be directly exposed to open flame or
heated metal; otherwise, toxic gas will be Used for the disassembly and
Lengthening
assembly of fixing bolts of
generated. connecting rod
evaporator
To avoid injury from refrigerant, goggles and Plastic bag and
Used for pipe joint sealing
gloves shall be worn for the operation, and adhesive tape
open flames or smoking shall be prohibited. Marking pen Used to mark the removed joint
List of Special Tools and Tooling
Specification
Main functions
of tools
Used for refrigerant release and
Manifold meter
filling
Vacuum pump Used for refrigerant filling
5-4
Structure, Function and Principle June 9, 2020
Component Composition and Location DW90A
Structure, Function and Principle
Component Composition and Location
1. Compressor
P2TA00001
The compressor is installed at the fan end of the engine and located below the left side of the whole
machine. It works driven by the belt by means of the driving force of the engine. The compressor is the
core component of air conditioning and refrigeration system. Its function is to compress low-temperature
low-pressure gaseous refrigerant into high-temperature high-pressure gaseous refrigerant. The air
conditioning compressor used in this system is of swash plate type.
The compressor model is GK7-5.0K-70. The displacement is 138 cm3 and the brand of refrigerating
machine oil is PAG100.
2. Evaporator assembly
P2TA00002
The evaporator assembly of the air conditioner is located in the right side of the instrument panel. Its
internal components include expansion valve, air door and servo motor, evaporation fan and return air
filter screen. The evaporator is used to absorb a large amount of heat in the surrounding air when the
low-temperature and low-pressure liquid refrigerant evaporates in the evaporator after throttling, thus
cooling or dehumidifying the vehicle. The evaporator for this type of air conditioner is of double parallel
flow type.
3. Air duct assembly and air inlet and outlet
The air conditioner of this machine has 3 front air outlets, 4 defrosting ventilation orifices and 2 foot air
outlets. The air outlets are connected with the evaporator through an air duct. The air duct is arranged
inside the interior trim of the instrument panel in front of the cab.
5-5
June 9, 2020 Structure, Function and Principle
DW90A Component Composition and Location
4. Control panel
1 2 3
P2TA00003
1. Fan gear switch 3. Air door control switch

2. Temperature adjustment switch for refrigerating
The air conditioning control panel is located on the right side of the steering wheel of the cab. It is used to
control the ventilation, air change, refrigeration, heating, defrosting and other functions of the air
conditioning system. By manually adjusting the knob, the temperature in the cab can be controlled to be
kept around the set temperature.
5. Condenser with reservoir assembly
P2TA00004
The condenser liquid storage tank assembly is installed on the platform on the right side of the cab, the
pressure switch is integrated on the pipe from the liquid storage tank to the evaporator, and the
condenser radiates heat through an electric fan. The condenser is a heat exchange device that
condenses the high-pressure superheated gaseous refrigerant discharged from the compressor into
liquid for supercooling after it emits heat. The air conditioner of this machine is of parallel flow type.
5-6
Component Composition and Location DW90A
6. Air conditioning pipeline
P2TA00005
The connecting pipes of the air conditioning system are divided into high pressure pipes and low
pressure pipes. The compressor-to-condenser pipe and the liquid storage tank-to-evaporator pipe are of
high pressure, and the evaporator-to-compressor pipe is of low pressure.
7. Pressure switch
The pressure switch monitors the pressure of the system to control the engagement and disengagement
of the compressor clutch, thus protecting the refrigeration system. The pressure switch used in this
system is of high- and low-pressure compound type, with the upper limit of high pressure being 3.14 Mpa
and the lower limit of low pressure being 0.196 Mpa.
8. Expansion valve
An expansion valve, as a throttling device, is used to throttle, reduce pressure and regulate flow as well
as to prevent wet compression, liquid percussion and abnormal overheating. The air conditioner of this
machine is provided with H-type thermal expansion valve.
9. Receiver-drier
A receiver dryer is necessary to ensure the normal operation of the compressor and refrigeration
system. It is used for liquid storage, filtration and drying.
Threaded connection or pressure plate connection shall be adopted. During the connection, the sealing
ring must be pushed into place before fastening.
5-7
DW90A Technical Parameters of the System
Technical Parameters of the System
Working medium Engine cooling water Unit

Heating module
Heating capacity 4800 W
Refrigerant R134a
Refrigerating capacity 4800 W
Air conditioning module
Filling quantity of refrigerant 1.2~1.3 kg
Voltage 24 V
Operating principle
Working process
The air conditioner of this machine is a steam compression type refrigeration air conditioner.
1. Compression process
The refrigerant after absorbing heat in the evaporator becomes low-temperature and low-pressure
vaporized refrigerant which after being absorbed and compressed in the compressor becomes high-
temperature and high-pressure vaporized refrigerant and is discharged in the condenser.
2. Condensation process
After the high-temperature and high-pressure vaporized refrigerant enters the condenser, its heat is
taken away by the engine radiator fan forcing the air across the condenser surface. Thus the refrigerant
is condensed into medium-temperature and high-pressure liquid refrigerant.
3. Throttling process
The medium-temperature and high-pressure liquid refrigerant is throttled by the expansion valve (the
refrigerant is expanded suddenly after being sprayed out of the expansion valve pores) after passing
through the dryer, thus becoming low-temperature and low-pressure liquid refrigerant mist and entering
the evaporator.
4. Evaporation process
The refrigerant after being throttled by the expansion valve becomes low-temperature and low-pressure
liquid refrigerant and is vaporized in the evaporator. The air inside the compartment, driven by the
evaporator fan, flows through the surface of the evaporator, and the refrigerant cools the air inside the
compartment by absorbing its heat, separating the condensate water. The refrigerant after absorbing the
heat is vaporized into low-temperature and low-pressure vaporized refrigerant and is compressed again
after being sucked into the compressor. Thus one refrigeration cycle is finished.
The compressor keeps on operating, the above refrigeration process circulates continuously, and the
heat inside the cab is continuously taken away by the refrigerant in the evaporator, thus cooling and
dehumidifying the complete vehicle.
5-8
Operating principle DW90A
Working Principle Diagram
P2TA00006
The above figure shows the complete cycle process of an air conditioning system:
High-temperature and high-pressure gaseous refrigerant is discharged from the compressor. Then, it
exchanges heat with the ambient air (generally 30-43°C) through the condenser and is cooled into
medium-temperature and low-pressure liquid. The liquid refrigerant from the condenser enters the
receiver dryer (receiver). The liquid refrigerant enters the expansion valve, which is a throttling element
that changes the medium-temperature and high-pressure refrigerant into low-temperature and low-
pressure liquid refrigerant after throttling and expanding. The liquid refrigerant with low temperature and
low pressure absorbs the heat from the cab in the evaporator (refrigeration core) and becomes gaseous.
The air cooled through the cooling core is blown to the cab by an evaporating fan for cooling. The low-
temperature and low-pressure gaseous refrigerant discharged from the evaporator (refrigeration core)
enters the compressor for the next cycle.
The heating system works directly with the antifreeze in the small circulation of the engine cooling
system. Its working process is as follows:
When the warm air and water valve are opened at the same time and the air conditioning control panel is
in heating state. The high-temperature antifreeze of the engine enters the warm air core of the
evaporator through water pipes, exchanging heat with outside cold air in the warm air core, and then the
evaporator fan blows the warm air after heat exchange into the interior of the cab for heating. Finally, the
low-temperature antifreeze returns to the engine and continues working in the small cycle of the engine
cooling system.
5-9
DW90A Operating principle
Electrical Schematic Diagram
P2TA00007
5-10
Air conditioning system test DW90A
Test and Adjustment
Air conditioning system test
It is suggested that the air conditioning system be inspected when the temperature is above
28°C. The air conditioning system may not start normally when the temperature is too low. The
following steps are used to simply judge whether the air conditioning system works normally and
in good condition. If there are conditions, a pressure gauge shall be connected for more accurate
judgment. If it is found that there is obvious abnormality in the operation of the air conditioning
system, refer to the "Fault Diagnosis and Judgment" in this manual for the handling method.
Step 1
Park the whole machine on a horizontal ground and check it to make sure that the parking brake is
pulled up. Start the engine and let your partner step on the accelerator to run the engine at high idle
speed.
Step 2
Turn on the air conditioner switch, adjust the air conditioner to the cooling mode, and control the air
supply speed to the high-speed mode through the adjustment of the air speed switch. Select the lowest
temperature.
Step 3
Allow the air conditioning system to operate stably for 2 min. Observe the end face of the belt pulley of
the air conditioning compressor. Under normal circumstances, the clutch shall be engaged and the end
face of the belt pulley shall rotate with the belt. If the pulley end face is stationary, the compressor is not
working. After confirming the operation of the compressor, proceed with the following steps.
5-11
DW90A Air conditioning system test
Step 4
Check whether the refrigeration function operates normally according to the following steps
1. Check whether the air temperature at the cab outlet is obviously lower than the outside air
temperature. If not, the air conditioning system works abnormally.
2. Observe the level glass beside the liquid storage tank. Under normal circumstances, bubbles should
not be seen through the level glass, or there are only a few bubbles. If a large number of bubbles are
seen, or the liquid shows foam, the air conditioning system is faulty.
3. Touch the upper part of the condenser near the air inlet and the lower part near the air outlet with
hands respectively. Under normal conditions, the upper part should feel a little hot and the lower part
should feel close to the air temperature. If the temperature near the air inlet is not high, it indicates
that the refrigerant is insufficient or the compressor is not working properly. If there is no obvious
temperature difference between the normal temperature area and the high temperature area, it
means that the condenser has poor heat dissipation, and needs to be cleaned on the surface.
4. Observe the level glass beside the liquid storage tank and touch the lower end of the liquid storage
tank by hand. If the lower end of the liquid storage tank is cold and bubbles are seen in the level
glass, it indicates that the filter screen in the liquid storage tank is blocked. Under normal conditions,
the temperature of all parts of the liquid storage tank is basically the same as that at the condenser
outlet.
5. Touch the compressor suction pipe joint (thicker joint) by hand. If it is not cold, it means that the
refrigerant is insufficient or the refrigeration system is blocked or the compressor valve plate is
damaged. Further checking is needed.
6. The anti-frost sensor in the evaporator is damaged if the cold air is turned on for about 20-50
minutes, the air at the outlet is not cold, and the air volume becomes smaller and smaller, and if the
cold air is turned off (but the air is turned on) for 10-15 minutes, then the cold air is turned on again,
and the cooling and air volume become normal again.
7. Check the compressor for normal working after turn on the refrigeration for a few minutes, then stop
it for a few minutes and repeat this cycle for a few times; if the compressor works with or without the
refrigeration on, it indicates that the system contains too much water; if the compressor works with
the refrigeration on and fails to work without the refrigeration on, it indicates that the air temperature
is lower than or near the setting temperature, or the control panel fails.
8. If the refrigeration works for several seconds ~ dozens of seconds and then stops for several
seconds ~ dozens of seconds, and this cycle is repeated a few times, it indicates that the refrigerant
is excessive, or the refrigeration system contains air or the condenser is too dirty, making a high
system pressure and activation of automatic protection; therefore, further inspection and processing
are required.
5-12
Removal and installation of air conditioning components June 9, 2020
Removal and Installation of Compressor DW90A
Removal and installation of air conditioning components
Removal and Installation of Compressor
Discharging (recycling) of refrigerant in the air conditioning system
The release of refrigerant is only described in this manual. If conditions permit, special equipment is
recommended for recovery and reuse of refrigerant. Incorrect operation of refrigerant releasing will have
a bad effect on the life of the air conditioning system, especially compressor.
Tools Required
1 Manifold meter 1

1. Stop or turn off the air conditioning system for at least
one hour, turn off the main power switch and hang a
warning sign of "Do not operate".
P2TA00008
2. Close the high and low pressure valves at the instrument
of the manifold meter first. (Manifold meter)
P2TA00009
3. Close the valve of high and low pressure joints.
P2TA00010
5-13
June 9, 2020 Removal and installation of air conditioning compo-
nents

4. Open the front cover door of the cab and open the front
cover door to fully expose the connecting line on the
evaporator.
P2TA00011
5. Remove the plug caps from the HP/LP filling openings
on the evaporator. Respectively connect the HP and LP
valves of the manifold meter to the filling openings of the
HP and LP pipelines. Then open the valves at the
connectors.
Note: If the pipeline is relatively thick, the pipe

with a relatively thin connector is the LP pipe. If the
pipeline is relatively thin, the pipe with a relatively thick
connector is the HP pipe. The error prevention design
is adopted for the connector. That is to say, the
P2TA00012 connector can only be installed on a correct pipe.
6. Slowly loosen the low-pressure valve on the manifold
meter to allow the refrigerant to slowly eject. Pay
attention to the opening of the control valve. If the flow
rate is too high, the refrigerant oil may gush out with the
refrigerant. It is only necessary to control whether the
refrigerant oil gushes out (the refrigerant is gaseous
after being discharged, and the refrigerant oil is liquid.
You can aim the refrigerant outlet at a blank sheet of
paper and observe whether there are any liquid drops
P2TA00013 gushing out). In 10 min, slowly open the HP valve and
control flow velocity at the same time, to avoid loss of
refrigerant oil. The overall release process shall last
15~30 min.
Alarm: It is prohibited to discharge the

refrigerant from the HP end at the very beginning
because refrigerant oil will easily come out with the
refrigerant.
7. Close the high- and low-pressure connectors and
remove them.
P2TA00014
5-14
Removal and Installation of Compressor DW90A
Remove the line connecting the compressor and the compressor.
Tools Required
2 Plastic bag
3 Adhesive tape
If the compressor is damaged internally or the refrigerator oil is observed to turn gray or black,
the liquid storage tank must be replaced while the compressor is replaced. Otherwise, the
service life of the compressor will be affected.

