EXPLANATION OF DW90A

CONTROL DEVICE

TOUGH WORLD. TOUGH EQUIPMENT.

极限工况 强悍设备
CONTENTS
Main components of transmission-related subsystems
1. Transmission mounting system: transmission, clutch and auxiliary support
2. Main clutch control system: clutch master pump, clutch slave cylinder (booster cylinder),
pipeline
3. Shift control system: shift knob, flexible shaft, gear selector, shift rocker arm, etc.
4. Drive shaft: main drive shaft, rear axle drive shaft, eddy-current retarder system (optional for
10-gear ), hydraulic retarder (optional for 8-gear)
I. TRANSMISSION MOUNTING (BENDING
PLATE STRUCTURE)
I. TRANSMISSION MOUNTING
I. TRANSMISSION MOUNTING
TRANSMISSION COUPLING SLEEVE
II. MAIN CLUTCH CONTROL SYSTEM
Installation of clutch
The clutch is mounted between the engine and the transmission for
transmitting power.
II. MAIN CLUTCH CONTROL SYSTEM
Working principle of clutch

Support ring
Flywheel

Membrane spring

Release bearing

Pressure plate

Yoke
Driven disc
II. MAIN CLUTCH CONTROL SYSTEM
Common clutch faults

Please note the clutch application:

The clutch wearing may lead to no travel or weak travel of the vehicle.
II. Main clutch control system
Installation of thrust bearing and fork
Correct schematic: please pay attention to the contact Wrong Schematic:
point between the shift fork and the release bearing

Observation hole
II. MAIN CLUTCH CONTROL SYSTEM
Main clutch control system: hydraulic control and pneumatic power-assisted structure are adopted.
Main functions: by controlling the clutch, the engine power can be cut off and transmitted to create
conditions for gear shifting of the transmission; reduce the labor intensity of the operator.
II. MAIN CLUTCH CONTROL SYSTEM
Overview of control system

CLUTCH BRAKE
CYLINDER

Clutch Connected to the

master transmission
cylinder
II. Main clutch control system
BASIC PRINCIPLE OF CONTROL SYSTEM

1 Clutch pedal 5. Clutch booster cylinder

2. Clutch master cylinder 6. Release fork
3. Control lines 7. Clutch release bearing
4. Air reservoir 8. Clutch assembly
II. MAIN CLUTCH CONTROL SYSTEM
CLUTCH BRAKE CYLINDER
II. MAIN CLUTCH CONTROL SYSTEM
Clutch master cylinder

II Working principle of clutch master cylinder

1
Oil inlet pipe
(connecting the
Working principle diagram of clutch oil can)
master cylinder:
Piston

Fuel outlet
(connecting the Valve Y-ring Push rod
oil pipe) (connecting the
pedal)

3 Hydraulic Return spring Y-ring Limit bar Mechanical

pressure force

The clutch control system adopts the hydraulic control and air-boost structure; when the
clutch pedal is depressed, the master cylinder pushes brake fluid to enter the hydraulic
control chamber of the assistant cylinder; brake fluid is acted on the piston under operating
pressure, while controlling the intake valve of the air chamber of the assistant cylinder under
control pressure.
II. MAIN CLUTCH CONTROL SYSTEM
Clutch engaging and release
When compressed air enters the air chamber of the assistant cylinder, air assistance is generated, which
pushes the piston to make the push rod of the assistant cylinder move forwards; under the lever action, the
separation rocker arm and the clutch release fork push the clutch release bearing backward; the clutch
release bearing drives the diaphragm spring of the clutch pressure plate move rightwards via deformation;
and pressure plate pressing force between friction plates and the flywheel is lost, which achieves separation.
The pedal is released, the clutch master cylinder returns, oil pressure disappears, and the clutch pressure
plate, the clutch release bearing, the clutch release fork, and the push rod of the clutch booster return under
the action of the diaphragm spring.

