Blaz. Manual

PRODUCTION ASSOCIATION
«BELORUSSIAN AUTOWORKS»
OPEN-CAST MINING DUMP TRUCKS

BELAZ-7514-10, BELAZ-75145,
BELAZ-75131, BELAZ-75132
REPAIR MANUAL
7513-3902080 RM
REPUBLIC OF BELARUS
© PRODUCTION ASSOCIATION «BELoRUSSIAN AUTOWORKS», 2004
Contents
7513-3902080 RM
CONTENTS
1GENERAL INFORMATION................................................................................................................................................. 1-1
2 TECHNICAL SPECIFICATIONS OF DUMP TRUCKS ....................................................................................................... 2-1
3GENEARL DIRECTIONS UNDER REPAIR........................................................................................................................ 3-1
3.1 Dismantling................................................................................................................................................................... 3-1
3.2 Flaw detection ............................................................................................................................................................. 3-1
3.3 Assembling .................................................................................................................................................................. 3-2
4 SAFETY INSTRUCTIONS AND FIRE-FIGHTING REGULATIONS UNDER REPAIR ..................................................... 4-1
4.1Safety instructions ........................................................................................................................................................ 4-1
4.2 Preventive fire-fighting regulations…............................................................................................................................ 4-3
5ENGINE SYSTEMS............................................................................................................................................................. 5-1
5.1 Removal and mounting of the diesel generator............................................................................................................ 5-1
5.2 Engine connection with the traction generator ............................................................................................................. 5-3
5.3 Repair and service of the cooling system................................................................................................................ 5-7
5.4 Fuel systems service ................................................................................................................................................. 5-11
5.5 Air filter cleaning ........................................................................................................................................................ 5-12
5.6 Service and repair of the pneumatic starter engine system ......................................................................................... 5-14
5.7 Service of the engine preheater ................................................................................................................................ 5-16
6 TRACTION ELECTRIC DRIVE .......................................................................................................................................... 6-1
6.1General information about the drive .............................................................................................................................. 6-1
6.2 Description and operation of the drive components ..................................................................................................... 6-2
6.2.1 Electrical machines ............................................................................................................................................. 6.2
6.2.1.1 Traction alternator .................................................................................................................................. 6-2
6.2.1.2 Traction motor ........................................................................................................................................ 6-11
6.2.2 Electric apparatuses............................................................................................................................................ 6-23
6.2.2.1 Control cabinet ....................................................................................................................................... 6-23
6.2.2.2 Contactors ............................................................................................................................................. 6-27
6.2.2.3 Mounting of vented brake resistor .......................................................................................................... 6-31
6.2.2.4 Motion controller ..................................................................................................................................... 6-34
6.2.2.5 Braking controller.................................................................................................................................... 6-34
6.2.2.6 Measuring instruments ........................................................................................................................... 6-35
6.2.3 System of ventilation and cooling of traction drive .............................................................................................. 6-37
6.3 Repair of electrical machines and apparatuses of traction drive .................................................................................. 6-39
6.3.1 Repeair of electric machines............................................................................................................................... 6-39
6.3.1.1 Repeair of traction alternators ................................................................................................................ 6.39
6.3.1.2 Repair of traction motors ........................................................................................................................ 6-47
6.3.2 Repair of electric apparatuses ............................................................................................................................ 6-56
6.3.2.1Repair of motion controlller...................................................................................................................... 6-57
6.3.2.2 Repair of braking controller .................................................................................................................... 6-57
7ELECTRO-MOTOR WHEEL ............................................................................................................................................... 7-1
7.1 General information ..................................................................................................................................................... 7-1
7.2 Repair of electro-motor wheels..................................................................................................................................... 7-1
7.2.1 Removal of electro-motor wheel from the truck ............................................................................................ 7-1
7.2.2 Dismantling of reducer ....................................................................................................................................... 7-5
7.2.3 Checking of the technical state of parts of motor-wheel reducer ................................................................ 7-7
7.2.4 Assembling of motor-wheel ................................................................................................................................ 7-11
7.2.5 Running-in of the motor-wheel reducer.......................................................................................................... 7-19
8 RUNNING GEAR ............................................................................................................................................................... 8-1
8.1 Suspension .................................................................................................................................................................. 8-1
8.1.1 General information ............................................................................................................................................ 8-1
8.1.2 Suspension cylinders troubleshooting................................................................................................................. 8-8
8.1.3 Safety precautions at removal, repair and mounting of suspension cylinders on dump truck .............................. 8-8
8.1.4 Removal of suspension cylinders from dump truck............................................................................................. 8-9
8.1.5 Disassembly of suspension cylinders ................................................................................................................. 8-11
8.1.6 Disassembly of central hinges of front and rear suspension............................................................................... 8-12
8.1.7 Disassembly of pivot unit of front suspension on dump trucks BELAZ-7514-10, BELAZ-75145................................ 8-13
8.1.8 Removal and disassembly of transversal rods of front and rear suspension...................................................... 8-14
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Contents
7513-3902080 RM
8.1.9 Check-up of technical condition of suspension parts ......................................................................................... 8-16