1. Loosen the fixing bolt of the compressor pipeline with a
wrench and take off the pipeline. (14# open-end wrench,
plastic bag and adhesive tape)
P2TA00015
2. Wrap the removed two pipeline joints and the air inlet
and outlet of compressor with clean and undamaged
plastic bags and tie them tightly with adhesive tapes to
prevent air and foreign matters from entering the
pipeline.
3. Disconnect the compressor clutch harness connector.
P2TA00016
4. Remove the belt according to the removal and assembly
of belt and tension pulley in this manual. First, loosen
the tension pulley and remove the belt.
5. Remove the 4 M8 bolts fixing the compressor to remove
the compressor. (#13 open-end wrench)
5-15
nents
Installation Method
Tools Required
2 Preset torque wrench 1

1. Tighten 4 M8 fixing bolts of air conditioning compressor
with preset torque wrench, and control the torque to
15.7-19.6Nm. (Preset torque wrench)
P2TA00017
2. Install the belt according to the removal and assembly of
belt and tension pulley in this manual.
3. Connect the compressor clutch connector and fix the
compressor pipeline to the air conditioning compressor
with bolts. (13# open-end wrench)
P2TA00018
5-16
Removal and Assembly of Belt and Tension Pulley DW90A
Removal and Assembly of Belt and Tension Pulley
Tools Required
1 Ratchet wrench 1

1. Clamp the concave hole on the outer profile of the
tension pulley with a ratchet wrench and press it down to
move the tension pulley down.
P2TA00019
2. Loosen the belt and remove the ratchet wrench.
P2TA00020
3. Remove air conditioning compressor belt.
5-17
nents
Removal and installation of evaporator mounting assembly
Tools Required
2 Cross screwdriver 1
3 Straight screwdriver 1
4 Ratchet wrench 1
5 Sleeve 10#, 18# 2
6 Lengthening connecting rod 1
The following operation sequence is used to remove the evaporator assembly from the cab. Most
of the actual failures occur at some components (such as fans and circuits) in the evaporator.
Therefore, to avoid unnecessary operations, it is recommended to selectively remove, repair and
replace the evaporator assembly after performing fault judgment according to the content of
"Fault Diagnosis and Judgment" in this manual.

1. Discharge the refrigerant in the air conditioning system
according to the requirements of "discharging (recycling)
of refrigerant in the air conditioning system".
2. Pick up the cushion.
P2TA00021
5-18
Removal and installation of evaporator mounting assembly DW90A

3. Remove the set screw on the panel (cross screwdriver).
P2TA00022
4. Remove the integral panel.
P2TA00023
5. Remove the fixing clamp on the inlet and outlet pipes of
the air conditioner. (Electronic runner and 10# sleeve)
P2TA00024
5-19
nents

6. Remove the fixing knob of the pipeline. (24# and 17#
open-end wrenches)
P2TA00025
7. Remove the bolts fixing the evaporator. (Sleeve 18#)
P2TA00026
8. Remove the electrical connector on the evaporator.
5-20
Replacement of A/C control panel DW90A
Replacement of A/C control panel
Tools Required
1 Cross screwdriver 1

1. Pull out the control panel trim cover. The trim cover is
fixed on the interior trim part via a plastic buckle, and it
can be pulled out directly.
P2TA00027
2. Remove the entire inlaid inner panel (cross screwdriver).
P2TA00027
3. Remove the control panel by unplugging the control
panel connector.
Check and replacement of A/C fuse
When it is found that the air conditioner is not working after the whole machine is started, it is necessary
to check whether the air conditioner fuse is burnt out. Please refer to the electrical part of this manual for
specific operation.
5-21
nents
Removal and replacement of reservoir
Removal of Liquid Storage Tank
Tools Required
1 Wrench 10# 1
2 Adhesive tape 1
3 Plastic bag 1

according to the requirements of discharging (recycling)
of refrigerant in the air conditioning system.
2. Remove the fixing bolts of the pipes from the condenser
to the liquid storage tank and those of the pipes from the
liquid storage tank to the evaporator. Remove the pipes
from the condenser to the liquid storage tank and those
from the liquid storage tank to the evaporator. Seal the
open joints and air inlet and outlet with plastic bags and
adhesive tapes. (8# wrench, plastic bag and adhesive
tape)
P2TA00028
3. Loosen the hoop fixing bolt on the bracket of the liquid
storage tank. Then, the liquid storage tank can be
removed. (8# wrench)
P2TA00028
5-22
Removal and replacement of reservoir DW90A
Replacement of Liquid Storage Tank

P2TA00028
2. Loosen the hoop fixing bolt on the bracket of the liquid
storage tank. Then, the liquid storage tank can be
removed. (8# wrench)
P2TA00028
5-23
nents
Removal and installation of condenser
Tools Required
1 Wrench 10# 1
2 Adhesive tape 1
3 Plastic bag 1

1. Perform steps 1-3 in the removal and installation of the
reservoir.
2. Remove the fixing bolts of the pipes from the
compressor to the condenser and those of the pipes
from the evaporator to the liquid storage tank, and seal
the open joints and air inlet and outlet with plastic bags
and adhesive tapes. (10# wrench, plastic bag and
adhesive tape)
P2TA00029
3. Remove the condenser fixing bolts (with 4 bolts on the
left and right sides respectively). (13# wrench)
P2TA00030
5-24
Removal and installation of pressure switch DW90A
Removal and installation of pressure switch
Tools Required
1 Wrench 27# 1

2. Pull out the connector of the pressure switch upwards.
P2TA00031
3. Unscrew the pressure switch. (27# wrench)
P2TA00031
4. The assembling sequence is in the reverse order of
disassembling.
5-25
June 9, 2020 Fault diagnosis and judgment
DW90A Common fault classification
Fault diagnosis and judgment
Common fault classification
Common Faults of Air-Conditioning System:

1. No or small air supply by the air conditioner (when the correct gear position is selected)
2. Warm air or natural air is generated when the refrigeration mode is started.
3. Natural air is generated when the warm air mode is started.
Diagnosis and removal of common faults in air conditioning system
The main faults of air conditioner are divided into two conditions:
1. The air conditioner has no air, or has small air output.
2. The air conditioner has insufficient refrigeration or no refrigeration.
The air conditioner has no air, or has small air output.
Phenomenon Cause and Inspection Site Countermeasures and Treatment

Verify whether the vehicle voltage is not less
Insufficient voltage
than 24V.
Insufficient air volume Fault of evaporation fan or speed Replace the evaporation fan or adjust the
regulating resistor resistor.
Filth blockage of filter screen Clean the filter screen.
The evaporating fan is damaged Replace evaporating fan
The air conditioner has no
air output. Detect the air conditioner fuse, power
Evaporating fan has no voltage
supply voltage and relay.
5-26
Fault diagnosis and judgment June 9, 2020
Diagnosis and removal of common faults in air conditioning system DW90A
The system can run, but there is insufficient refrigerating capacity (mainly check with a manifold
pressure gauge).
The normal range of high pressure is 1.4-1.6 MPa and the normal range of low pressure is 0.13-0.25
MPa at the ambient temperature of about 30-35 °C.

Release excessive refrigerant and check
Excessive refrigerant filling or frost on the
the pressure gauge and sight glass until
Both high pressure and low air suction pipe (sometimes)
they are in normal condition.
pressure are excessive
Release the refrigerant, vacuumize and fill
There is incoming air.
again.
The high pressure is too high
Filth blockage of air inlet mesh on
and the low pressure is Clean the air inlet mesh or condenser core
condenser side or condenser core
slightly high.
The high pressure is slightly
high and the low pressure is The opening of expansion valve is too big. Replace the expansion valve
too high.
Leak detection, repair and filling of
System leakage (insufficient refrigerant)
Both high pressure and low refrigerant
pressure are too low. Receiver-dryer or expansion valve Replace the receiver dryer or expansion
blocked valve
The refrigerant is insufficient; the air
return pipe of the compressor is not cool
when touched by hand; the refrigerant has Add refrigerant
bubbles as observed through the sight
glass.
The high pressure is far lower The opening of expansion valve is too
than the normal low-low Replace the expansion valve.
small
pressure.
The air inlet screen of evaporator is dirty
Clean the filter
and blocked
The expansion valve is polluted and
Replace the expansion valve.
blocked.
The high pressure is far

The valve plate of the compressor is
higher than the normal low- Replace the compressor.
damaged.
low pressure.
The system cannot run normally

Check the air conditioning circuit and remove
The compressor has no electrical input.
The compressor fails to the fault
work (Clutch does not With electricity, the clutch is burned down. Replace the compressor.
engage) Check leakage points, repair, pump vacuum
No refrigerant; pressure switch protection
again and fill refrigerant.
5-27
DW90A Doggerel for the Repair of Air Conditioner
Doggerel for the Repair of Air Conditioner
If the low pressure is high and the high pressure is low, replace the compressor.
If both the high and low pressures are too high, please exhaust air or solve the heat dissipation problem.
There is water vapor in the gauge shaking system, and the vacuum must be completely evacuated.
If both the high and low pressures are too low, there may be insufficient refrigerant or the system is
blocked.
5-28
Fault diagnosis and judgment June 9, 2020
Precautions for Maintenance DW90A
Precautions for Maintenance
1. When replacing system components, it is important to ensure that the open ports can be connected
in a short period of time, and those that cannot be connected in a short period of time need to be
wrapped with dust caps or plastic bags to prevent foreign matters and dust from entering the
pollution system.
2. When replacing large components (such as condenser, evaporator or long pipes), please add the
refrigerant oil with the same brand to maintain the lubrication requirements of the compressor.
3. When the air conditioner discharges refrigerant, it shall slowly discharge it from low pressure to
prevent the compressor oil from discharging.
Process of vacuum pumping and refrigerant filling:
1. Gauge set connection: Connect the fluorine adding hose with manifold pressure gauge according to
color, with the end of the blue hose connected to the blue low-pressure gauge and the other end
connected to the blue quick connector; with the end of the red hose connected to the red high-
pressure gauge and the other end connected to the red quick connector; with the end of the yellow
hose connected to the intermediate interface and the other end connected to the vacuum pump.
Connect the high and low pressure quick connectors to the high and low pressure filling ports of the
compressor respectively.
2. Vacuum pumping: Start the vacuum pump and open the high and low pressure gauge set to pump
vacuum. First, pre-pump vacuum for 5 min, close the gauge set, and observe whether the pressure
gauge shows pressure rise. If there is no obvious rise, open the gauge set and continue pumping
vacuum for 20-30 min, so as to ensure that the vacuum degree of the system is below 750 mmHg (-
0.1 MPa).
3. Refrigerant filling: Close the gauge set, connect one end of the yellow hose connected to the vacuum
pump to the refrigerant bottle (or tank), loosen the connection between the yellow hose and manifold
pressure gauge, and use refrigerant to discharge air from the hose section before tightening. Open
the hand valve of the gauge set and fill it with refrigerant. (Note that the compressor is not started at
this time and that the refrigerant can only be added by means of the pressure difference between the
refrigerant tank and the system). If the refrigerant charge volume in this way cannot meet the
demand, the hand valve of the high-pressure gauge must be closed, the air conditioning compressor
must be started, and the refrigerant must be sucked through the low-pressure port.
At this point, it must be ensured that the interface of the refrigerant bottle (or tank) faces
upwards. The system sucks gaseous refrigerant. In case of liquid refrigerant, it may easily cause
damage to the compressor due to liquid impact.
When replacing system components, it is important to ensure that the open ports can be
connected in a short period of time, and those that cannot be connected in a short period of time
need to be wrapped with dust caps or plastic bags to prevent foreign matters and dust from
entering the pollution system.
When replacing large components (such as condenser, evaporator or long pipes), please add the
refrigerant oil with the same brand to maintain the lubrication requirements of the compressor.
5-29
DW90A How to judge whether there is enough refrigerant?
How to judge whether there is enough refrigerant?
1. Look at the sight glass (located on the receiver dryer): When the engine is idling, start the air
conditioner. When it is just started, there is a slight amount of bubble. It disappears after the throttle is
advanced. A clear lens indicates that the refrigerant is just right. If it is always clear during starting, it
indicates that there is excessive refrigerant; if there are bubbles all the time, the refrigerant is still
insufficient. If there is fog, it means that there is water, and vacuum must be re-pumped.
2. Judging by the high and low pressure and hand feeling: The normal range of high pressure is 1.4-1.6
MPa and the normal range of low pressure is 0.13-0.25 MPa at the ambient temperature of about 30-
35 °C. If both the high and low pressures are too high, the air return pipe of the compressor shall feel
cold by hand and there is serious condensation, even frost, it indicates that there is too much
refrigerant. If both the high and low pressures are too low and the air return pipe of the compressor is
not cool by touch, the refrigerant is insufficient.
5-30
System maintenance June 9, 2020
Regular Maintenance of Air-Conditioning System DW90A
System maintenance
Regular Maintenance of Air-Conditioning System
Cleaning of Internal Air Filter Screen

1. Open the cab front cover door and remove the
maintenance cover of the internal air filter screen.
P2TA00032
2. Remove the internal air filter screen.
3. Blow off dust from the air outlet face of the internal air
filter screen to the air inlet face with compressed air.
Adjustment of compressor belt

1. Vertically apply a load W=1.5Kg(3.3075lb) to the center
of tangential line of the belt and two belt pulleys (air
conditioning compressor belt pulley and engine belt
pulley) by hands. The deflection f of belt shall be 5 ±
1mm(0.197 ± 0.039in). If there is great or little belt
deformation, the belt tensioning force is inappropriate
and needs to be adjusted. (Ratchet wrench)
P2TA00033
2. Clamp the tension pulley recess with a wrench. (Ratchet
wrench)
P2TA00034
5-31
June 9, 2020 System maintenance
DW90A Regular Maintenance of Air-Conditioning System

3. Tighten the tensioning bolt to fasten the belt; loosen the
tensioning bolt to loosen the belt. Constantly adjust the
tensioning bolt and test the belt deformation until the belt
tensioning force is appropriate. (Ratchet wrench)
4. Lock the fixing nut of the tension pulley. (Ratchet
wrench)
Filling Method of Air Conditioner Refrigerant
Even if there is only a small amount of water in the air conditioning system, the water vapor at
low temperature may freeze, causing such problems as blockage of refrigeration cycle or
corrosion of compressor valve. Therefore, during the replacement of parts or refilling of
refrigerant after the air conditioning system is reinstalled in the whole machine, the refrigerant
filling can only be continued after the vacuum pumping, pressure maintaining and leak detection
are strictly carried out and the system is confirmed to be of good airtightness.
Since the air conditioning system is not an absolutely sealed system, there may be a lack of refrigerant
after it is used for a long time. If it is confirmed that the refrigerant in the system has not completely lost
at this time, the refrigerant can be replenished according to step 6 of this instruction.

