| Contents
General information
Dump truck specifications
General repair instructions
Disassembly
Fault detection
Build
Safety regulations and fire safety requirements for repair work
Engine systems
Maintenance and repair of the cooling system
Power system maintenance
Cleaning the dust from the air filter
Maintenance of the exhaust system
Service and repair of the pneumatic starter engine start system
Engine preheater maintenance
Hydromechanical transmission
General information
Possible malfunctions of hydromechanical transmission and ways to eliminate them
Removing the hydromechanical transmission from the dump truck
Disassembly of the hydromechanical transmission
Removing and disassembling the matching gear
Dismantling the torque converter
Dismantling the gearbox
Dismantling the clutch
Disassembly of the hydraulic system components
Dismantling the oil pump
Dismantling the oil intake and full-flow filter
Disassembly of the valve body
Disassembling the compensating valve
Disassembly of the control mechanism
Disassembly of the torque converter release mechanism
Disassembly of the retarder control drive mechanism
Disassembly of the retarder control mechanism
Checking the technical condition of hydromechanical transmission parts
Hydromechanical transmission assembly
Assembling the matching gear
Assembling the oil pump
Assembling the oil intake and full-flow filter
Spool box and control assembly assembly
Assembling the relief valve
Assembling the torque converter release mechanism
Assembling the control drive mechanism and the retarder control mechanism
Hydromechanical transmission shaft assembly
Hydromechanical transmission clutch assembly
Hydromechanical transmission assembly
Running-in and control check of a five-speed hydromechanical transmission
Installing a hydromechanical transmission on a dump truck
Cardan drive
General information
Possible malfunctions of cardan shafts, flexible couplings and how to fix them
Removing propeller shafts and flexible coupling from a dump truck
Dismantling propeller shafts and flexible couplings
Checking the technical condition of elastic coupling parts and propeller shafts
Assembling propeller shafts and flexible couplings
Installing cardan shafts and flexible couplings on a dump truck
Drive axle
General information
Possible drive axle malfunctions and remedies
Dismantling of the drive axle of BelAZ-7540A, 75404 dump trucks
Removing and disassembling wheel gears
Removing and disassembling wheel hubs
Removal and disassembly of the final drive
Dismantling of the drive axle of BelAZ-7548A, 75481, 75483, 7547, 75471, 75473 dump trucks
Checking the technical condition of the drive axle parts
Assembling the drive axle of BelAZ-7540A, 75404 dump trucks
Building and installing the final drive
Assembly and installation of wheel hubs and wheel gears
Assembling the drive axle of BelAZ-7548A, 75481, 75483, 7547, 75471, 75473 dump trucks
Drive axle running in
Chassis
Suspension
General information
Possible malfunctions of the suspension cylinders and how to fix them
Safety measures when removing, repairing and installing suspension cylinders on a dump truck
Removing the suspension cylinders from the dump truck
Disassembly of suspension cylinders
Removing from a dump truck and disassembling the reaction rods of the front and rear suspension and the forks with a pivot connection of the rear suspension
Checking the technical condition of suspension parts
Assembly of suspension cylinders
Installing the suspension cylinders on a dump truck
Assembling the reaction rods of the front and rear suspension and the rear suspension fork with a kingpin and installing them on a dump truck
Front axle
Removing the front axle from a dump truck
Dismantling the front axle
Checking the technical condition of the front axle parts
Front axle assembly
Installing the front axle on a dump truck
Wheels and tires
Removing wheels from a dump truck
Disassembly and assembly of wheels
Installing wheels on a dump truck
Steering
General information
Possible malfunctions of the steering and how to fix them
Removing steering assemblies from a dump truck
Removing the steering column
Removing the Relief Valve Steering Gear
Removing the filter
Removing the hydraulic steering cylinder, rods and steering linkage arms
Removing the emergency steering drive
Disassembly of steering assemblies
Dismantling the steering column
Disassembly of the steering propeller shaft
Dismantling the hydraulic steering gear with safety valve
Disassembly of the swing hydraulic cylinder
Dismantling the steering linkage
Dismantling the hydraulic filter
Dismantling the emergency steering actuator
Checking the technical condition of steering parts
Steering assembly assembly
Assembling the steering column
Steering propeller shaft assembly