8.1.10 Assembly of suspension cylinders .............................................................................................................. 8-22
8.1.11 Mounting of suspension cylinders on dump truck .................................................................................... 8-28
8.1.12 Assembly of central hinges of front and rear suspension. ........................................................................ 8-29
8.1.13 Assembly and mounting of transversal rods of front and rear suspension............................................. 8-31
8.1.14 Assembly and mounting of pivot unit of front suspension on dump trucks BELAZ-7514-10, BELAZ-75145
........................................................................................................................................................................... 8-32
8.2 Front axle .................................................................................................................................................................... 8-33
8.2.1 Front axle of dump trucks BELAZ-75131 and BELAZ-75132 ............................................................................ 8-33
8.2.1.1 General information .............................................................................................................................. 8-33
8.2.1.2 Removal of front axle from dump trucks BELAZ-75131 and BELAZ-75132 ................................... 8-33
8.2.1.3 Disassembly of front axle of dump trucks BELAZ-75131 and BELAZ-75132................................. 8-34
8.2.2 Swivel member with hub of dump trucks BELAZ-7514-10 and BELAZ-75145 .................................................. 8-39
8.2.2.1 General information .............................................................................................................................. 8-39
8.2.2.2 Removal and disassembly of hub of front wheel ................................................................................... 8-39
8.2.3 Check-up of technical condition of front axle parts of dump trucks BELAZ–75131, BELAZ–75132 and
of swivel member with hub of dump trucks BELAZ–7514-10, BELAZ–75145 ................................................... 8-39
8.2.4 Assembly and mounting of front axle of dump trucks BELAZ-75131 and BELAZ-75132 8-42
8.2.5 Assembly and mounting of hub of front wheel on dump trucks BELAZ-7514-10 and BELAZ-75145 8-45
8.2.6 Adjusting of bearings of front wheel hubs during operation of dump trucks....................................................... 8-46
8.3 Wheels and tires ................................................................................................................................................... 8-49
8.3.1 Removal of wheels from hubs ............................................................................................................................ 8-50
8.3.2 Disassembly and assembly of wheels ............................................................................................................... 8-51
8.3.3 Mounting of wheels on hubs .............................................................................................................................. 8-54
9STEERING .......................................................................................................................................................................... 9-1
9.1 General information .................................................................................................................................................... 9-1
9.2Possible malfuctions of steering ................................................................................................................................... 9-1
9.2.1 Main malfunctions of steering of trucks BELAZ-7514-10, BELAZ-75145,
reasons and remedies ........................................................................................................................................ 9-1
9.2.2 Main malfunctions of steering of trucks BELAZ -75131, BELAZ-75132,
reasons and remedies ........................................................................................................................................ 9-2
9.3 Removal of steering units from the truck ..................................................................................................................... 9-4
9.3.1 Removal of steering units from the truck BELAZ-7514-10, BELAZ-75145 ........................................................ 9-4
9.3.2 Removal of steering units from the truck BELAZ -75131, BELAZ-75132 .......................................................... 9-5