1. According to the order of "releasing (recovering)
refrigerant in the air conditioning system" in this manual,
connect the manifold meter with the air conditioning
filling port and confirm that there is no refrigerant in the
system.
2. Connect the hose connecting port A on the manifold
meter to the vacuum pump. (Vacuum pump and
manifold meter)
P2TA00035
5-32

3. Start the vacuum pump and vacuumize for 5 min and
make sure the high and low pressure gauge indication is
about -750mmHg (or-0.1MPa).
Note: Generally, the high pressure gauge and

joint are red, while the low pressure gauge and joint
are blue.
P2TA00036
4. First ,close the high-pressure valve (HI) and low-
pressure valve (LO) of the pipe pressure testing device,
and then close the vacuum pump.
P2TA00035
5. Wait for 5 min in this state and observe whether there
are changes on the reading of the low pressure gauge. If
the pressure rises, there is a leak in the system. Find
and repair the leak position and repeat steps 3-5.
P2TA00037
The following 6-8 steps are used for operations by using

portable canned refrigerant. Depending on the refrigerant
packaging form, it may be different. Please make sure that
the refrigerant container is properly connected to the
manifold meter.
6. Install the cock onto the refrigerant container.
7. Connect the hose connecting point A of manifold meter
to the cock of the refrigerant container.
P2TA00038
5-33
DW90A Regular Maintenance of Air-Conditioning System
The following table provides reference values for the corresponding relation between pressure and
temperature. As the actual working pressure of the air conditioning system is related to such factors as
compressor speed, solar sunshine intensity and evaporator air volume, the data in the table below are
for reference only:
Indication Range of High Indication Range of Low

Ambient temperature
Pressure Gauge Pressure Gauge
Degree centigrade (°C) Kg.f/cm2 Kg.f/cm2
15.5 °C 8.4-10.5 1.57-1.9
21.1 °C 10.5-12.6 1.57-1.9
26.6 °C 12.6-14 1.67-2.1
32.2 °C 14-15.4 1.67-2.1
35 °C 15.4-16.4 1.77-2.1
37.7 °C 16.1-17.5 1.77-2.1
40.5 °C 17.5-19.3 1.9-2.4
43.3 °C 18.2-21.8 1.9-2.6
Use and Maintenance of Air Conditioning Refrigerant Oil
Since R134a is used as refrigerant in this air conditioning system, it does not contain chlorine molecules,
so the refrigerant itself has no lubricating performance. For moving parts with high lubrication
requirements, such as the compressor, insufficient lubricant may cause friction loss and sintering. In
order to avoid this phenomenon, the whole machine is filled with refrigerant oil that is mutually soluble
with R134a refrigerant when it is shipped from the factory.
Considering the displacement and motion performance of the compressor, PAG (Polyalkyl glycol) engine
oil --100 is used in this machine. When the condenser, reservoir, compressor and evaporator in the air
conditioning system are disassembled or the refrigerant in them is discharged, a certain amount of
refrigerant oil (PAG100) needs to be refilled.
PAG100 refrigerant oil is suitable for working environment at -40 °C to 200 °C, which can meet the needs
of daily work.
Only PAG100 is allowed to fill in the machine as refrigerant oil. If refrigerant oil of other brands
are added or mixed, the lubricating oil will deteriorate and other components in the air
conditioning system will be damaged.
The following is a brief introduction to how to add refrigerant oil.

After discharging the refrigerant, disassembling the compressor pipeline and compressor according to
the foresaid, place the air conditioning compressor on a flat ground. Fill appropriate amount of refrigerant
oil into the compressor cylinder with a measuring cup, and reinstall the compressor and corresponding
pipelines after filling. After refilling the refrigerant, the filled refrigerant oil will dissolve with the refrigerant
and circulate in the air conditioning system.
5-34
Refrigerant oil filling position on the compressor:
P2TA00039
The filling amount of refrigerant oil is as follows:
Model of refrigerant oil PAG46 NO-OIL8 PAG100

Replace the supplementary quantity of the
44ML/0.05qt 35-40ML/0.04qt 36ML/0.04qt
evaporator core assembly;
Replace the supplementary quantity of the
22ML/0.02qt 35-40ML/0.04qt 18ML/0.02qt
condenser assembly, drying bottle and pipeline;
Quantity of refrigerant oil refilled 22ML/0.02qt 20-25ML/0.03qt 18ML/0.02qt
Replace the supplementary quantity as required by
10ML/0.01qt 10ML/0.01qt 10ML/0.01qt
the compressor;
Quantity to be replenished after installation of air
conditioner for new machines arriving at the 80ML/0.08qt 35-40ML/0.04qt 40ML0.04qt
designated port
5-35
DW90A Accessory
Accessory
Tightening torque for each pipe joint of air conditioning system:
Tightening torque
Thread Size
Metric Unit Imperial Unit
5/8-18UNF, M16×1.5 15.7~19.6 N.m
3/4-16UNF, M22×1.5 19.6~24.5 N.m
7/8-14UNF, M24×1.5 29.4~34.3 N.m
5-36
Accessory DW90A
6-1
June 9, 2020 Cab and covering parts
DW90A
Cab and covering parts

Structure, function and principle of cab .............................................................................6-3
Cab System ...........................................................................................................................................6-3
Platform..................................................................................................................................................6-3
Composition of platform assembly .....................................................................................................6-3
Removal and Installation of Cab Assembly .......................................................................6-4

Removal and installation of cab .............................................................................................................6-4
Disassembly sequence of cab for lifting.............................................................................................6-4
Removal of steering gear assembly...................................................................................................6-4
Removal of clutch and brake pedal assembly....................................................................................6-5
Removal of shock absorption system ................................................................................................6-6
Lifting..................................................................................................................................................6-7
Removal of driver's seat.....................................................................................................................6-8
Removal and installation of platform ......................................................................................................6-9
Precautions for installation and removal ............................................................................................6-9
Removal of platform ...........................................................................................................................6-9
Removal and installation of protection device .................................................................6-10

Removal of protection device...............................................................................................................6-10
Installation of protection device............................................................................................................6-14
6-2
Cab and covering parts June 9, 2020
DW90A
6-3
June 9, 2020 Structure, function and principle of cab
DW90A Cab System
Structure, function and principle of cab
Cab System
The cab system mainly consists of cab assembly, instrument panel assembly, driver chair assembly,
rearview mirror assembly, berth assembly and interior trim assembly. Among them: electrical, air
conditioning parts, hydraulic, control parts are assembled on the cab assembly.
Platform
Composition of platform assembly
The platform consists of a platform assembly and a rearview mirror assembly.

6-4
Removal and Installation of Cab Assembly June 9, 2020
Removal and installation of cab DW90A
Removal and Installation of Cab Assembly
Removal and installation of cab
Disassembly sequence of cab for lifting
Disassemble air conditioning components → Disassemble wiring harness connecting cab and frame →
Disassemble the main pump oil pipe of cab clutch → Disassemble the air pipe of foot operated brake
valve and hand brake valve in the cab → Disassemble air pipe of lifting handle → Disassemble steering
gear → Disassemble rear suspension → Disassemble front suspension of the cab → lifting.
Steps to install cab to machine: are in the reverse sequence of removal.
Removal of steering gear assembly

1. Remove the main instrument panel (1)
P2TC00001
2. Remove the bolts of the steering gear (2) and the
steering gear fixing bracket (3)
P2TC00002
6-5
June 9, 2020 Removal and Installation of Cab Assembly
DW90A Removal and installation of cab

3. Remove the fixing bolts of the dust cover and the dust
cover fixing bracket (4) at the bottom of the steering gear
P2TC00003
4. Loosen the bolts of the universal joint at the bottom of
the steering gear and separate it from the connecting
shaft (6)
6
2
P2TC00004/P2TC00005
Removal of clutch and brake pedal assembly

1. Remove the bolts connecting the clutch, brake pedal
assembly and cab housing.
P2TC00006
6-6
Removal of shock absorption system
Removal of Front Suspension Structure

1. Remove the nylon locknut (1) and the fixing bolt (2) and
then take out the pin shaft (3), with one on the left and
1
one on the right of the cab.
3
P2TC00007
2. Remove the front suspension vulcanizing sleeve (4),
with one on the left and one on the right of the cab.
P2TC00008
6-7
DW90A Removal and installation of cab
Removal of Rear Suspension Damping Structure

1. Release the mechanical lock (1) to separate the cab
from the shock absorber assembly.
P2TC00009
Lifting

1. Use suitable lifting tools to hook the 4 lifting rings at the
top of the cab.
1 2. Start the lifting device and slowly lift the cab away.
The weight of the cab is 950 kg. Please select an

applicable lifting appliance.
P2TC00010
6-8
Removal of driver's seat
Seat removal

1. Push the seat (1) to the rearmost position
2. Remove the seat fixing bolt (2)
P2TC00011
2 P2TC00012
6-9
DW90A Removal and installation of platform
Removal and installation of platform
Precautions for installation and removal
Before the disassembly and assembly, attention shall be paid to that the release of the electrical wiring
harness on the platform shall not affect the lifting of the platform and the water pipe of the air conditioner
condenser and the air filter assembly have been removed.
Removal of platform

1. Remove the 12 bolts (1) connecting the platform and the
platform support
2. Hook the platform handrail with lifting appliance;
3. Start the lifting device and slowly lift the cab away.
P2TC00013
4. Remove the fixing bolts (3) of the platform damping pad
(2).
2
The weight of the platform is 150 kg. Please select
3 an applicable lifting appliance.
P2TC00014
6-10
Removal and installation of protection device June 9, 2020
Removal of protection device DW90A
Removal and installation of protection device
Removal of protection device
Tools Required
1 Wrench #16, #18, #24, #30 4

1. Remove the M10 mounting bolts (symmetrically, with 8
bolts in total) on the wind scooper with #16 wrench, and
then remove the wind scooper.
P2TC00015
2. Use #24 wrench to remove the mounting bolts (10 bolts
in total, symmetrically on the left and right) of front
protective net M16, and then remove the front protective
net.
P2TC00016
6-11
June 9, 2020 Removal and installation of protection device
DW90A Removal of protection device

3. Remove the M10 mounting bolts (with 2 bolts in total) on
the lamp bracket with #16 wrench, and then remove the
bracket;
the lower rubber with #16 wrench, and then remove the
rubber;
5. Remove the upper M10 mounting bolts (with 3 bolts in
total) with #16 wrench;
6. Remove the M10 mounting bolts (with 6 bolts in total) in
the middle of the right fender with #16 wrench, and then
remove the right fender.
P2TC00017
7. Remove the M16 mounting bolts (with 3 bolts in total) of
the right fender bracket with #24 wrench, and then
remove the right fender bracket.
P2TC00018
the lamp bracket with #16 wrench, and then remove the
bracket;
the lower rubber with #16 wrench, and then remove the
rubber;
10.Remove the upper M10 mounting bolts (with 4 bolts in
total) with #16 wrench;
11.Remove the M10 mounting bolts (with 6 bolts in total) in
the middle of the left fender with #16 wrench, and then
remove the left fender.
P2TC00019
6-12
Removal of protection device DW90A

12.Remove the M16 mounting bolts (with 2 bolts in total) of
the left fender bracket with #24 wrench, and then
remove the bracket.
P2TC00020
13.Remove the M16 mounting bolts (with 3 bolts in total) of
the left fender bracket with #24 wrench, and then
remove the left fender bracket.
P2TC00021
14.Remove the M12 mounting bolts (with 3 bolts in total) on
the accumulator box bracket with #18 wrench, and then
remove the small bracket;
15.Remove the M16 mounting bolts (with 4 bolts in total,
including 2 in the front and 2 at the rear) on the
accumulator box bracket with #24 wrench, and then
remove the accumulator box bracket.
P2TC00022
6-13
June 9, 2020 Removal and installation of protection device
DW90A Removal of protection device

16.Remove the M10 mounting bolt (with 1 in total) in the
middle with #16 wrench, and then remove the vertical
plate.
17.Remove the M16 mounting bolts (with 3 bolts in total) on
the bracket with #24 wrench, and then remove the stone
deflector bracket.
P2TC00023
18.Remove the M20 mounting bolts (symmetrically, with 3
bolts in total) on the bracket with #30 wrench, and then
remove the rear anti-backward tilt bracket.
P2TC00024
6-14
Installation of protection device DW90A
Installation of protection device
Steps to install protection device: are in the reverse sequence of removal.

There is no connection among the front protective cover and wind scooper, the front fender and bracket
(left and right), the accumulator box bracket, the stone deflector (left and right) and the rear anti-
backward tilt assembly, which can be removed and installed simultaneously.
7-1
June 9, 2020 Structure
DW90A
Structure
Frame System ...................................................................................................................7-3
Frame overview .....................................................................................................................................7-3
Frame Structure Diagram...................................................................................................................7-3
Frame cross assembly ...........................................................................................................................7-4
Overview and Structure Diagram of Beam Assembly ........................................................................7-4
Frame cross assembly ......................................................................................................................7-4
Removal and installation of beam assembly..........................................................................................7-5
Removal of beam assembly...............................................................................................................7-5
Installation of beam assembly............................................................................................................7-7
Removal and installation of dump body assembly ............................................................7-8

Removal .................................................................................................................................................7-8
Installation ............................................................................................................................................7-10
7-2
Structure June 9, 2020
DW90A
7-3
June 9, 2020 Frame System
DW90A Frame overview
Frame System
Frame overview
The frame is of trapezoidal steel structure formed by connecting two longitudinal main beams and a
plurality of cross beams. It, as the substrate of the vehicle, supports all relevant parts of sprung mass
such as the engine, transmission, oil tank, vehicle body and cargo compartment and bears various
forces and moments transmitted to it.
Frame Structure Diagram

DW90A Frame System
P2TS00001
7-4
Frame System June 9, 2020
Frame cross assembly DW90A
Frame cross assembly
Overview and Structure Diagram of Beam Assembly
The beam assembly is a key component that connects the left and right longitudinal beams together to
form a complete frame. Its main functions are as follows:
1. Ensure that the frame has sufficient torsional rigidity, limit its deformation and reduce the stress in
some parts;
2. Serve as the fastening point for braking, hydraulic and electrical components and pipeline.
Frame cross assembly
8
7 9
6
5
4
3
2
1 10
11
12
13
P2TS00002
1. 1st beam 8. 7th beam

2. 2nd beam 9. Rotary seat
3. 3rd beam 10. Left longitudinal beam
4. 4th beam 11. Lifting cylinder support
5. Right longitudinal beam 12. Plate spring support
6. 5th beam 13. Upper wing surface
7. 6th beam
7-5
DW90A Removal and installation of beam assembly
Removal and installation of beam assembly
Removal of beam assembly
Tools Required
1 Wrench 24#, 30# 2
2 Copper hammer 1
8
7 9
6
5
4
3
2
1 10
11
12
13
P2TS00002
1. 1st beam 8. 7th beam

2. 2nd beam 9. Rotary seat
3. 3rd beam 10. Left longitudinal beam
4. 4th beam 11. Lifting cylinder support
5. Right longitudinal beam 12. Plate spring support
6. 5th beam 13. Upper wing surface
7. 6th beam
7-6
Frame System June 9, 2020
Removal and installation of beam assembly DW90A
Removal of the first cross member: remove the left and

right bolts with a wrench (24#).
P2TS00003
Removal of the second cross member: remove the left and

P2TS00004
Removal of the third cross member: knock out the pin with
a copper hammer after removing the cotter pin.
P2TS00005
Removal of the fourth cross member: remove the left and

