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