9.4 Dismantling of steering units........................................................................................................................................ 9-7
9.4.1 Dismantling of steering units of trucks BELAZ-7514-10, BELAZ-75145 ........................................................... 9-7
9.4.2 Dismantling of steering units of trucks BELAZ -75131, BELAZ-75132 ............................................................ 9-15
9.5 Checking up of parts technical state ............................................................................................................................ 9-22
9.5.1 Checking up of parts technical state of trucks BELAZ-7514-10, BELAZ-75145 ................................................ 9-22
9.5.2 Checking up of parts technical state of trucks BELAZ -75131, BELAZ-75132 ................................................. 9-24
9.6 Assemblage of steering units....................................................................................................................................... 9-24
9.6.1 Assemblage of steering units of trucks BELAZ-7514-10, BELAZ-75145 . ......................................................... 9-24
9.6.2 Assemblage of steering units of trucks BELAZ-75131, BELAZ-75132 ............................................................. 9-30
9.7 Mounting of steering units to the truck. ........................................................................................................................ 9-34
9.7.1 Mounting of steering units to the truck s BELAZ-7514-10, BELAZ-75145 ........................................................ 9-34
9.7.2 Mounting of steering units to the trucks BELAZ-75131, BELAZ-75132 ............................................................ 9-35
10BRAKE SYSTEMS ........................................................................................................................................................... 10-1
10.1 General information .................................................................................................................................................. 10-1
10.1.1 Braking systems of dump trucks BELAZ-7514-10, BELAZ-75145 ................................................................... 10-1
10.1.1.1 Service brake system .......................................................................................................................... 10-1
10.1.1.2Parking brake system ........................................................................................................................... 10-2
10.1.2 Braking systems of dump trucks BELAZ-75131, BELAZ-75132 ...................................................................... 10-3
10.1.2.1Service brake system............................................................................................................................ 10-3
10.1.2.2Parking brake system ........................................................................................................................... 10-4
10.2 Possible troubles of braking systems and methods of their removal................................................................ 10-6
10.3 Repairing of braking systems of dump trucks BELAZ-7514-10, BELAZ-75145 ................................................. 10-6
10.3.1 Repairing of brake gears of front wheels........................................................................................................ 10-6
10.3.2 Repairing of brake gears of rear wheels .......................................................................................................... 10-9
10.3.3 Repairing of a parking braking system............................................................................................................. 10-12
10.3.4 Repairing of gears of the hydraulic actuator of braking systems ..................................................................... 10-16
10.3.4.1 Brake valve .......................................................................................................................................... 10-16
10.3.4.2 Double protective valve........................................................................................................................ 10-18
10.3.4.3 Pressure relay ...................................................................................................................................... 10-19
10.3.4.4 Pneumohydraulic accumulator ............................................................................................................ 10-20
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Contents
7513-3902080 RM
10.3.4.5 Filter of hydraulic drive of the service braking system......................................................................... 10-22