P2TS00006
7-7
DW90A Removal and installation of beam assembly
Removal of the fifth cross beam: remove the upper and

lower bolts with a wrench (24#).
P2TS00007
Removal of the sixth beam:

1. Remove the bolt of the draw arm support with a wrench
P2TS00008 (30#);
2. Remove the fixing bolt between the middle support and
the cross beam mounting plate with a wrench (24#);
3. Remove the upper and lower wing bolts of the cross
beam with a wrench (30#).
P2TS00009
Installation of beam assembly
Tools Required
1 Wrench 24#, 30# 2
2 Torque spanner 24#, 30# 2
Tighten the bolts in turn against the hole positions to ensure that the tightening torque of M16 is 305±25
NM and that of M20 is 600±55 NM.
7-8
Removal and installation of dump body assembly June 9, 2020
Removal DW90A
Removal and installation of dump body assembly
Removal
Tools Required
1 Wrench 19#, 24# and 65# open-end wrenches 4

1. Remove flange bolts and nuts (1) with 24# wrench,
totaling 12 pairs;
2. Remove the right support (2) and the left support (3) and
hold the oil cylinder (4);
4
Note: Two persons are required for cooperation.
1 The oil cylinder needs to be supported to avoid falling.
3
2
P2TS00010
3. Remove the flange bolts (5) with 19# wrench, totaling 2
5 6 bolts;
4. Remove the pressure plate (6);
P2TS00011
7-9
June 9, 2020 Removal and installation of dump body assembly
DW90A Removal

5. Remove the pin shaft (7) with a copper hammer and a
7 rapping bar;
Note: Two persons are required for cooperation.
One person hammers the pin shaft out of the pin hole
with a copper hammer and a rapping bar from one end
of the pin shaft, and the other person holds the pin
shaft at the other end. The pin shaft weighs 22.5 kg
{49.6 lb}.
P2TS00012
6. Remove the pin shaft on the other side according to
steps 3, 4 and 5;
7. Remove the cotter pin (11), remove the pin shaft (12),
and then remove the tail hook (10);
12
11
10
P2TS00013
8. Remove the cotter pin (13), remove large slotted nut
13 14 15 (14) with 65# wrench or adjustable wrench, and remove
the pin shaft (15);
9. Remove the pin shaft on the other side according to step
8;
Note: Before the removal of pin shaft, the rear

tailgate must be hoisted and fixed to prevent it from
falling off. The total weight of the rear tailgate is about
1,300 kg {2,866 lb}.
P2TS00014
10.Remove the carriage assembly and lift the carriage
assembly to a safe place for storage.
Note: The total weight of the carriage is about

10,800 kg {23,814 lb}; slings with sufficient strength
shall be used.
7-10
Removal and installation of dump body assembly June 9, 2020
Installation DW90A
Installation
Install in the reverse order of removal.

● Please clean the pin hole and pin shaft surface before the installation.
● If the pin shaft is difficult to knock in, re-adjust the installation position of the carriage assembly and
then knock in.
● Fill grease after the installation.
8-1
June 9, 2020 Electrical system
DW90A
Electrical system
General information ...........................................................................................................8-3
Service Manual ......................................................................................................................................8-3
Precautions for Welding .........................................................................................................................8-4
Introduction to Symbols of Electrical Schematics ..................................................................................8-5
Graphic symbols of control switch and two-position manual control switch.......................................8-5
Graphic symbols for relays and electromagnets ................................................................................8-5
Graphic symbols of lights, signals and sensors .................................................................................8-6
Overview of instrument ......................................................................................................................8-7
Structure, Function and Principle ....................................................................................8-11

Power supply system ...........................................................................................................................8-11
Introduction to Functions..................................................................................................................8-11
Schematic Diagram of Power Supply System..................................................................................8-11
Electric lock ......................................................................................................................................8-12
Fuse .................................................................................................................................................8-14
Power main switch ...........................................................................................................................8-16
Battery..............................................................................................................................................8-17
Power supply relay...........................................................................................................................8-20
Starting system ....................................................................................................................................8-21
Starting motor...................................................................................................................................8-21
Generator .........................................................................................................................................8-26
Monitoring System ...............................................................................................................................8-30
Engine speed display .......................................................................................................................8-30
Service brake air pressure display ...................................................................................................8-30
Speed display...................................................................................................................................8-31
Engine water temperature display....................................................................................................8-31
Fuel level display..............................................................................................................................8-31
Hourmeter, mileage and fault information display............................................................................8-32
Voltage indicator ..............................................................................................................................8-32
Engine oil pressure display ..............................................................................................................8-32
Braking system ....................................................................................................................................8-33
Exhaust brake ......................................................................................................................................8-34
Intake heating ......................................................................................................................................8-36
Driving indication system .....................................................................................................................8-37
8-2
Electrical system June 9, 2020
DW90A
Turn/parking lights............................................................................................................................8-37
Clearance lamp ................................................................................................................................8-37
Reversing lamp/reversing alarm ......................................................................................................8-38
Horn .................................................................................................................................................8-39
Warning light ....................................................................................................................................8-41
Inter - axle differential lock ...................................................................................................................8-42
Lighting System .................................................................................................................................8-42
High/low beam .................................................................................................................................8-43
Front fog light/front top work light/side work light .............................................................................8-44
Wall light...........................................................................................................................................8-44
Windscreen wiper system ....................................................................................................................8-45
Air conditioning system ........................................................................................................................8-46
Sound system ......................................................................................................................................8-46
8-3
DW90A Service Manual
General information
Service Manual
This service manual is prepared in modules according to the main functions of the electrical system. In
this way, the maintenance personnel can quickly locate chapters corresponding to relevant faults any
time during maintenance. Although this service manual is written to be simple and easy to understand
especially regarding the jargon of a certain discipline, it is required that the maintenance personnel have
certain specialized knowledge to truly understand it.
First of all, this manual introduces the functions of each model; then main elements involved in each
function are introduced by describing their working principles, functions and schematics. After that,
module operation, fault diagnosis and testing are introduced.
The symbols on the schematics of elements represent the elements on the schematics. Most of them
represent the actual schematics of elements with some exceptions which will be specified in detail during
introduction of corresponding elements. This will help diagnosis of element faults.
When the elements are introduced, the fault diagnosis methods of some elements are included.
Nevertheless, these methods only apply to the elements themselves. That is to say, tests can only be
carried out with the above methods when the elements are removed from the whole machine.
Otherwise, these test methods cannot be used. In this case, operation may be carried out according to
the system fault diagnosis methods introduced in later chapters. If necessary after that, corresponding
elements may be removed and tested according to the element fault diagnosis methods mentioned
above.
The module fault diagnosis and test methods in this manual do not cover all faults. Therefore,
maintenance personnel shall use their brains and accumulate experience during troubleshooting.
To better describe the working principles of the electrical system in this manual, colored full lines will be
used to indicate the direction of current on the system schematics.
During fault diagnosis, the relationship between the overall and the individual (the system and an
element) shall be fully considered so that electrical system faults can be handled quicker, and more
accurately and easily.
Where digital multimeters are used, due to their measurement errors, corresponding values may be a
little bit different from those described in the manual. For example, when the Ω measuring capability
(with a measuring range of 200) of a digital multimeter is used, the red probe and the black probe shall
be shorted to measure the lead resistance; then when the resistance of other circuits is measured, the
measured resistance is subtracted by the lead resistance and then compared with the value described in
the manual.
8-4
General information June 9, 2020
Precautions for Welding DW90A
Precautions for Welding
To avoid possible damage to electrical parts and bearings, correct welding procedures must be followed.
The following operating procedures shall be followed for welding on loaders or diesel engines with
electrical parts installed.
1. Place the machine on a flat surface.
2. Put the electric lock in the “OFF” position and shut down the diesel engine.
3. Pull up parking brake.
4. Turn off the disconnect switch to disconnect the storage battery with the frame.
5. Clamp the ground cable of the welding machine with the component to be welded. The closer the
grounding position to the welding position, the better. Check and confirm that none of the following
are included in the circuit from the ground cable to the component to be welded.
● Bearing
● Hydraulic oil cylinder
● Controller or internal circuits of other electronic elements and components; This is to reduce possible
damage to the following components:
● Bearing
● Hydraulic parts
● Electronic elements and components
● Other possible parts on the machine
6. Inflammables shall be kept far from the welding site. Each cable shall be well protected against the
spark or spatter generated during welding, thus preventing unnecessary losses and injuries caused
by fire disasters.
7. Welding shall be carried out according to normal welding safety procedures.
8-5
DW90A Introduction to Symbols of Electrical Schematics
Introduction to Symbols of Electrical Schematics
Graphic symbols of control switch and two-position manual control switch
Schematic Symbol of Two-Position Hand-

Schematic Symbol of Control Switch
Operated Switch
Graphic Graphic
S/N Description Description S/N Description Description
symbol symbol
Pressure Emergency
1 Normally open 1 Hold
switch stop switch
Pressure
2 Normally closed 2 Button switch Snap
switch
Temperature
3 3 Knob switch Hold
switch
4 Level switch 4 Knob switch Snap
Inductive
5 proximity
switch
Magnetic
induction
6
proximity
switch
Graphic symbols for relays and electromagnets
Graphic symbols of relay Graphic symbols of electromagnets

Graphic Graphic
symbol symbol
General- A set of normally Switch

1 1
purpose relay open contacts electromagnet
8-6
Introduction to Symbols of Electrical Schematics DW90A
Graphic symbols of relay Graphic symbols of electromagnets

Graphic Graphic
symbol symbol
A group of
transfer contacts
Relay with opened first and
normally- closed later; coils Proportion
2 2
closed are connected in electromagnet
contacts parallel with
suppression
diode
Double-coil
3
electromagnet
Graphic symbols of lights, signals and sensors
Graphic symbols of lights and signals Graphic symbols of sensor

Graphic Graphic
symbol symbol
Variable
1 Lamp 1 resistance
type sensor
Temperature
Rotating
2 2 sensor with
signal lamp
alarm switch
Pressure
3 Electric horn 3 sensor with
alarm switch
Buzzer and back Inductive

4 Buzzer 4
alarm speed sensor
5 Speaker
6 Flasher relay
8-7
Overview of instrument
Icon of instrument
1 2 3 4
5 6 7 8 9 10 11
P2TE00026
1. Tachometer 4. Speedometer 7. Button 1 10. Voltmeter

2. Air pressure gauge I 5. Coolant temperature 8. LCD display area 11. Oil pressure gauge
3. Barometer II gauge 9. Button 2
6. Fuel gauge
Input Signal Level

Input signal level
S/N Description Alarm light color under Normal Icon
in alarm state
Condition
1 Energy saving indication Green Suspended GDN
2 Exhaust brake indication Yellow Suspended GDN

8-8
Input Signal Level

Input signal level
in alarm state
Condition
3 High speed indication Green Suspended GDN
4 Low speed indication Green Suspended GDN
5 Left-turn indicator Green Suspended +24V
6 Right-turn indicator Green Suspended +24V
Storage battery charging

7 Red +24V GDN
indication
Inter-axle differential
8 Green Suspended GDN
lock indication
Engine preheating
9 Yellow CAN
indication
10 Truck bed lifting alarm Red Suspended GDN
11 Low fuel alarm Yellow Software control
12 Parking brake indication Red Suspended GDN
13 Low air pressure alarm Red Software control

8-9
Input Signal Level

Input signal level
in alarm state
Condition
14 High beam indicator Blue Suspended +24V
Alarm for high water

15 Red Software control
temperature of engine
Door open warning

16 Red Suspended +24V
indication
Indication of low engine

17 Red Software control
oil pressure
18 Cab rear work light Green Suspended +24V
19 Cab tilting alarm Red Suspended GDN
20 Air clogging alarm Yellow Suspended GDN
Clearance lamp
21 Green Suspended +24V
indication
Alarm for low engine

22 Red Suspended GDN
coolant level
23 Water-in-fuel alarm Red CAN
Engine shutdown
24 Red CAN
indication
25 Engine fault alarm Red CAN
Engine diagnostic
26 Red CAN
indication
8-10
Input Signal Level

Input signal level
in alarm state
Condition
Alarm for high oil

27 Red Suspended GDN
temperature of gearbox
28 Fog light indicator Yellow Suspended +24V
29 Gearbox fault alarm Red Suspended GDN
Working indication of
retarder
Reversing lamp
indication
Front top lamp

indication
Indication of side work

light
Rear work lamp

indication
Instrument power source/GND
P2TE00061
8-11
DW90A Power supply system
Structure, Function and Principle
Power supply system
Introduction to Functions
The power supply system of DW90A supplies power for the whole vehicle. Before the diesel engine is
started, it is powered separately by the storage battery. After it is started, it is powered together with the
generator.
Under normal working conditions, switching on the electric lock or starting the diesel engine can both
realize normal power supply.
The wall light is the electrical component that can work normally after the main power switch is closed
and the electric lock is not opened.
Schematic Diagram of Power Supply System
The following figure shows the schematic diagram of DW90A power supply system. When
the battery main switch is closed, power will be supplied to wire size 100/110/176/177/178.
When the key switch is rotated to position 1, the contact of the power relay will be closed,
and 103 will receive power, i.e. the bus fuse will be powered through the electric lock.
P2TE00062
8-12
Power supply system DW90A
Electric lock
Installation position and front view of electric lock

