500 HOURS MAINTENANCE CHECKLIST

FOR BELAZ-75137
CHASSIS NO. ________ DATE: ________ TIME: ________
MOTOR-HOURS: ________ KM: ________
Please refer the 500-MH procedure when carrying out maintenance
1. Check engine oil, coolant, fuel, hydraulic oil levels
2. Check condition of pipelines and hoses of hydraulic system and fuel, air, and coolant supply
3. Check operable condition of running gear and suspension
4. Check condition of the tires (incl. air pressure) and rims
5. No oil leaks or damage in the steering, service and parking brake system components
6. Clean lights, windows, and mirrors
7. Check the fastening of the headlight beams and the lighting armature and light alarm devices
8. Correct voltage of the batteries
9. Check the fastening of the lugs to the terminals and fastening of the batteries
10. Good condition of cab dashboard, lighting, light and audible alarms
11. Correct operation of engine systems and engine parameters indication on electronic display
after start
12. Condition and operation of the acceleration pedal
13. Correct operation of the steering and brake systems
14. Check the condition of tire pressure control system
15. Top up water in cab windows washer tanks
16. Check correct operation of the windscreen wiper and windscreen washer
17. No air leaks in pneumatic system
18. Drain of the condensate from the receiver of the pneumatic system
19. Check condition of the centralized automatic lubrication system
20. No fault signals on the centralized automatic lubrication system control unit in the cab
21. Check of the oil level in the reduction gears of the motor-wheels and top up if necessary
22. Oil sampling for analysis
23. Adding of 150 g of grease to the each of two lubricators of the motor-wheels
24. Cleaning of the magnets in the drain tubes of the reduction gears of the motor-wheels
25. Visual inspection the condition of the welds
26. Lubrication of the cardan shaft joints of the drive of the integrated hydraulic system pump
27. Cleaning the air filter cyclones from dust
28. Air blowing of engine air filter
29. Maintenance of the traction electric drive cooling and venting systems
30.1. Cleaning of the filters, dust guards and monocyclones of the air ducts from dust
30.2. Check the fastening the components of air cooling
30.3. Check the output conductors and cables of the traction electric drive
30.4. Check the condition of the control cabinet with start-and-control equipment
30.5. Check the tightness of the controls and apparatus fixtures
30.6. Check the condition of electrical apparatus
30. Maintenance of the ventilated brake unit (Grid Box)
31.1. Inspection and cleaning of the unit
31.2. Inspection of the attachment of the unit components
31.3. Check movement of motor brushes

31.4. Check the fastening (tightness) of insulators sections

31.5. Check tightening torques of :
31.5.1 bolts fastening the fan unit to the framework of the ventilated brake unit should be of 40 – 45 Nm.
31.5.2 nuts of screws fastening the input branch-pipe to the resistors unit should be of 40 – 45 N.m;

31.5.3 bolts locking the electric motors in the housing should be of 15 – 22 Nm.
31.5.4 bolt fastening the bracket of “fork” should be of 20 – 30 Nm
31. Check the condition and installation of the output conductors
32. Check the condition and installation of the cables of the traction electric drive and low voltage
electric equipment
33. Check the intactness of the hoses of the integrated hydraulic system
34. Check the intactness of the hoses of the engine external systems
35. Check the fastening of the gears of the service and parking brake systems
36. Check the wear of the linings of the brake gears of the front and rear wheels
37. Check the clearance between the brake disk and linings of the parking brake system
38. Check and retighten
39.1. Bolts fastening the pins of the steering cylinder and steering linkage arm (490 – 600 Nm)
39.2. Nuts of the tips of the steering cylinders and of the steering arm (110 – 140 Nm)
39.3. Nuts of the pins fastening the steering linkage levers (800 – 1000 Nm)
39.4. Bolts of the pins of the front suspension rod on the frame and front axle (1100 – 1250 Nm)
39.5. Fastening of the cardan shaft of the hydraulic system pump drive (105 -130 Nm)
39.6. Bolts fastening the pin of the central joint of the front suspension (no axial clearance on both
sides of the inner ring of the bearing is allowed) – torque: 1100 – 1250 Nm
39.7. Bolts fastening the pressure plates to the pin of the transverse rod of the rear suspension –
torque: 450 – 560 for the bolts without grease hole; 310-330 Nm for bolts with the same
grease hole.
39.8. Check and retighten of the front (1150-1300 Nm) and rear (800-900 Nm) wheel nuts
39. Remove and check the torque rod assembled with the sun gear of the reduction gears
40. Check the nitrogen pressure in the hydropneumatic accumulators (8 MPa)
41. Replace the filtering element of the hydraulic tank breather
42. Replace the steering filtering element
43. Maintenance of the alternator
44. Maintenance of the traction electric motors
45. Maintenance of the air conditioner
46. Replace the cabin filtering elements (2 pcs)
47. Check and top up (if necessary) grease level in Lincoln Centromatic lubrication system
48. Readjusting of the interval for the next maintenance on the electronic display in the cab
49. Blow with the air the filtering element of the control cabinet filter
Additional operations
 1. * Replace filtering element installed in the traction electric drive control cabinet
2. * Perform the maintanence of storage batteries
3. *Check the necessity of adjustment of bearings of the hubs of the reduction gears of the
power-wheels
4. **Adjust the taper bearings of the hubs of the front wheels

5. ** Grease Electric motor of the fuel priming pump

6. *** Replace the oil of reduction gears of motor wheels
7. **** Lubricate the front wheels’ hub bearings
NOTES:
* - shall be performed once in 3000 hours;
** - shall be performed once in 5000 hours;
*** - shall be performed each 2500 HMR;
**** - shall be performed each 1500 HMR.

REMARKS CHECK PERFORMED BY:

NAME: _________________

POSITION: _________________

SIGNATURE: _________________