10.3.4.6 Control valve a parking braking system................................................................................................ 10-23
10.3.5 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-7514-10, BELAZ-75145..... 10-25
10.4 Repairing of braking systems of dump trucks BELAZ-75131, BELAZ-75132 ............................................................ 10-26
10.4.1 Repairing of brake gears of front wheels .......................................................................................................... 10-26
10.4.2 Repairing of brake gears of rear wheels and a parking braking system................................................................. 10-28
10.4.3 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-75131, BELAZ-75132
……………………………………………………………………………………………………………………. 10-32
11PNEUMATIC SYSTEM...................................................................................................................................................... 11-1

11.1General information. .................................................................................................................................................... 11-1
11.2 Possible troubles of pneumatic system and methods of their removal ................................................................... 11-1
11.3 Repairing of devices of pneumatic system. ............................................................................................................... 11-1
11.3.1 Repairing of a dehumidifier ........................................................................................................................... 11-2
11.3.2 Repairing of a pressure regulator. ................................................................................................................ 11-4
11.3.3 Repairing of the single protective valve. ...................................................................................................... 11-6
11.3.4 Repairing of a safety valve............................................................................................................................ 11-7
11.3.5 Repairing of antifreezer. ................................................................................................................................. 11-8
11.3.6 Repairing of he pneumatic switch................................................................................................................. 11-9
12 ELECTRIC EQUIPMENT ................................................................................................................................................. 12-1
12.1 Technical requirements to an electrical equipment.............................................................................................. 12-1
12.2 Faultiness elimination of the the protection system ................................................................................................... 12-4
12.3 Faultiness elimination and repair of the electricity supply system. ............................................................................ 12-6
12.3.1 Service of storage batteries.. ......................................................................................................................... 12-6
12.3.2 The storage batteries possible faultiness. ................................................................................................... 12-9
12.3.3 The repair operations not requiring the disassembly of the storage battery. .......................................... 12-9
12.4 Repair and service of the alternator. ...................................................................................................................... 12-10
12.4.1 Alternator disassembly. ................................................................................................................................. 12-11
12.4.2 Alternator technical state after repair. .......................................................................................................... 12-11
12.5 Repair and service of of external and internal illumination system .................................................................... 12-12
12.5.1 Light headlights adjustment. ......................................................................................................................... 12-12
13 POWER TAKEOFF AND CARDAN SHAFT.................................................................................................................... 13-1
13.1Power takeoff............................................................................................................................................................... 13-1
13.1.1 General information .......................................................................................................................................... 13-1
13.1.2Repair of power takeoff. ..................................................................................................................................... 13-1
13.1.2.1Removal of power takeoff from the truck............................................................................................... 13-1
13.1.2.2Dis mantling of power takeoff. ............................................................................................................... 13-5
13.1.2.3Checking up of the technical state of power takeoff parts. .................................................................... 13-6
13.1.2.4Assemblage of power takeoff. ............................................................................................................... 13-9
13.1.2.5Running-in of power takeoff................................................................................................................... 13-13
13.1.2.6Mounting of pumps and speed transducer. ........................................................................................... 13-14
13.1.2.7Mounting of power takeoff. .................................................................................................................... 13-14
13.2Cardan shaft. ............................................................................................................................................................... 13-15
13.2.1General information............................................................................................................................................ 13-15
13.2.2 Possible malfunctions of cardan shaft and its remedies................................................................................. 13-15
13.2.3 Repair of cardan shaft ...................................................................................................................................... 13-16
13.2.3.1Removal of cardan shaft from the truck................................................................................................. 13-16
13.2.3.2Dismantling of cardan shaft. .................................................................................................................. 13-16
13.2.3.3Checking up of the technical state of cardan shaft parts....................................................................... 13-17
13.2.3.4Assembling of cardan shaft ................................................................................................................... 13-17
13.2.3.5Mounting of cardan shaft to the truck .................................................................................................... 13-18
14DUMPING GEAR .............................................................................................................................................................. 14-1
14.1General information ..................................................................................................................................................... 14-1
14.2 Possible faults of the dumping mechanism.................................................................................................................... 14-4
14.2.1 Major faults of the dumping mechanism in BELAZ-7514-10, BELAZ-75145 dump trucks,
their causes and remedy ................................................................................................................................... 14-4
14.2.2 Major faults of the dumping mechanism in BELAZ-75131, BELAZ-75132 dump trucks,
their causes and remedy .............................................................................................................................................. 14-6
14.3 Dismounting of the dumping mechanism assemblies from dump truck ..................................................................... 14-7
14.3.1 Dismounting of the dumping mechanism assemblies. ...................................................................................... 14-7
14.3.2 Dismounting of the dumping mechanism cylinder............................................................................................. 14-7
14.4 Dismantling of dumping mechanism assemblies........................................................................................................ 14-8
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7513-3902080 RM
14.4.1 Dismantling of dumping mechanism assemblies from BELAZ-7514-10, BELAZ-75145 dump trucks …………..14-8
14.4.1.1 Disassembly of dumping mechanism cylinder ..................................................................................... 14-8