Electric lock mounting position Electric lock front view
P2TE00063 P2TE00064
Description of gear position
Among pin 1, pin 2, pin 3, pin 5, pin 6, pin 7 and pin 8; pin 1 is for power supply, pin 6 for power
connection (controlling power supply relay coil) and pin 8 for starting.
“LOCK”: It is a gear position for inserting in and pulling out the key to the electric lock. In this position, the
power supply for all electrical equipment on board will be cut off except some not controlled by the
electric lock, such as the wall lamp, but they are controlled by the main power switch.
“ON”: It is the second gear position reached by inserting the key in the electric lock and turning
clockwise. The position “ON” is used to connect power supply for all electrical equipment of the whole
machine. Such power supply comes from the storage battery.
“START”: It is the fourth gear position reached by inserting the key in the electric lock and turning
clockwise. It is used to start the diesel engine and is not self-holding. After the hand is released, the
electric lock key will automatically go back to the gear position “ON”.
Wire size 1 2 3 5 6 7 8
Line color White 1 White 2 White 3 White 5 White 6 White 7 White 8
Cross-sectional area
1.5 1 1 1 1 1 1
(mm^2)
Wire length (mm) 700 700 700 700 700 700 700
Load (A 5 5 5 5 5 5 5
LOCK ● ●
ACC ● ● ●
Gear ON ● ● ● ●
PH ● ● ● ●
START ● ● ●
8-13
Precautions
1. After the diesel engine is started, release the electric lock immediately to let it go back to its position.
Otherwise, serious electrical fault will be caused.
2. If the first start fails, the electric lock needs to be closed before the second and third starts begins.
First, turn the electric lock key to the gear position "LOCK". Then turn it to the gear position “ON” and
finally the gear position “START” to finish a starting cycle.
3. If the diesel engine is not started after a starting period of 15 s, turn off the electric lock and begin the
second and third starts. Do not start consecutively for more than three times. Each start shall not
longer than 15 s. Otherwise, the continuous high-power output of the storage battery will result in a
low battery.
4. If starting fails three times in a row, turn off the electric lock and start again for the second round after
30 min. If necessary, check the storage battery and the starting circuit and determine whether any
fault affects starting.
5. Starting difficulty mostly occurs outdoors in cold winter when the ambient temperature may be lower
than -18 °C. If possible, starting may be tried indoors or helped by heating.
Procedures for Detection of Electric Lock Fault
1. Remove all connectors on the electric lock pin to separate the electric lock from the whole machine
circuit.
2. Put the digital multi-meter to the “Ω” position and adjust its range to 200 Ω.
3. Put the electric lock in the gear position of “LOCK”. Measure two of the seven pins of the electric lock
one by one by use of the two probes of the digital multi-meter. At this time, except that the display
value of [1,5] pin is "0", the display values of any other combinations shall be "1". [1, 5] pin shall
display the value of "0" at any position, which will not be described again below.
4. Put the electric lock in the gear position "ON". As is described in step 3, measure two of the six pins
of the electric lock one by one by use of the two probes of the digital multi-meter, among which the
measurement display values between pins [5] and [7] as well as pin [8] and any other pins are "1",
and the display values of other pins are "0".
5. Put the electric lock in the gear position "START". Since the gear position "START"cannot self-hold,
the help from a third party may be needed to keep the electric lock in the gear position "START". As
is described in step 3, measure two of the six pins of the electric lock one by one by use of the two
probes of the digital multi-meter, among which the measurement display values between pins [2], [3]
and [5] as well as pin [7] and any other pins are "1", and the display values of other pins are "0".
Note: "0" means that the resistance between the two pins measured is zero while “1” means that the
resistance between the two pins measured is infinite.
8-14
Fuse
Fuse arrangement position
A fuse is mainly used for shorting and overcurrent protection. DW90A power supply system uses a
variety of series of plug-in fuses and bolt type fuses. Plug-in fuses with specifications of 50A, 30A, 25A,
20A, 15A, 10A and 5A are used in branch circuits. Bolt type fuses with specifications of 80A and 125A
are used in main circuit.
Schematic Diagram of the Whole Schematic Diagram of the Whole
Machine Position of Plug-in Fuse Machine Position of Bolt Type Fuse
P2TE00065 P2TE00066
The color of the plug-in fuse is related to its specification. The following table lists the specifications and
colors of the plug-in fuses as well as the part No. of Liugong used by the machine for reference.
Liugong Part No. Specifications Color

37B0359 5A Brown
37B0361 10A Red
37B0362 15A Blue
37B0363 20A Yellow
37B0364 30A Green
8-15
Function definitions of the plug-in fuse
1 18 19
20 37 38
P2TE00067
1. Right high beam 14. Standby 27. Radio and cigarette lighter
2. Left high beam 15. Ignition lock 28. Fog lamp
3. Retarder 16. ECU power supply 29. Start
4. Excitation 17. Air conditioner 30. GPS
5. Sensor 18. Backup alarm 31. Standby
6. Wiper 19. 100 main fuse 32. Standby
7. Lifting alarm 20. Right low beam 33. Electric turning
8. ON control switch work light 21. Left low beam 34. "Shuihanbao" fuel filter
9. Instrument 22. Wall light of speaker 35. Side work lamp
10. Gauge 23. Flasher 36. Brake
11. Generator 24. Front work lamp 37. Clearance lamp
12. Horn 25. Standby 38. 101 main fuse
13. Standby 26. ECU ON power supply
Precautions
The specifications of all fuses are obtained by calculation during circuit design. Therefore, in case of fuse
break, the fuse must be replaced with one of the same series and specification. It is forbidden to replace
with a fuse of a different specification.
When the fuse is melt and replaced with a new one, and the new one is also melt, the circuit under the
control of the fuse must be checked first and corresponding fault removed before further replacement is
carried out.
8-16
Fuse Fault Detection Method
After the plug-in fuse is blown, the corresponding indicator light beside the fuse will be on; the plug-in
fuse can be pulled out from the fuse holder, and whether the internal fuse is blown can be judged by
visual inspection. It can also be detected by judging whether the bolt-type fuse is blown.
Procedures for determining melting of a bolting type fuse:
2. Connect the probes of the digital multi-meter respectively with the two terminals of the fuse.
3. If the indicated value of the digital multi-meter is “1”, it means that the fuse is melt and requires
replacement; if the indicated value of the digital multi-meter is “0”, it means that the fuse is in good
condition and can be used further.
Power main switch
Introduction of power main switch
The battery main switch controls the connection between the battery terminal positive and the positive
pole of the load of the whole machine. When the power main switch is in the "O" (closed) position, the
power positive pole of the whole machine will be cut off. In this case, the electrical equipment of the
whole machine will not work even if the electric lock is turned on. When the disconnect switch is in the "I"
(open) position, the power positive pole of the whole machine will be connected. At this time, the electric
lock can be used to control connection of power supply for electrical equipment of the whole machine
and to start the diesel engine.
Main power switch mounting position
P2TE00068
8-17
Precautions
1. The power main switch must be turned off each time after work or driving. Otherwise, a serious
consequence of electric leakage will be caused;
2. It is forbidden to turn off the power main switch during running of the machine. Such wrong operation
will seriously damage the electrical system of the whole machine.
3. To shut down each time, first turn off the electric lock and then the power main switch.
4. To start up each time, first turn on the power main switch and then the electric lock.
5. When connecting or removing the battery cable or fastening the battery cable pile heads, the power
main switch must be turned off.
6. When carrying out welding on the whole machine, the power main switch must be turned off.
Battery
Introduction of battery
For the whole machine, two storage batteries are connected in series to provide +24 V power supply.
The rated capacity of the power supply is 120 Ah and the low-temperature starting current 850 CCA. The
storage battery can be connected in parallel with the generator as reversible DC power supply for
electrical equipment of the whole machine. It can provide a large starting current for the starting motor
within a short time to start the diesel engine. The storage battery equivalent to a large capacitor can
absorb the overvoltage occurring any time in the circuit to protect the electrical equipment of the whole
machine.
Battery mounting position
P2TE00069
Determination of the Storage Battery Condition
In adequate light, observe built-in hydrometer on the storage battery cover and determine the state of
charge of the storage battery or take corresponding measures according to its color:
Color of Indicator Green Black Transparent
State or Measure Good Charging is needed. To be replaced
8-18
Battery Charge
The storage battery with a black hydrometer needs to be charged.

For the storage battery with a transparent hydrometer, there may be bubbles in the eye. In this case, all
storage battery cables shall be removed. After the storage battery is fully cooled, gently shake it. If the
hydrometer still looks transparent, the storage battery shall be abandoned.
1. Place the disconnect switch in the "O" position. Turn the electric lock in the "LOCK" position and pull
out the key.
2. Remove the battery from the machine. To do so, first disconnect the cable at the storage battery
cathode and then disconnect that at the anode.
3. Clear oxide scale on the battery terminals and surface with a clean cloth.
4. Under the room temperature, connect the positive (+) charging chuck of the charger with the positive
(+) terminal of the storage battery, and then the negative (-) charging chuck with the negative (-)
terminal. Confirm that the battery terminals are clean and the charging circuit is well connected.
5. Charge the battery with a constant voltage of 16.0 V (not greater than 16.2 V to the maximum) until
its hydrometer turns green which means the battery is fully charged.
6. If charging with a constant voltage is impossible, charge with a constant current, i.e. 12 A until the
hydrometer turns green which means the battery is fully charged.
Relationship between charging time and battery voltage
Battery voltage 12.45 ~12.55V 12.45 ~12.35V 12.35 ~12.20V 12.20 ~12.05V
Charging time 2h 3h 4h 5h
Battery voltage 12.05 ~11.95V 11.95 ~11.80V 11.80 ~11.65V 1.65 ~11.50V
Charging time 6h 7h 8h 9h
Battery voltage 11.50 ~11.30V 11.30 ~11.00V Below 11.00V
Charging time 10 h 12 h 14 h
7. For a battery with an extremely low level, the battery level may not increase in the initial charging
stage. With the charging goes on, the battery charging current gradually restores to normal. It may
take about 14 h to finish this charging process.
8. During charging, if the battery is too hot, above 45 °C, stop charging until the battery temperature
drops to the room temperature; then reduce the charging current by half and continue charging.
9. During battery charging, check the state of the hydrometer once every hour. If the battery hydrometer
turns green, it means that the battery has been fully charged. At this time, stop charging.
10. After charging, apply vaseline on the terminals to prevent galvanic corrosion.
8-19
Precautions for Battery Charging
1. Do not connect two storage batteries in series for charging.

2. During charging, keep the environment well ventilated and charge under the room temperature.
3. In case of acid jetting from the battery vent during charging, stop charging immediately.
4. Battery charging shall be carried out in a well-ventilated area with attention paid to electrical safety.
5. Where the battery case is broken or the battery leaks acid and cannot be charged, scrapping is
required.
6. Where the battery cannot be charged due to damaged terminals, it shall be scrapped.
7. Where the battery cannot be charged due to over-discharge or inflation caused by over-discharge, it
shall be scrapped.
8. If the hydrometer remains black after charging for a certain period, check whether the charging
connection is firm, whether the connecting point is clean and whether the charging voltage is 16 V.
Procedures for Battery Fault Detection
The whole machine is in a brake state and the shift control lever is in the NEUTRAL position. The built-in
hydrometer on the battery cover is green. The detection in this step requires help from others.
1. Place the battery main switch to "O".
2. Put the digital multi-meter to the voltage position and adjust its range to 50V.
3. Let the red probe of the digital multi-meter contact the positive terminal of the battery and the black
probe contact the negative terminal of another battery. Pay attention that the red or black probe does
not contact their connection cable terminals. The value displayed by the digital multi-meter is in the
range of "24" to "32" V.
4. Keep the positions of the two probes of the digital multi-meter unchanged. Place the battery main
switch to "I". Turn on the electric lock and start the diesel engine.
5. At the moment when the starting motor begins to rotate, the value displayed by the digital multi-meter
is in the range of "20" to "24" V. After the diesel engine is successfully started, the value displayed
will restore to that described in step 3. If the above procedures can be finished and the diesel engine
can be started smoothly, then the battery is in good condition. Otherwise, continue the test with the
following methods.
6. Remove all cables of the battery. At this time, the two batteries are completely disconnected.
7. Put the digital multi-meter to the voltage position and adjust its range to 50V.
8. Let the red probe of the digital multi-meter contact the positive terminal of one battery and the black
probe contact the negative terminal. The value displayed by the digital multi-meter is approximately
in the range of "12" to "16" V .
9. Test the other battery according to the method described in step 3. The value displayed shall be the
same as that in step 8. The battery whose voltage does not meet the requirement shall be charged or
replaced.
8-20
Power supply relay
Introduction of power supply relay
An ignition ON relay with a rated load current of 30A is used for the machine for power supply control.
The relay only has one working contact which is a normally open contact. When a +24 V voltage is
applied on the relay coil, the electromagnetic force generated will help internal armature to overcome the
spring force and thus close the operating contacts, i.e. normally open contacts. After the operating
contacts are closed, the external circuit with rated load current of 30A can be connected. Cancel the +24
V voltage applied on the contactor coil and the contactor will restore to its original state
The ignition “ON” relay is located in centralized control box of the cab
P2TE00070
Procedures for Detection of Relay Fault
1. Pull the relay off from its base.

2. Put the digital multi-meter to the “Ω” position and adjust its range to 1,000 Ω.
3. Let the red probe of the digital multi-meter contact terminal “86”of the relay and the black probe
contact terminal “85”. The value displayed by the multi-meter shall be about “300”.
5. Let one probe of the digital multi-meter contact terminal "30" of the relay and the other probe contact
terminal "87". The value displayed by the multi-meter shall be "1".
6. Let the + 24V external power supply positive pole contact the terminal "86" of the relay, and the
negative pole contact the terminal "85". Let one probe of the digital multi-meter contact terminal "30"
of the relay and the other probe contact terminal "87". The value displayed by the multi-meter shall
be "0".
After the above procedures are finished and the value displayed by the multi-meter is the same as is
described, it can be basically determined that the relay is in good condition.
Note: "0" means that the resistance between the two pins measured is zero while “1” means that the
resistance between the two pins measured is infinite.
The above procedures do not apply to the situation in which operating contacts are moderately worn.
8-21
DW90A Starting system
Starting system
1 2
P2TE00071
1. Generator 2. Starter
Starting motor
Introduction of starting motor
The parameter of the starting motor for the machine is 24 V/5.5KW. The DC motor inside the starting
motor can convert the electric energy of the storage battery into mechanical energy. Thus the internal
transmission gear can drive the engine flywheel realizing starting of the engine.
Overall sectional view of starter
P2TE00072
8-22
Starting system DW90A
Startup principle pf starting motor
The starter control of this machine is controlled by ECU which makes logical judgment of starting
conditions and outputs current to control the starter "50".
Startup principle
P2TE00073
Advantages of the control of starter by ECU:

1. Starting protection is enabled only when the power train system is disconnected. The neutral position
switch is used for control. If it is damaged, ECU has emergency starting function, i.e. T50 will be
restarted after more than 3s.
2. Secondary startup protection. If the engine is started, press T50 starter again and the starter will not
respond.
3. If the engine is started but the key is stuck in T50 state, the starting relay will not respond at this time.
4. Startup time control. When starting is difficult, if starting is not successful after a certain period of
time, the relay will be automatically disconnected.
5. Blind meshing should be prevented. When the starter drives the crankshaft to fail to reach the rated
speed within a certain period of time, ECU will detect that the starter is not engaged with the flywheel,
which will disconnect the starter relay.
6. Intake preheating control When the intake air is being heated, the starter usually does not work;
otherwise it will cause great damage to the battery. If starting is conducted before the intake air
heating is not completed, the intake air heating will be terminated. If starting is not controlled by ECU,
the intake air will be automatically heated at a low temperature. Starting and large current will
consume the battery a lot.
7. Out-of-vehicle startup control. An additional starting control switch can be added for convenient
maintenance.
The above control logic relation judgment can be completed by ECU, so that many other functional
control components and circuits can be saved in the starter control circuit system, and the influence of
additional external control circuits (components) on the starter system can be reduced.
8-23
Specification for service and maintenance of starter motor
1. Starter is a short-time working device, and the starting time should not exceed 15s each time, and
the interval between adjacent secondary starts should be greater than 30s.
2. When the temperature in winter is below minus 5°C, the engine should be preheated before starting.
3. Once the engine is started, the starting switch should be released immediately to disengage the
starter drive gear from the flywheel ring gear.
4. Do not energize the starter until the engine stops running. The damage caused by collision between
flywheel and starter gear should be prevented.
5. When the starter is installed, the wiring diagram must be followed. Before disassembling and
assembling the starter, ensure that the battery is disconnected from the main starting line of the
starter.
6. Always check whether the fasteners and wire insulation of the starter are damaged, whether the
wires are connected well, and remove accumulated dirt.
7. The overhaul period of the starter is the same as that of the car equipped with it.
8. Start the vehicle controlled by ECU and equipped with automatic gearbox, do not start the vehicle by
pushing it
8-24
Common failure modes of starter motor and solutions
Fault mode Possible cause Measures taken

