BELAZ 7540 / 7548 / 7547, service e-manual (in Russian)

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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