14.4.1.2 Disassembly of hydraulic distribution valve in the dumping mechanism ............................................. 14-11
14.4.1.3 Dismantling of the dumping mechanism cylinder................................................................................. 14-11
14.4.1.4 Disassembly of control valve in the dumping mechanism ................................................................... 14-12
14.4.1.5 Disassembly of auxiliary hydraulic distribution valve in the dumping mechanism ............................... 14-13
14.4.1.6 Disassembly of solenoid distribution valve of body raise interlock in the dumping mechanism ……... 14-14
14.4.2 Dismantling of dumping mechanism assemblies from BELAZ-75131, BELAZ 75132 dump tucks………….. ……..14-14
14.4.2.1 Disassembly of dumping mechanism cylinder ..................................................................................... 14-14

14.4.2.2 Disassembly of dumping mechanism control unit................................................................................ 14-14
14.4.2.3 Disassembly of hydraulic distribution valve in the dumping mechanism ............................................. 14-15
14.4.2.4 Disassembly of relief valve in hydraulic distribution valve of the dumping mechanism ....................... 14-17
14.4.2.5 Disassembly of auxiliary valve in hydraulic distributor of the dumping mechanism……………………. 14-17
14.5 Checking up of parts technical conditions.................................................................................................................. 14-18
14.5 1 Checking up of technical condition of dumping mechanism parts in BELAZ-7514-10,
BELAZ-75145 dump trucks .............................................................................................................................. 14-18
14.5 2 Checking up of technical condition of dumping mechanism parts in BELAZ -75131,
BELAZ-75132 dump trucks .............................................................................................................................. 14-19
14.6 Assembly of dumping mechanism units..................................................................................................................... 14-20
14.6.1 Assembly of dumping mechanism units in BELAZ-7514-10, BELAZ-75145 dump trucks ……………………... 14-20
14.6.1.1 Assembly of dumping mechanism cylinders ........................................................................................ 14-20

14.6.1.2 Assembly of hydraulic distribution valve (dumping mechanism).......................................................... 14-21
14.6.1.3 Assembly of solenoid control distribution valve (dumping mechanism) ………………………………….14-22
14.6.1.4 Assembly of control valve in the dumping mechanism ........................................................................ 14-22
14.6.1.5 Assembly of auxiliary hydraulic distribution valve (dumping mechanism) ........................................... 14-23
14.6.1.6 Assembly of solenoid distribution valve of body raise interlock (dumping mechanism)....................... 14-23
14.6.2 Assembly of dumping mechanism units in BELAZ-75131, BELAZ-75132 dump trucks…………………….14-24
14.6.2.1 Assembly of dumping mechanism cylinders ........................................................................................ 14-24

14.6.2.2 Assembly of dumping mechanism control unit..................................................................................... 14-24
14.6.2.3 Assembly of hydraulic distributor relief valve ....................................................................................... 14-25
14.6.2.4 Assembly of auxiliary valve (hydraulic distributor) ............................................................................... 14-25
14.6.2.5 Assembly of hydraulic distribution valve .............................................................................................. 14-25
14.7 Mounting of dumping mechanism assemblies into dump truck ................................................................................. 14-26
14.7.1 Mounting of dumping mechanism assemblies into dump truck............................................................................. 14-26
14.7.2 Mounting of dumping mechanism cylinders into dump truck............................................................................ 14-26
15CAB, CAB EQUIPMENT AND EMPENNAGE ................................................................................................................. 15-1
15.1 Taking off of cabs, empennage and its repair............................................................................................................ 15-3
15.2 Repair of cab equipment............................................................................................................................................ 15-6
15.2.1 Repair of cab equipment of trucks BELAZ-75131, BELAZ-75132……………………………………………. 15-6
15.2.2 Repair of cab equipment of trucks BELAZ-7514-10, BELAZ-75145. ............................................................... 15-16
16 FRAME AND BODY ........................................................................................................................................................ 16-1
16.1 Technical condition inspection of frame (body)and defects imperfections definition…………………………………… 16-1
16.2 Preparation of frame (body) for repair........................................................................................................................ 16-1