The vehicle controlled by ECU is not Check the gear position and ensure
put into neutral gear the vehicle is neutral gear
Start the vehicle controlled by ECU; Check or replace neutral position
the neutral position switch is damaged switch
Poor contact of ignition switch or start Check the ignition switch and start
button of the vehicle button
The ignition control circuit is Check the ignition control circuit and
disconnected ensure its normal operation.
The main cable connecting bolt of the Check the main connecting cable of
starter is loose the starter and tighten it
Starter electromagnetic switch burnout
Ablation and oxidation of
electromagnetic switch contact
Magnetizing coil is short-circuited,
disconnected and connected with
vehicle body
The starter fails to work. The movable iron core does not
operate properly. Clean, repair or replace starter
Open circuit inside the starter

Short circuit and bonding of armature
winding
Brush wear and poor contact
Bearing is too loose and armature
shaft is bent
The storage capacity of the battery is Check the battery for charging or
insufficient or there is an internal fault. replacement
The nut of the main binding post of the Check the battery connection terminal
battery is loose of the starter and tighten it
Contact ablation and oxidation of relay
Too large contact clearance Check whether the relay matches
Short circuit and open circuit of coil correctly, replace the corresponding
relay or replace the starter
Improper adjustment of contact
closing voltage
8-25

Charge the storage battery and
Voltage of the battery is too low. ensure sufficient electric quantity of
the storage battery in use
Poor contact of relay contacts Clean, repair or replace
The connecting bolts of the main Check starter's main cables and
circuit of the starting system are loose tighten them
Armature and excitation winding have
short circuit fault
Brush wear, insufficient brush spring
pressure
Powerless starting
Oxidation, ablation or oil stain on Overhaul or replace the starter
commutator surface
Poor contact of electromagnetic
switch
Slipping of isolator of starter
Check whether the installation surface
is normal
Starter gear is damaged Replace the starter
Eliminate misoperation of starting
before flywheel is stationary
Reinstall the starter and control the
Abnormal installation of starter
torque of the fastening screws
Battery largely under voltage Charging
Turn-to-turn short circuit of relay coil
Poor contact of relay contacts
Overhaul or replace
Turn-to-turn short circuit of
electromagnetic switch coil
Loud noise, abnormal noise or
intermittent work The ignition switch is not released in Operate in strict accordance with the
time after starting starter operation method
Starter bearing and shaft sleeve fail Replace the starter as appropriate
Check whether the installation surface
is normal
Starter gear is damaged Replace the starter
Eliminate misoperation of starting
before flywheel is stationary
Ignition switch does not return Replace ignition switch
Contact sintering of relay
Contact disconnection voltage does Overhaul, adjust and replace
not meet the requirements
Continuous rotation without stop
The starter contact is stuck or the
contact coil spring is damaged
Overhaul or replace the starter
Transmission fork return spring is too
soft or broken
8-26

Slipping or damage of one-way clutch
Shifting fork is deformed or shifting Replace the starter
fork linkage mechanism is loose
The drive gear does not mesh with the
Idling of starter
engine ring gear
The tooth ring gear is broken or worn Reinstall, overhaul or replace
too much.
Drive gear damaged
Generator
Introduction of generator
The generator is the main power supply equipment of the whole machine. It converts the energy from the
diesel engine into electric energy that can be used by electrical equipment. With an electrical parameter
of 24V/80A, it is equipped with an electronic voltage regulator inside. The generator is in parallel
connection with the storage battery to form a power supply system for the whole machine. Before the
diesel engine is started, the storage battery is used to supply power for electrical equipment of the whole
machine. After the diesel engine is started, the generator is mainly used for power supply and meanwhile
for charging the storage battery. When the energy supplied by the generator cannot satisfy the needs of
the electrical equipment of the whole machine, both the generator and the storage battery are used for
power supply
Section Diagram of Generator Structure
P2TE00074
8-27
Generator multifunction regulator
The main function of the regulator is to keep the generator output voltage stable under different loads
and different engine speeds.
Schematic Diagram Outline Drawing of Regulator
P2TE00075 P2TE00076
Description of regulator terminal:

Terminal 15: Input on/off signal of ignition switch to realize pre-excitation of generator (when the engine
starts) and disconnect external excitation of generator.
Terminal S: Connect the positive electrode of the storage battery, detect the actual voltage of the storage
battery (separate detection cable is required), make the regulator compensate the voltage lost on the
cable, give full play to the capacity of the storage battery, and enable the storage battery to have longer
service life and better starting performance; when there is a problem at terminal 15 and the generator
speed is greater than 5000 rpm, terminal S will supply excitation current to the generator.
Terminal L: generator status indication; output signal can be used to control equipment working
simultaneously with generator. When the generator works, it outputs a continuous signal, which is
connected to the electrical system of the whole vehicle through an indicator light to display the normal
state of the generator ( ≦ 160mA); it can be used as a switch signal for some equipment of the vehicle.
When the generator is in normal operation, it outputs current to drive other electronic devices ( ≦ 500
mA).
Terminal W: output a voltage signal of one-phase winding, and infer engine speed ( ≦ 100mA) from
generator speed.
Terminal DFM: it is connected with ECU, providing corresponding pulses according to the duty ratio of
generator excitation current, outputting the load state of generator, and realizing efficient energy
management of vehicle ( ≦ 10mA, note: not connected temporarily).
Compared with a single-function regulator, multi-function regulator has many advantages, such as over-
voltage protection, soft start, soft loading and automation.
Overvoltage means that when the terminal voltage of B+ exceeds 42V, the regulator is turned off, which
plays a double protection role for the whole vehicle's electrical appliances when used together with
avalanche diodes.
8-28
Operation and maintenance specification of generator
1. After the engine is started, from low speed to high speed, observe whether the state of the charging
indicator light changes from on to off; otherwise, please conduct troubleshooting immediately.
2. Pay attention to whether the polarity of the battery is connected to vehicle body; otherwise the
generator and regulator will be burnt out.
3. When the generator operates, the method of fire test cannot be used to check whether the generator
generates electricity; otherwise the test lamp or diode will be burnt out.
4. When the rectifier is connected with the stator winding, it is forbidden to use a megohmmeter or 220V
AC power supply to check the insulation of the generator.
5. The connection between the generator and the storage battery should be reliable. Sudden
disconnection will generate excessive voltage and damage the generator or voltage regulator.
6. When an alternator is equipped with a regulator, the voltage of the alternator must be the same as
that of the regulator; the grounding type of the alternator must be the same as that of the regulator,
and the power of the regulator must not be less than that of the generator.
7. Wiring connection must be correct. At present, the installation positions and wiring methods of
regulators for various models are different, so special attention should be paid to wiring.
Common failure modes of generator and solutions
The most common fault of a generator is its failure to generate electricity. The simple method to judge
whether it is a generator fault is as follows:
1. Using a multimeter to measure
(1) Check the drive belt of generator. For belt tension, a force of 150 N (15 kg) should be applied by
hand at 1/2 of the center distance between the two wheels. It is appropriate to press the belt down by
10 ~ 20 mm (or there is no obvious shaking when operating with a load). The belt tension should be
checked once every 2 months. If the belt has aged, skidded and cracked, it must be replaced.
(2) Check the connection parts of all external wires of the generator for looseness, disconnection, mis-
connection and short circuit, and use a multimeter to measure whether there is battery voltage at
terminal B+.
(3) Turn the key switch to "ON", but do not start the engine. At this time, use a voltmeter to measure the
voltage at the terminal D+ and observe whether the charging indicator light is bright.
(4) Start the engine and measure the voltage of B+ of generator with a voltmeter (the positive pole of the
voltmeter is connected to B+and the negative pole to the generator housing). The voltage should
reach the following value: 27V/13V (24V power supply system /12V power supply system
respectively) or above, and the voltage changes slightly (0.1-0.2V) when the accelerator is pressed
or loosened. It indicates that the generator is in good condition.
(5) Turn on some electrical appliances, such as headlights, and measure the voltage of terminal B+ of
generator with a voltmeter. The voltage is 27V/13V (24V power supply system/12V power supply
system respectively). The voltage changes greatly (0.5-1V) when the accelerator is pressed or
loosened. It indicates that the generator is in good condition.
8-29
2. Measure with a test lamp

(1) Check the drive belt of generator. For belt tension, a force of 150 N (15 kg) should be applied by
hand at 1/2 of the center distance between the two wheels. It is appropriate to press the belt down by
10 ~ 20 mm (or there is no obvious shaking when operating with a load). The belt tension should be
checked once every 2 months. If the belt has aged, skidded and cracked, it must be replaced.
(2) Check the connection parts of all external wires of the generator for looseness, disconnection, wrong
connection and short circuit. If any, re-tighten and connect them correctly.
(3) Turn on the battery main switch at the “ON” position and connect the two ends of the test lamp
across generator's terminal B+ and its housing. If the lamp is not on, the positive circuit is normal;
otherwise, if there is an open circuit in the positive or negative wiring, the wiring must be checked
and correctly connected.
(4) Connect the two ends of the test lamp between the terminals B+ and D+ of the generator. If the lamp
is on, the generator is normal; otherwise, the generator regulator or rotor fails, and the generator
needs to be repaired or replaced.
(5) Keep both ends of the test lamp connected between terminals B+ and D+ of the generator, and
disconnect the original excitation lead of the vehicle. When the engine is started, the lights are off, it
indicates that the generator is normal. If the lights are still on, it indicates that the generator stator or
rectifier assembly has failed and the generator needs to be repaired or replaced.
8-30
Monitoring System DW90A
Monitoring System
Engine speed display
The engine speed is displayed on the combination meter, and the signal is collected by ECM of
electronic fuel injection engine and then sent to the meter through CAN bus
P2TE00077 P2TE00078
Service brake air pressure display
The barometer value is displayed by the output voltage value of the barometer, and its normal working
pressure is not less than 0.6 MPa.
P2TE00079 P2TE00080
Barometer parameters
S/N 1 2 3 4 5 6 7 8
Division value /
0 2 4 6 8 10 12 14
bar
Value of sensor/V 0.5 1.04 1.59 2.13 2.68 3.22 3.76 4.31
8-31
DW90A Monitoring System
Speed display
The meter feeds back the number of pulses through the speed sensor of the gearbox, and the speed
ratio is 1:31160. The real-time speed can be calculated and displayed
P2TE00081 P2TE00082
Engine water temperature display
The Weichai electronic fuel injection engine is adopted for this machine. The engine water temperature
signal is collected by the electronic fuel injection engine ECM and then sent to the instruments via CAN
bus. After the instrument microcontroller reads the water temperature data, calculation and processing
are carried out. Finally, the engine water temperature gauge is driven to give water temperature
indication
P2TE00083 P2TE00084
Fuel level display
The resistance value of the fuel level sensor decreases with the increase of the oil level, and the
indication of the fuel level gauge is inversely proportional to the resistance of the fuel level sensor
P2TE00085 P2TE00086
Fuel level resistance meter

S/N 1 2 3 4 5 6
Division value 0 1/8 1/4 1/2 3/4 1
Resistance/Ω 120 102 85 50 27 5
8-32
Monitoring System DW90A
Hourmeter, mileage and fault information display
The hourmeter records the running time of the engine, which will be sent by the engine ECM. The
mileage parameter meter is calculated by information such as vehicle speed. The fault code is sent to
the instrument by the engine ECM through CAN communication, and the corresponding fault information
is displayed on the LCD screen of the instrument
P2TE00087 P2TE00088
Voltage indicator
The instrument can directly read the voltage parameters collected by the engine ECU through the CAN
bus.
P2TE00089 P2TE00090
Engine oil pressure display
The Weichai electronic fuel injection engine is adopted for this machine. The engine oil pressure signal is
collected by the electronic fuel injection engine ECM and then sent to the instruments via CAN bus. After
the instrument microcontroller reads the engine oil pressure data, calculation and processing are carried
out. Finally, the engine oil pressure gauge is driven to give engine oil pressure indication
P2TE00091 P2TE00092
8-33
DW90A Braking system
Braking system
The brake system of the machine consists of service brake system and parking brake system. Service
braking: step on the foot pedal and the wheel brake pad will act to execute the brake command; at the
same time, the brake sensor is closed to transmit the brake signal to the engine ECU, and the brake
indicator light in the rear combination tail lamp is turned on; parking brake: pull the hand brake and the
wheel brake pad will act to execute the parking brake command. At the same time, the parking brake
sensor is disconnected, and after conversion by the relay, the parking signal is transmitted to the engine
ECU, and the parking brake indicator light of the meter will be on.
P2TE00093
8-34
Exhaust brake DW90A
Exhaust brake
1 2 3
4 5 6 7 8 9 10 11 12 13
P2TE00094
1. Parking light switch 6. Front fog lamp switch 11. Exhaust brake switch
2. Instrument 7. Side work lamp switch 12. Inter-axle differential lock switch
3. Radio 8. Combination handle 13. Cigar lighter
4. Main lamp switch 9. Rotating signal lamp switch
5. Front top lamp switch 10. Horn switch
8-35
DW90A Exhaust brake
When the exhaust pipe of the engine is closed, back pressure will be established in the engine to serve
as an auxiliary braking device, so that the engine will absorb the kinetic energy of the vehicle to achieve
the purpose of continuous braking.
Function description: when the driver uses the exhaust brake, press the exhaust brake switch. The ECU
determines the opening and closing of the solenoid valve according to the working condition of the
engine at that time.
Exhaust brake enabling condition (defaulting condition):
1. Vehicle speed > 1km/h;
2. The clutch has not been depressed;
3. The rotating speed is greater than 900 rpm;
Exhaust brake failure condition (defaulting condition):
1. The vehicle speed is less than 1 km/h;
2. The clutch is depressed;
3. The rotating speed is less than 800 rpm
P2TE00095
8-36
Intake heating DW90A
Intake heating
The ECU senses the ambient temperature according to the temperature sensor on the engine and
automatically controls the operation of the air intake grille through the intake heating relay to facilitate
cold start. In fact, the intake air heating of cold start is divided into two processes: “pre-heating” before
start-up and post-heating after start-up, of which the latter process goes unnoticed by the driver. The
post-heating time varies according to the ambient temperature. Generally, the preheating time is within
one minute, and the post-heating time is slightly longer, usually more than two minutes (-10 °C). Failure
condition of intake air heating: battery voltage is lower than 10V for more than 200 ms.
P2TE00096
8-37
DW90A Driving indication system
Driving indication system
Turn/parking lights
When the parking light switch is turned on, the left and right turn lights flash together.
P2TE00097
Clearance lamp
The front clearance light (small light) is white and the rear clearance light (small light) is red. They are
used to indicate the width of the whole vehicle at night.
P2TE00098
8-38
Driving indication system DW90A
Reversing lamp/reversing alarm
In addition to reversing indicator lights and reversing alarm, reversing working lights are added to
improve the rear lighting effect during reversing. The working conditions must be satisfied: the clearance
light is on.
P2TE00099
The backup alarm is a buzzer that buzzes intermittently. It works together with the backup light when the
operator is backing up.
P2TE00100
Electrical Parameters of Backup Alarm