The power is outputting if the clutch pedal is not The power is cut-out if the clutch pedal is
depressed depressed
II. MAIN CLUTCH CONTROL SYSTEM
Working principle of control system

1. Cylinder
2. Push rod
3. Reaction valve
4. Air bleeding channel
5. Control valve
6. Air chamber
7. Piston
8. Indicator valve
9. Washer
10. Oil can
11. Upper limit screw
12. Piston rod
13. Piston
14. Lower limit screw
15. Rocker arm
16. Release shaft
A. Clutch master cylinder
B. Clutch slave cylinder
Connecting the
compressed air
II. MAIN CLUTCH CONTROL SYSTEM
Working principle of control system - clutch release
II. MAIN CLUTCH CONTROL SYSTEM
Working principle of control system - balanced state
II. MAIN CLUTCH CONTROL SYSTEM
Working principle of control system - clutch engaging
II. MAIN CLUTCH CONTROL SYSTEM
Control system commissioning

When filling the brake fluid for the first time, unscrew
the bleeder plug and tighten it immediately after the
brake fluid flows out of the hole; Then depress the
clutch pedal several times continuously (after the pedal
has a heavy feeling), depress the clutch pedal, release
the bleeder plug again, and the brake fluid ejects in a
column. After a few seconds, tighten the bleeder plug
again, and finally, release the clutch pedal. (This
process should be repeated at least twice).

Adjust the height of

the clutch pedal
with this bolt (after
confirming that the
air in the oil pipe is
exhausted)
III. SHIFT CONTROL SYSTEM
Shift control system: it adopts the double-levers remote control and manual operation.
Main function: by moving the shift lever back and forth, it will be transformed into the front and back
movements of the connected selection and gearshift flexible shaft through the shift controller, and
finally drive the rocker arm to rotate to the corresponding position to realize the shift.
III. SHIFT CONTROL SYSTEM
Gear shift controller

For DW90AH For DW90A

III. SHIFT CONTROL SYSTEM
Shift fork

Input Output
shaft shaft

Idler

Intermediate
Shaft

Selector rocker arm: the 10-gear transmission is different from the 8-gear and 7-gear (2 types)
Shift controller: the tilt cab is different from the fixed cab (2 types)
Shift knob ball:
8-Gear: the tilt cab is different from the fixed cab (2 types)
10-Gear: at present, it only realizes the installation of tilt cab (1 type)
7th gear: At present, it is only arranged according to the fixed cab (1 type)
Flexible shaft: the tilt cab is longer, the fixed cab is short, and the lengths of gears 8 and 7 are also different
III. SHIFT CONTROL SYSTEM

10-gear handle 8-gear handle Shift controller

10-gear flexible shaft support Gear
(Yuchai)
arrangement (Yuchai)

Front
Empt
y
8-Gear handle (Weichai)
When in neutral, the front and rear
Adjusting nut telescopic strokes are symmetrical

10-gear selector rocker arm

III. SHIFT CONTROL SYSTEM

10-gear
transmis
sion

8-gear transmission
7-gear
transmis
sion

The red and black colors

Shift rocker correspond to each other, and
arm (same) reverse installation is not allowed
III. SHIFT CONTROL SYSTEM
Adjustment method of shift knob

The
deflection
shall not
be
greater
than 3
degrees

The
flexible
shaft
length
adjusting
nut can
make all
gears
shift
smoothly.
IV. DRIVE SHAFT
The power output from the transmission is transmitted to the drive
axle, and the propeller shaft layout is as follows:
IV. DRIVE SHAFT
Daily maintenance

1. The tightening torque of

M14 bolt (No. 4) is 180-
210Nm, and 1262 thread
locker is applied. It must
be 100% tested,
2. The grease nozzle of
universal joint cross and
sliding fork shall be
located on the same side
after assembly, and No.
2 lithium-base grease
shall be refilled at the
place with oil cup.
IV. Drive shaft
EQUIPPED WITH AT TRANSMISSION
谢谢 THANK YOU
TOUGH WORLD. TOUGH EQUIPMENT.
极限工况 强悍设备