16.3 Frame (body) repair. .................................................................................................................................................. 16-5
16.3.1 Down hand welding. ......................................................................................................................................... 16-5
16.3.2 Welding in horizontal position........................................................................................................................... 16-6
16.4 Welding in overhead position..................................................................................................................................... 16-7
16.5 Welding quality control and defects elimination ......................................................................................................... 16-8
17 FIRE-FIGHTING SYSTEM ............................................................................................................................................... 17-1
17.1 General and safety requirements............................................................................................................................... 17-1
17.2 Technical condition of fire-fighting system and trouble shooting. .............................................................................. 17-2
17.3 Possible faults in fire-fighting system and their remedy............................................................................................. 17-3
17.4 Repairs in fire-fighting system.................................................................................................................................... 17-3
18 RUNNING IN OF DUMP TRUCKS AFTER REPAIR ......................................................................................................... 18-1

19 OPERATION MATERIALS ............................................................................................................................................. 19-1
19.1Lubricants ................................................................................................................................................................... 19-1
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Contents
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19.2 Fuel ............................................................................................................................................................................ 19-8

19.3Cooling fluid................................................................................................................................................................. 19-9
19.4 Spirit engineering ..................................................................................................................................................... 19-9
19.5 Nitrogen ..................................................................................................................................................................... 19-9
АPPENDIX A Assembly protocol of engine КТА 38С (КТА 50С) with alternator ГС525 ……………………………… 20-1
APPENDIX Б Torques of the most crucial threaded joints............................................................................................. 20-2

APPENDIX В Torques of the most crucial threaded joints............................................................................................. 20-4
V
Contents
7513-3902080 RM
VI
General
7513-3902080 RM
1 GENERAL
The given manual sets scope of routine and mid-life repairs and is intended for operators, mechanical
engineers and other personnel working at enterprises operating, servicing and repairing quarry dump trucks
(further – dump trucks) with payload capacity 120 -130 T and their modifications models, produced by Produc-
tion Association «Belarusian Automobile Works».
Manual includes procedure for trouble shooting in units and assemblies mounted into dump truck; pro-
cedure for dismantling of defective units and assemblies from the vehicle and their disassembly; tables stating
design and tolerance limit dimensions for major parts, determining further usage or rejection of the dismantled
article; assembly regulations; technical requirements to repaired units and assemblies and testing procedure
on special stands; procedure for mounting of repaired or brand new units and assemblies into dump truck; list
of activities for integrated testing of the dump truck after repairs.
Manual features list of technical equipment (arbors, extractors, appliances, stands) required for servicing
and repairing, as well as regulations for their application in the process of units and assemblies repair.
1-1
General
7513-3902080 RM
1-2
Technical Specification of Dump Trucks
7513-3902080 RM
2 TECHNICAL SPECIFICATION OF DUMP TRUCKS
Overall dimension of BELAZ-7514-10 and BELAZ-75145 dump truck basic models with payload capacity
120 T are shown in figure 2.1, overall dimensions of basic models of BELAZ-75131 and BELAZ-75132 dump
trucks with payload capacity 130 T are shown in figure 2.2, technical specification of the dump trucks is given
in table 2.1.
Figure 2.1 – BELAZ-7514-10, BELAZ-75145 dump trucks. Overall dimensions
Figure 2.2 – BELAZ-75131, BELAZ-75132 dump trucks. Overall dimensions
2-1
7513-3902080 RM
Table 2.1 – Dump Truck Specification
Parameters BELAZ-7514-10 BELAZ-75145 BELAZ-75131 BELAZ-75132

