BELAZ 7555B / 7555E, 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 Security requirement Fire safety rules Safety rules and warnings when performing welding work Engine systems Removal and engine installation Cooling system repair and maintenance Pumping the fuel supply system Cleaning the dust from the air filter Repair of the electric starter engine start system Possible malfunctions of the exhaust system Possible malfunctions of the engine preheater 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 Dismantling the torque converter Dismantling the gearbox Dismantling the clutch Disassembly of units of the hydraulic system of the hydromechanical transmission Checking the technical condition of hydromechanical transmission parts Hydromechanical transmission assembly 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 lockup control drive mechanism Assembling the retarder control mechanism Relief valve assembly Filter assembly Hydromechanical transmission shaft assembly Hydromechanical transmission clutch assembly Hydromechanical transmission assembly Break-in and control check of a six-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 Removing the propeller shaft of the hydromechanical transmission Removing the flexible coupling Removing the drive axle propeller shaft Dismantling propeller shafts and flexible couplings Dismantling the propeller shaft of the hydromechanical transmission Dismantling the flexible coupling Dismantling the drive axle propeller shaft Checking the technical condition of elastic coupling parts and propeller shafts Assembling propeller shafts and flexible couplings Assembling the flexible coupling Hydromechanical transmission propeller shaft assembly Assembling the drive axle propeller shaft Installing cardan shafts and flexible couplings on a dump truck Drive axle General information Possible drive axle malfunctions and remedies Dismantling the drive axle Removal and disassembly of wheel gears and wheel hubs Removal and disassembly of the final drive Removing and disassembling the drive axle housing Checking the technical condition of the drive axle parts Drive axle assembly Assembly and installation of drive axle housing Building and installing the final drive Assembly and installation of wheel hubs and wheel gears Drive axle running in 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 Dismantling the front suspension center pivot Dismantling the rear suspension center pivot Removing and disassembling the front and rear crossbars Checking the technical condition of suspension parts Assembly of suspension cylinders Assembling the top and pump cover and bottom cover Main Cylinder Assembly General assembly of suspension cylinders Installing the suspension cylinders on a dump truck Assembling the front suspension center pivot Assembling the center pivot of the rear suspension on a dump truck Assembly and installation of front and rear suspension transverse bars Front axle. Wheels and tires 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 steering gear Removing the regulator valve Removing the filter Removing the steering and steering linkage hydraulic cylinders Removing the emergency steering drive Disassembly of steering assemblies Dismantling the steering column Disassembly of the steering propeller shaft Dismantling the hydraulic steering gear Disassembly of the regulator valve Disassembly of the swing hydraulic cylinder Dismantling the steering linkage Filter disassembly 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 Assembling the regulator valve Swing Hydraulic Cylinder Assembly Assembling the steering linkage 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 Installing the control valve Installing a filter Installation of hydraulic cylinders for steering and steering linkage Installing emergency steering actuator Braking systems General information Service brake system Parking brake system Possible malfunctions of brake systems and how to fix them Repair of brake systems Repair of the brake mechanism of the front wheels Rear wheel brake repair Repair of multi-disc wet brakes of rear wheels Parking brake system repair Repair of hydraulic brake system units Brake valve Automatic pump unloading Double safety valve Pneumatic hydroaccumulator Two-way valve Retarder control valve Parking brake control valve Checking the technical condition of brake system parts Pneumatic system General information Possible malfunctions of the pneumatic system and methods of their elimination Repair of pneumatic system devices Pressure regulator repair Safety valve repair Anti-freeze repair Electrical equipment Possible malfunctions of electrical equipment Troubleshooting security issues Energy saving troubleshooting and repair Possible malfunctions and repair of batteries 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 Preparing the frame (platform) for repair 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 tipper assembly from the tipper Disassembly of the tipping mechanism components Dismantling the tipping cylinder Dismantling the tipping mechanism control panel Dismantling the tipping mechanism safety valve Disassembly of the tipping mechanism auxiliary valve Checking the technical condition of the tipping mechanism parts Tipping mechanism assembly Assembling the tipping cylinder Assembling the tipping mechanism control unit Assembling the tipping mechanism control panel Assembling the tipping mechanism safety valve Tipping auxiliary valve assembly Installing the tipper assembly on the tipper Installing the tipper assembly on the tipper Installing the tipper cylinders on the tipper Fire extinguishing system General information and safety requirements Device and principle of operation Security requirements Technical condition of the fire extinguishing system and identification of malfunctions Possible malfunctions of the fire extinguishing system, causes and methods of their elimination Fire extinguishing system repair Dismantling the fire extinguishing system Fire extinguishing system assembly Dump truck check after repair Operating materials Fuel Lubricants Coolant Nitrogen Ethyl technical alcohol Applications Appendix A Tightening torques for the most critical threaded connections Appendix B List of equipment for the repair of mining dump trucks BelAZ-7555V, BelAZ-7555E and their modifications

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