Assembling the hydraulic steering gear with relief valve
Swing hydraulic cylinder assembly
Assembling the steering linkage
Hydraulic filter assembly
Assembling emergency steering actuator
Installing steering assemblies on a dump truck
Installing a steering column with a propeller shaft
Installing the steering gear with relief valve
Installing a filter
Installing the steering cylinder and steering linkage
Installing emergency steering actuator
Braking systems
General information
Possible malfunctions of brake systems and how to fix them
Service brake system
Dismantling the brake mechanism of the front wheels of dump trucks BelAZ-7548A, 75481, 75483, 7547 75471, 75473
Assembling the brake mechanism of the front wheels of the BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
Dismantling and assembly of the brake mechanism of the front wheels of BelAZ-7540A, 75404 dump trucks
Dismantling the brake mechanism of the rear wheels of BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
Assembling the brake mechanism of the rear wheels of BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
Dismantling and assembly of the brake mechanism of the rear wheels of BelAZ-7540A, 75404 dump trucks
Disassembling the brake cylinder
Assembling the brake cylinder
Dismantling the compressor
Compressor assembly
Dismantling the service brake control valve
Assembling and testing the service brake control valve
Dismantling the pressure regulator
Assembling, adjusting and testing the pressure regulator
Dismantling the water separator
Assembling and testing the water separator
Disassembly of the anti-freeze device
Anti-freeze assembly and testing
Disassembly of the single safety valve
Assembly, adjustment and testing of a single safety valve
Dismantling the double safety valve
Assembling and testing the double safety valve
Disassembly of the pressure relief valve
Pressure relief valve assembly
Dismantling the relief valve
Relief valve assembly
Replacing the brake pads
Parking brake system
Dismantling the brake mechanism of the parking brake system of BelAZ-7540A, 75404 dump trucks
Assembly, adjustment and testing of the brake mechanism of the parking brake system of dump trucks BelAZ-7540A, 75404
Dismantling and assembly of the brake mechanism of the parking brake system of dump trucks BelAZ-7548A, 75481, 75483, 7547, 75471, 75473
Dismantling the parking brake control valve
Assembling, adjusting and testing the parking brake control valve
Checking the technical condition of brake system parts
Electrical equipment
Troubleshooting security issues
Energy saving troubleshooting and repair
Repair and maintenance of outdoor and indoor lighting systems
Cab, cab equipment and empennage
Removal of plumage, cockpit and their repair
Cabin equipment repair
Frame and platform
Checking the technical condition of the frame (platform) and determining defects
Frame (platform) repair
Welding in the down position
Vertical welding
Horizontal welding
Overhead welding
Welding quality control and elimination of defects
Removing and installing the platform
Tipping mechanism
General information
Possible malfunctions of the tipping mechanism and methods of their elimination
Removing the tipping mechanism assemblies
Disassembly of the tipping mechanism components
Dismantling the tipping cylinder
Disassembly of the electromagnetic control valve of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
Disassembly of the control panel of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
Dismantling the tipping mechanism safety valve
Disassembly of the tipping mechanism auxiliary valve
Dismantling the control unit of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
Dismantling the control panel of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
Checking the technical condition of the tipping mechanism parts
Tipping mechanism assembly
Assembling the tipping cylinder
Assembling the tipping mechanism safety valve
Tipping auxiliary valve assembly
Assembling the control panel of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
Assembling the control unit of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
Assembling the control panel of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
Testing the knots of the tipping mechanism
Testing the tipping mechanism cylinders
Testing the tipping mechanism control unit
Testing the tipping mechanism control panel
Installing the tipper cylinders on the tipper
Running in dump trucks after repair
Operating materials
Lubricants
Fuel
Coolant
Ethyl technical alcohol
Nitrogen
Applications
Appendix A Tightening torques for main screw connections
Appendix B List of equipment for the repair of mining dump trucks BelAZ- 7540A, 75404, 7548A, 75481, 75483, 7547, 75471, 75473 and their modifications |
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