Rated weight of transported load, kg 120000 130000
Vehicle weight, kg:
operation 90000 88000 105000
gross 210000 208000 235000
Weight distribution, %:
front axis 33
rear axis 67
Minimum turning radius (over front outer wheel) in
13
respect to turning center , m
Overall turning diameter, m 28
Maximum traveling speed with pay load on hori-
48 42
zontal track, km/h
Braking distance of gross weight vehicle applying
service brake system from traveling speed of 8.3 21
m/sec (30 km/h), m
Overall dimensions, mm:
length 11380 11500
width 6140 6900
height (unloaded) 5580 5720
Base, mm 5300
Wheel track, mm
front 4980 5100
rear 4150 6510
Height along visor of raised body, mm 11000
3
Rated body volume, struck, m 47 46
3
Rated body volume, (heaped 2:1), m 61 71
Loading height along side board of body, mm 5000 4800
Grade at which parking brake system ensures zero
16
movement of vehicle, %
Raising time of body with net weight sec, not more 20
Body lowering time, sec 20 18
ENGINE
Model 8ДМ-21АМ KTA 38C KTA 50C 8ДМ-21АМС
Type Diesel 4-cycle with V-cylinder arrangement, turbine charging and intermediate
cooling of charged air
Power rating, kW 1029 882 1176 1103
Revolution frequency corresponding to power rat-
-1 1500 1900 1900 1500
ing, min
Minimum steady revolution frequency at idling,
-1 700 725 725 700
min
-1
Maximum revolution frequency at idling, min 1545 2400 2000 1545
Number of cylinders 8 12 16 8
Displacement, l 58,15 37,8 50 58,15
Cylinder bore, mm
210 159 210
Piston stroke, mm
2-2
7513-3902080 RM
Sequel to table 2.1

TRACTION ELECTRIC DRIVE
AC-DC type, actuates synchronous traction alternator, traction electric motors, three-phase power rectifiers, aerated brake resistors,
switching units and automatic control system
СГД 89/38, СГДУ 89/38-8,
Traction alternator СГД2-89\38 СГД2-89\38-8
ГСН-500 ГСН-500
Rating, kW 800 1000 920
Traction electric motor ДК-722Д ЭК-420 ЭД-136 ТЭД-6
Rating, kW 360 420 590 640
Electric motor wheel reduction gear Two- row differential
Total ratio 31,63 30,36
RUNNING GEAR
Frame Welded structure of high-strength steel, box-section rails are interconnected by
cross-members
Suspension:
Front wheels Unconventional of pneumatic hydraulic Conventional of pneumatic hydraulic
Rear wheels type type
Conventional of pneumatic hydraulic type
Wheels discless, with split rim
Tires tubeless, pneumatic
Bias tire designation 33.00-51 HC 50 (E3 or E4) 33.00-51 HC 58 (E3 or E4)
Inflation pressure, MPa 0.55±0.025 0.6±0.025
Radial tire designation 33.00R51
Inflation pressure, MPa 0.625±0.025* 0.725±0.025*
STEERING
Hydraulic drive Hydrostatic with two non-interconnected circuits
Emergency drive Actuated by pneumatic hydraulic accumulators
BRAKING SYSTEMS
Parking brake system Brake gears of shoe type with auto- Brake gears of disc type with auto-
matic clearance adjustment between matic adjustment clearance between
shoes and drums. Actuation is hydrau- linings and discs. Actuation is hydrau-
lic separate for front and rear wheels. lic separate for front and rear wheels.
Source of energy is of pump type, Source of energy is of pump type,
pneumatic hydraulic accumulators per- pneumatic hydraulic accumulators per-
form capacitating function form capacitating function
Parking brake system Brake gears of shoe constantly closed Brake gears of shoe constantly closed
type. Spring actuation, hydraulic control type. Spring actuation, hydraulic control
Auxiliary brake system Electric braking by traction electric mo- Electric braking by traction electric mo-
tors in generator mode tors in generator mode
Emergency brake system Parking brake system is used
ELETRIC EQUIPMENT
Wiring scheme Of single-wire type, negatives outlets of power sources and consuming units are
connected to “ground”. Engine compartment light and portable lamp socket are
connected according to double-wired scheme
Current continuous
Voltage, V 24
Batteries 6СТ-190А, 2 pieces, of series connection
2-3
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Sequel to table 2.1