1. Rated voltage: 24V;
2. Working current: 6A;
3. Frequency: 1600Hz ± 20%;
4. Sound level: 112 dB.
8-39
Procedures for Detection of Backup Alarm Fault

1. Connect the positive pole of the 24 V DC power supply with the terminal at jack 1 of the backup
alarm, and the negative pole with the terminal at jack 2;
2. Turn on the DC power switch.
3. The backup alarm gives an alarm with the sound pressure level at 112 dB.
Horn
This machine is connected in parallel with two electric horn buttons, which are respectively located on
the steering wheel and the combined function handle
P2TE00101
This machine is equipped with 2 electric horns, one is high frequency horn and the other is low
frequency horn.
Electrical equipment parameters:
1. Rated voltage 24V;
2. Operating current 3A;
3. Basic frequency: 400 ± 20Hz;
4. Sound pressure level: 105dB-118dB(A)
1. Rated voltage 24V;
2. Operating current 3A;
3. Basic frequency: 335 ± 20Hz;
4. Sound pressure level: 105dB-118dB(A)
8-40
Driving indication system DW90A
P2TE00102
Procedures for detection of electric horn fault:

1. Connect the negative pole of the 24 V DC power supply with the terminal at jack 1 of the electric
horn, and the positive pole with the terminal at jack 2.
2. Turn on the DC power switch.
3. The electric horn gives an alarm with the sound pressure level in the range of 105 dB-118 dB(A).
In addition, the machine is equipped with a double-tube air horn which can be switched to the electric
horn by operating the horn switch. Electrical parameters of air horn:
1. Working voltage: 24V;
2. Current MAX3.0A;
3. Working pressure: 1.0 MPa;
4. Sound level: 105-125 dB;
5. Resistance: 11.2Ω
P2TE00103
8-41
Warning light
The rotatory warning light is installed at the front left position on the top of the cab
P2TE00104
8-42
Inter - axle differential lock DW90A
Inter - axle differential lock
To improve the trafficability of the vehicle on the potholed road surface, the vehicle is equipped with
differential lock function.
P2TE00105
Lighting System
1 2 3
4 5 P2TE00106
1. High/low beam 3. Wall light 5. Side work lamp

2. Front top work lamp 4. Front fog lamp
8-43
DW90A Lighting System
High/low beam
Press the small light and headlight switch to the headlight position to turn on the low beam. Switch the
high/low beam through the combined function handle. Among them, the electrical parameters of the
high/low beam are DC24V 70W/75W
P2TE00107
8-44
Lighting System DW90A
Front fog light/front top work light/side work light
The front fog light/front top work light/side work light switches have two positions, and the parameter of
each work light is 24V/70W.
P2TE00108
Wall light

1. Rated working voltage: 24V;
2. Rated power: 10W
P2TE00109
8-45
DW90A Windscreen wiper system
Windscreen wiper system
The water spraying function of front wiper and the front window are all realized through the combined
function handle. The wiper has three positions, including intermittent, low-speed and high-speed
positions. The schematic diagram is as follows:
P2TE00110
8-46
Air conditioning system DW90A
The schematic diagram of the air conditioning system is as follows. Please refer to the air conditioning
section for details
P2TE00111
Sound system
The schematic diagram of the sound system is as follows. The sound system is equipped with a radio-
cassette player, speaker and antenna
P2TE00112
9-1
June 9, 2020 Braking system
DW90A
Braking system
Structure and Function ......................................................................................................9-3
System Overview ...................................................................................................................................9-3
Working Principle and Components.......................................................................................................9-3
Compositions of Pneumatic Brake and Layout of Pipelines ..............................................................9-3
Operating principle .............................................................................................................................9-4
Air handling unit ...............................................................................................................................9-5
Operating principle of desiccator........................................................................................................9-6
Four-circuit protective valve ...............................................................................................................9-7
Operating principle .............................................................................................................................9-7
Relay valve.........................................................................................................................................9-8
Differential relay valve......................................................................................................................9-10
Removal and installation of brake system .......................................................................9-12

Removal and installation of air reservoir ..............................................................................................9-12
Removal ...........................................................................................................................................9-12
Installation ........................................................................................................................................9-12
Removal and installation of desiccator assembly ................................................................................9-13
Removal ...........................................................................................................................................9-13
Installation ........................................................................................................................................9-13
Removal and installation of brake air chamber ....................................................................................9-14
Removal ...........................................................................................................................................9-14
Installation ........................................................................................................................................9-14
Removal and installation of relay valve/differential relay valve ............................................................9-15
Removal ...........................................................................................................................................9-15
Installation ........................................................................................................................................9-15
9-2
Braking system June 9, 2020
DW90A
9-3
DW90A System Overview
Structure and Function
System Overview
A brake system consists of service brake system and emergency & parking brake system. The service
brake system is used to frequently control the vehicle speed or stop the vehicle in general. The
emergency & parking brake system is used as the parking brake in general or the emergency brake
when the service brake system failures.
Structural features of brake system: The service brake is of the double-circuit pneumatic brake while the
parking brake is of the spring loaded fail safe brake.
Working Principle and Components
Compositions of Pneumatic Brake and Layout of Pipelines
P2TB00001
1. Air compressor, 8. Foot valve 15. Clutch booster

2. Desiccator 9. Relay valve 16. Differential
3. Four-circuit protective valve 10. ABS pressure regulating valve 17. Manual valve
4. Safety valve 11. Front brake air chamber 18. Low pressure alarm (parking light
5. Regeneration air reservoir 12. Multi-way valve switch)
6. Air kettle 13. Solenoid valve 19. Differential relay valve
7. Water drain valve 14. Exhaust brake valve 20. Spring brake chamber
9-4
Working Principle and Components DW90A
Operating principle
An air pump (air compressor) delivers air to the desiccator for drying. Then, the dry air flows to the four-
circuit protective valve and finally to the air circuits of the vehicle. The desiccator is installed with a
pressure regulating valve inside, which restricts the maximum air pressure in all the air circuits of the
vehicle as 8~8.5 bar. The desiccator is filled with desiccants. When compressed air from the air
compressor flows through the desiccator, moisture contained in the compressed air is absorbed by the
desiccants. Relatively pure air is delivered from the desiccator to the four-circuit protective valve. When
the air pressure of the whole vehicle reaches the rated value, the pressure regulating valve inside the
desiccator will be opened to unload the air compressor so the air pressure of the whole vehicle will not
rise anymore. Meanwhile, the backflushing channel between backflushing air reservoir and desiccator
will be opened. The compressed air from the air reservoir then flows through the orifice inside the
desiccator, namely, flowing back to the desiccator in a reverse direction. The compressed air quickly
pushes the moisture absorbed by desiccants outside the desiccator. As a result, the desiccants become
dry and can be used again. The pressure regulating valve will be closed when the air pressure of the
vehicle drops to its closing pressure. When a vehicle is running, the desiccator will repeatedly perform
the above actions, thus providing each air circuit with relatively pure compressed air.
The compressed air flowing from desiccator to four-circuit protective valve makes the vehicle has four air
circuits, which are correlated with each other but mutually independent sometimes. When any one of the
circuits fails (e.g. opening circuit or leakage), the four-circuit protective valve is used to close the faulty
circuit and keep both normal operation and air filling of other circuits from being affected.
Brake circuit of front axle
Air is filled to the front brake air reservoir through the port "22" of the four-circuit protective valve. Then,
the air is delivered from the air reservoir through the port "12" on the lower chamber of main brake valve.
When the brake pedal is depressed, the main brake valve is opened and air flows through the port "22"
to the front axle brake chamber. During braking, the air pressure in brake chamber is in direct proportion
to the stroke of main brake valve pedal.
Brake Circuit of (Intermediate) Rear Axle
Air is filled to the (intermediate) rear brake air reservoir through the port "21" of the four-circuit protective
valve. Then, the air is delivered from the air reservoir through the port "11" on the upper chamber of main
brake valve. The air flows from the port "21" of main brake to the main brake relay valve. Then, the air
reservoir directly supplies air to the relay valve. When the main brake valve is working, the relay valve is
opened and air is respectively delivered to the intermediate axle main brake chamber and the rear axle
main brake chamber. The air pressure in brake chamber is in direct proportion to the stroke of main
brake valve pedal. The relay valve is used to reduce the response time of brake, realizing both "fast
filling" and "fast exhausting" functions.
9-5
DW90A Working Principle and Components
Parking brake circuit
Air is supplied to the parking brake through the port "23" of the four-circuit protective valve. The parking
brake valve controls the relay valve. When the parking brake is working, the control air pressure in the
relay valve is released through the parking brake valve. The air in the (intermediate) rear axle parking
brake air chamber is exhausted through the relay valve. Then, the air chamber spring forces both piston
and push rod to extend outside, achieving the braking function. The braking intensity depends on the
pre-tightening force of spring. When the parking brake valve is in the "running" position, it supplies an air
pressure to the dual-chamber relay valve, thus opening the dual-chamber relay valve. The compressed
air directly supplied by the air reservoir quickly flows into the (intermediate) rear axle parking brake air
chamber. As long as the compressed air pressure is more than 600 kPa, it can overcome the spring
force and completely jack back both piston and push rod, thus stopping the braking. The so-called "dual-
chamber relay valve" means that the valve can be respectively controlled by the parking brake valve and
the main brake valve. That is to say, if the brake pedal is depressed when the parking brake of a vehicle
is working, the main brake valve will supply a brake air pressure to the main brake chamber and
simultaneously supply an air pressure to the dual-chamber spring-loaded chamber, thus stopping the
braking. As a result, the brake chamber push rod will not be overloaded.
Air handling unit
P2TB00002 P2TB00003
1. Working medium air

2. Working temperature -40 °C~+65 °C
3. Maximum working pressure 13 bar
4. Cut-out pressure 8.5±0.2 bar
5. Restored air supply pressure drop 0.7-1.2 bar
6. Backflow pressure drop 0.4±0.05bar
7. Rated power/operating voltage of electric heater 100 W/24V DC
Starting temperature of heater 7°C±6°C
Heater break-off temperature 29.5°C±3°C
8. Drying efficiency: relative air humidity at outlet ≤30%
9. Allowable maximum vibration frequency 50Hz
10.Allowable maximum acceleration ±10g
11.Other technical conditions conform to QCT37-2015
Technical requirements and bench test method for air pressure regulating and protection device of car and trailer
9-6
For the purpose of full removal of the moisture in the braking system, especially that in a vehicle running
in a relatively humid environment, it is crucial to ensure both safety and reliability of braking system, and
an air desiccator is installed on the dump truck chassis. The desiccator is filled with desiccants, which
are molecular sieves - aluminosilicates of microcellular structures with a lot of cavity-shaped unit cells
between which are holes. Water molecules and other molecules are absorbed inside the cavities of unit
cells through the holes. Under a certain specific condition,
the molecular sieves can release both impurities and moisture absorbed on their inner surfaces. This
process is called regeneration and activation. The desiccators are made based on this principle.
Operating principle of desiccator
Operating principle: When a vehicle is running, the compressed air from the air compressor flows into
the chamber A through the port 1. At this point, condensate water is generated from drop of temperature.
The condensate water is drained from the exhaust valve d through the channel C. The compressed air
flows through the fine filter (removing oil) on the drying cylinder and reaches the upper part of drying
cylinder b through the annular channel k. When the air flows through the desiccant a, its moisture is
absorbed by the desiccant a and the moisture is left on the surface of desiccant. Then, dry air flows
through the port 21 of one-way valve to the air reservoir and the brake connected to the air reservoir.
Meanwhile, the dry air flows through the port 22 to the regenerative air reservoir.
At the same time, one part of compressed air flows into the chamber D through inclined hole I and acts
on the membrane m. When the pressure on the membrane exceeds the pre-tightening force of spring,
the intake valve n is opened and the air pressure acts on the piston and pushes it to move downwards,
thus opening the exhaust valve d. The compressed air from the air compressor is exhausted from the
port 3 of desiccator through the port 1, channel C and exhaust valve d. Meanwhile, the compressed air
from the regenerative air reservoir flows through the port 22 to the lower end of drying cylinder. When the
expanded compressed air flows through the drying cylinder b from bottom to top, it will take away the
moisture absorbed on the surface of desiccant a and drain the moisture from the port 3 of desiccator
through the channel C and exhaust valve d.
When the air pressure in the pressure regulating valve reaches the opening pressure, the compressed
air is exhausted from the chamber B and the exhaust valve d is closed. The overall drying process is
performed again. The air desiccator is also installed with an electric heater to prevent the drain valve
from being frozen in winter.
9-7
Four-circuit protective valve
Main technical parameters
P2TB00005
Operating principle
P2TB00006 P2TB00007
The four-circuit protective valve is used to divide the air circuits of the whole vehicle into four connected
and independent circuits. When any one of the circuits fails (i.e. opening circuit or leakage), the other
circuits will still be able to work properly.
9-8
The compressed air from the desiccator flows into the chamber A through the port 1. It respectively
forms a pressure in the valves (g & k) through the bypass holes (b &c). When the air pressures rise high
enough to overcome the pre-tightening force of springs (1 & 2), the membrane 3 is pushed upwards. At
this point, the valves (g & k) are opened, and the air pressures respectively flow from the chambers (E &
F) through the ports 21 and 22 to the first and second air circuits of vehicle. Meanwhile, the air pressures
inside the chambers (E & F) overcome the pre-tightening force of two pressure regulating springs
through the internal air channel, and push the other end of membrane 3 upwards to open the valve. At
this point, the air pressures respectively flow through the ports 23 and 24 to the third and fourth air
circuits of vehicle. The opening pressures of the first and second circuits and those of the third and fourth
ones cam be the same or not; however, the former cannot be less than the latter, to facilitate the
regulations of pressure regulating pressure.
When one circuit fails, such as failure of the first circuit, the pressure at the port 21 will gradually drop
due to leakage. As four valves are all open, air will flow to the first circuit from other three circuits, and
the air pressure in all circuits will drop together till the closing pressure of faulty circuit is reached. When
the pressure of air source drops to the closing pressure of faulty circuit, the pressure-limiting check
membrane will be fully sealed. In this way, the pressure of air source will not be released from the faulty
circuit and the air source can supply air to other circuits again. Subsequently, the air pressure will rise to
the opening pressure of faulty circuit. Then, if the air supply rate of air source is still less than the exhaust
rate of faulty circuit, the pressure-limiting check valve membrane will be opened again and the above
pressure relief process will be performed again. The pressures in the circuits other than the faulty circuit
will be kept changing between closing and opening pressures of the faulty circuit. At this point, although
the air pressure at the port 21 drops to zero due to leakage, the pressures in the other three circuits can
be kept at the normal safe braking pressure and compensated on and on. Therefore, the driving safety is
significantly improved.
Relay valve
P2TB00008
The main brake relay valve is used to reduce the response time of brake. For the main brake chamber, it
has two functions, namely, "fast filling" and "fast exhausting".
According to the relevant international specifications, the brake response time of vehicle shall not be
more than 0.6s.
As the brake chamber of the (intermediate) rear axle has a relatively large total capacity and is far away
from the main brake valve, the brake response time is too long when the brake pedal is depressed and
the air pressure in the farthest air chamber reaches the corresponding value. For this purpose, a relay
valve is installed in the position nearest to the brake chamber of the (intermediate) rear axle. It is directly
supplied with air by the air reservoir through a relatively thick main pipeline and controlled by the main
brake valve with a relatively thin pipeline.
9-9
Operating principle
1 1
2 2
3 3 3
4
4
P2TB00009
(a)Relay valve in normal condition; (b)Relay valve in filling condition; (c)Relay valve in exhausting condition
1. Relay piston 2. Exhaust valve 3. Intake valve 4. Spring
When the main brake valve is working, an air pressure signal corresponding to the stroke of the brake
pedal is outputted from the upper chamber of the main brake valve and enters the control port of the
relay valve. The air pressure pushes the piston 1 down to close the exhaust port first and then open the
intake valve. The compressed air that has already been waiting in the main air circuit is quickly filled to
the brake chamber through the exhaust port to achieve the fast filing. When the air pressure in the brake
chamber rises to be equal to the control air pressure, its force acting on the bottom of piston 1 is
balanced with the force acting on top of piston under the control air pressure. The piston 1 rises back
and closes the air inlet again, so that the output air pressure does not rise and follows the stroke of the
brake pedal synchronously.
When the main brake valve is released from braking, the output air pressure from the brake chamber is
totally released through the main brake relay valve while the control air pressure from the relay valve is
totally released through the main brake valve. The air pressure inside the brake chamber circuit forces
the piston to rise quickly and open the exhaust port again. The air pressure in the air chamber is totally
released through the relay valve exhaust port, thus achieving the "fast exhausting" function.
The relay valve is only used to control a high air flow rate with a small air flow rate, without changing any
performance of brake.
9-10
Differential 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.
P2TB00010 P2TB00011
(a)Working State of Differential Valve Service Brake (b)Individual Working State of Relay Valve Service Brake
P2TB00012
(c)Individual Working State of Relay Valve Parking System and Common Working State of both Service Brake and
Parking Brake
Driving status: port 1 to air reservoir; port 2 to brake air chamber; port 41 to port 2 of brake valve; port 42
to port 2 of hand brake valve; port 3 to the atmosphere, and at this time, the hand brake valve constantly
supplies air to cavity A through port 42. Both upper piston and relay piston move downwards under the
pressure, to close the exhaust valve and push the valve frame downwards to open the intake valve. The
compressed air from the air reservoir through the port 1 flows outside through the port 2. As a result, the
spring brake chamber connected to the port 2 is filled with compressed air, and the spring brake is
disabled.
9-11
Individual working state of service brake: When the main brake is working, compressed air flows into the
chamber B through the port 41, and then presses the relay piston downwards. Because of the reactive
force from chambers A and C, the pressure applied to chamber B does not influence the working of
differential relay valve. The compressed air continues to flow to the spring brake in the spring brake
chamber, thus stopping the spring braking. Meanwhile, the compressed air directly from the brake valve
puts the membrane into operation again.
Individual working state of parking system: When the manual brake valve is working, the chamber A is
partially or fully emptied. The upper piston is not under the pressure. The piston (b) under the air
pressure from the air reservoir of chamber C pushes the upper piston upwards to open the exhaust
valve. Meanwhile, the valve frame rises to close the intake valve. As a result, the spring brake cylinder
forces the air to flow outside through the port 2, valve rod (c) and exhaust valve 3 depending on the
position of manual brake valve handle, thus realizing the spring braking.
Common working state of service brake and parking brake: The service brake exhausts air; that is to say,
the spring brake chamber is emptied when the spring brake cylinder is working. If the service brake is
also working, the compressed air flows into the chamber B through the port 41 and acts on the relay
valve. As the chamber C is emptied, the relay piston moves downwards. The valve frame is pushed to
close the exhaust valve and simultaneously open the intake valve. In this way, the compressed air from
the port 1 reaches the port 2 through the chamber C, and then enters the spring brake chamber. The
spring brake is released based on the rise height of service brake to avoid the overlapping action of two
brakes. The pressure at the port 2 rises. When the pressure is greater than that inside the chamber B,
the pressure from the chamber C pushes the relay piston to rise. As a result, the intake valve is closed
and the differential relay valve is in the balanced state.
9-12
Removal and installation of brake system June 9, 2020
Removal and installation of air reservoir DW90A
Removal and installation of brake system
Removal and installation of air reservoir
Removal
1. Stop the vehicle on flat working area; put the parking brake in the “parking” position; shut down the
engine and put the battery main switch in the OFF position.
2. Stop the wheel with wedge and open the air reservoir exhaust valve to release all the air in the
reservoir.

1. Remove the air reservoir
a. Disconnect the air pipe of the brake air cylinder
connected to the air tank. (Note the assembly
position of each air pipe)
b. Remove the strap of the air reservoir.
P2TB00013
Installation

9-13
June 9, 2020 Removal and installation of brake system
DW90A Removal and installation of desiccator assembly
Removal and installation of desiccator assembly
Removal
reservoir.
Carefully disconnect all air pipes and joints from the drier
interface and make marks.
Note: All interfaces of the desiccator are cast

with numbers for identification
Remove the mounting fasteners for connecting the
desiccator and remove the desiccator assembly.
P2TB00014
The air handling unit is an assembly and can be used to

replace the dryer or the four-circuit protection valve
separately.
1. First, mark the location of connector.
2. Remove the bolts connecting the dryer and the four-
circuit protection valve and remove the replacement
parts.
3. Remove the connector of the valve body and reinstall
the connector according to the original connector
position after the replacement.
P2TB00015
Installation

Notes:
1. The four-circuit protection valve is not within the warranty scope, and can only be replaced as a
whole once damaged.
2. To prevent personal injury and property loss, and ensure work safety, make sure the wheels are well
wedged.
9-14
Removal and installation of brake air chamber DW90A
Removal and installation of brake air chamber
Removal
reservoir.

1. Remove the front (rear) brake air chamber
a. Disconnect the pipes of the front (rear) brake air
chamber.
b. Remove the connecting pin between the front (rear)
brake air chamber and the brake adjusting arm.
c. Remove the retaining nut of the front (rear) brake air
chamber.
P2TB00016
Installation
Install in the reverse order of removal. Adjust the adjusting fork of the front- and rear-axle air chambers;
drive the vehicle on the road for testing and check if the brake power is normal.
9-15
June 9, 2020 Removal and installation of brake system
DW90A Removal and installation of relay valve/differential relay
Removal and installation of relay valve/differential relay valve
Removal
reservoir.

1. Disconnect the brake air pipe.
Note: Mark the assembly position of each hose

before the disconnection.
2. Remove the fixing nut of relay valve.
3. Remove the relay valve connector.
Note: Mark the position of each relay valve

connector before removing them.
P2TB00017
1. Disconnect the brake air pipe.
Note: Mark the assembly position of each hose

before the disconnection.
2. Remove the retaining nut of the differential relay valve.
3. Remove the joint of differential relay valve
Note: Mark the position of each relay valve

connector before removing them.
P2TB00018
Installation

9-16
Removal and installation of relay valve/differential relay valve DW90A
10-1
June 9, 2020 Annex
DW90A
Annex
Schematic Diagram of Machine Hydraulic System .........................................................10-3
Schematic Diagram of Hydraulic Lifting System..............................................................10-4
Schematic Diagram of Hydraulic Steering System..........................................................10-5
Brake System Schematic Diagram..................................................................................10-6
Electrical Schematic Diagram of A/C System..................................................................10-7
Schematic Diagram of Electrical System of the Whole Machine.....................................10-8
10-2
Annex June 9, 2020
DW90A
10-3
June 9, 2020 Schematic Diagram of Machine Hydraulic System
DW90A
Schematic Diagram of Machine Hydraulic System
举升油缸参数：
转向油缸参数：各级缸径mm：179/157/137/118
缸径：70mm 各级行程mm：1180/1205/1210/1210
杆径：40mm
行程：405mm
举升
进气
降落
排气
50Y1884
10-4
June 9, 2020 Schematic Diagram of Hydraulic Lifting System
DW90A
Schematic Diagram of Hydraulic Lifting System
50Y1884
10-5
June 9, 2020 Schematic Diagram of Hydraulic Steering System
DW90A
Schematic Diagram of Hydraulic Steering System
转向油缸
STEERING CYLINDER
转向器
STEERING GEAR
优先阀
PRESSURE-GRADIENT
CONTROL VALVE
回油滤
SCAVENGE FILTER
齿轮泵
GEAR PUMP
50Y1884
10-6
June 9, 2020 Brake System Schematic Diagram
DW90A
Brake System Schematic Diagram
50Y1885
10-7
June 9, 2020 Electrical Schematic Diagram of A/C System
DW90A
Electrical Schematic Diagram of A/C System
整车线束
Vehicle wiring harness
棕正极 Anode 负极 Cathode
压缩机继电器
DJ7031-6.3-21
DJ7031-6.3-11
Brown
黄 A/C COMP
B Yellow 保险保险
三档旋兰 Fuse Fuse
钮开关 C Blue
压缩机离合器
Three-speed knob switch R
A/C COMP clutch
DJ70116-6.3-21
DJ70116-6.3-11
控
红
R Red
DJ7062-3.5-11
DJ7062-3.5-21
R2 5.1K
制冷指示灯（绿）
DJ7021-6.3-11
Refrigerating light(green)
DJ7021-6.3-21
绿
制 K1
Temperature
controller
温
Green
DJ7061-6.3-11
DJ7061-6.3-21
面
控
继电器线圈
K1 Relay coil
器 Green
集
成压力开关
Press switch
块
板
Integrated
package
黑
电 Black
位
器
白
组
Potentiometer
White
白
新风 White
件一档旋钮开关
Free air one speed
rotary switch
红/兰线
Red/Blue wire
DJ7031-6.3-21
Control
DJ7031-6.3-11
R 黑
pannel R1 5.1K
新风指示灯（黄） Black
Free air light（yellow)
assembly 红
Red
白白
White White
DJ7022-6.3-11 DJ7031-6.3-11
DJ7022-6.3-21 DJ7031-6.3-21
白白
M1
R1 调
蒸速
发电
M2 风阻
R2
Speed resistance
机
Evaporation
温度传感器 fan
(热敏电阻)
M3 蒸发
Temperature sensor
风门电机*3 风机 M3
(Thermistor) Flap motor*3 Evaporation
fan
蒸发器总成
A/C evaporator assemply
10-8
June 9, 2020 Schematic Diagram of Electrical System of the Whole Machine
DW90A
Schematic Diagram of Electrical System of the Whole Machine
50Y1817

DW90A (Weichai T3) Service Manual 202006000-EN

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202006000

Applicable model: DW90A

Specification for Use of Oil ..............................................................................................1-17

How to use this Manual Instructions to Users

● Since the machine is affected by area or

Other reference manuals

Important Safety Tips As it is impossible for Liugong to predict all

The meaning of the safety warning symbol is

The hazard is explained with words or pictures

Manual identification PIN code nameplate

Important: Use a maintenance manual matching

Select a correct service manual

Based on the demands of different sales

Identification product serial number

The product PIN code nameplate is located on

The engine serial number nameplate is located

Identify the engine emission levels

Emission control information: In the United

Engine Serial Number Nameplate

Cable Identification Method

Color Abbreviation Code

Wire number P2TM00011

Color Abbreviation Code

Color In English Abbreviation Color In English Abbreviation

Color In English Abbreviation Color In English Abbreviation

Remarks: A code composed of 2 colors indicates a double-color wire.

Type of Circuit and Color Abbreviation Code

Type of Circuit Color Abbreviation Code

Description Specifications Main features & applications

There are two main colors used in this model:

S/N Item Index Testing method Remarks

S/N Item Index Testing method Remarks

Unit Conversion Table

Parameter Metric Unit Imperial Unit Multiple

Standard Torque Table

Torque parameters - metric metal parts

Bolts, nuts and screws with strength of Grade 8.8

Bolts, nuts and screws with strength of Grade 10.9/12.9

Inner Diameter of Tightening Torque

Tightening Torque for Bolt of Flange Sealed Pipe Connector

Performance Tightening Torque

Tightening Torque for Bolt of Flange Sealed Pipe Connector

Performance Tightening Torque

Tightening Torque for Thread Angle Sealed Pipe Connector

Tightening Torque of Connector

Tightening torque for inch thread

Standard torque lb.ft

Specification for Use of Oil

Type Description Volume Applying part Remarks

★ refers to the oil to be filled during delivery.

Maintenance Interval Schedule

Mainten- First Frequency (hours)

Every 50 High-pressure air is required to clean the

Mainten- First Frequency (hours)

Mainten- First Frequency (hours)

Mainten- First Frequency (hours)

Mainten- First Frequency (hours)

Note: Items with ★ are to be maintained as required.

Technical Specification of Complete Machine