CAB AND BODY
Cab All-metal structure, two-seat, sealed,
All-metal structure, two-seat, sealed,
temperature and sound isolated.
temperature and sound isolated.
Meets ROPS requirements.
Equipped with sun visors, two-brush
Equipped with sun visors, two-brush
electric windshield wiper, heater,
electric windshield wiper, heater,
windshield washer, clothes peg and
windshield washer, clothes peg and
seats. Rear view mirrors are located
seats. Rear view mirrors are located
on both sides of dump truck
on both sides of dump truck
Body Welded structure, of bucket type, with canopy protruding over the cab. Body floor
is heated by exhaust gases. Body is equipped with mechanical interlock device
in raised position, rock knocking off plates and rock ejectors
DUMPING MECHANISM
Mechanism type hydraulic
Cylinders telescopic
Pumps Of gear type, three pumps НШ-100А- Pumping group: of variable flow axial-
4, НШ10В-3 pump in hydraulic control plunger type and of steady flow blade
line type
FILLING CAPACITIES, L **
Engine lubrication system 202 156 195 202
Engine cooling system 390 380 410 390
Fuel tank 1500 1900
Hydraulic system 385 340
Power takeoff box 12 18 --
Electric motor wheels reduction gears, (two) 30x2=60 36x2=72
Suspension cylinder, kg:
front (two) 15x2=30
rear (two) 26x2=52
Notes:
1 * ASTERIX denominates pressure values estimated for Bridgestone tires. If mounting radial tires of other companies, pressure val-
ues are to be specified by tire manufacturer;
2 ** ASTERIXES denominate filling capacities of dump truck systems. They were obtained in the result of testing and are specified for
reference, fuelling is to be effected in compliance with recommendations of corresponding chapters in operation manuals.
Chassis of basic models are used for construction of dump trucks intended for coal and other bulk car-
gos of light specific density transportation, they differ from basic dump trucks in body featuring increased body
volume.
Overall dimensions of BELAZ-75145-0000110 and BELAZ-75138 coal carriers are shown in fig. 2.3 and
2.4, features of technical specification differing from basic dump truck models are given in table 2.2.
2-4
7513-3902080 RM
Figure 2.3 – BELAZ-75145-0000110 coal carrier. Overall dimension
Figure 2.4 – BELAZ-75138 coal carrier. Overall dimensions
Table 2.2 – Distinctive features of coal carriers
BELAZ-75145-0000110 BELAZ-75138
Parameters
(on basis of BELAZ-75145) (on basis of BELAZ-75131)
Rated weight of transported load, kg 110000 120000
Vehicle weight, kg:
operation 93600 110000
gross 203600 230000
Overall dimensions, mm:
Length 11840 11500
width 7100 7350
height (empty) 5900 5900
Loading height along side board of body, mm 5580 5700

Height from canopy of raised body, mm 11200 10800
3
Rated body volume, m 90 104
3
Rated body volume ( heaped 2:1), m 110 135
2-5
7513-3902080 RM
2-6
General instructions repairing
7513-3902080 RM
3 GENERAL INSTRUCTIONS AT REPAIRING

3.1 Disassembling
Sectors and shops, carrying out repair of dump trucks BELAZ, should be equipped with load-lifting
mechanisms, pull adaptations and other devices providing an opportunity of removal, disassembling and instal-
lation of any gear and unit on a dump truck, and also their installation on assembling benches and their re-
moval from assembling benches after testing.
During disassembling and repairing of a dump truck it is recommended to organize three-stage washing
which includes:
- External washing of dump truck before disassembling;
- Washing of removed and partly disassembled units and gears;
- Washing of parts of disassembled units and gears.
To prevent ingress of moisture to the engine system and to the gears of traction electric drive, the exter-
nal washing of the dump truck should be performed with the gaiters installed on the dump truck.
Disassembling of gears and units which have been removed from a dump truck, is necessary to per-
form on special benches or supports providing the highest possible access to disassembled parts.
At disassembling of the units having transition fit in joint, it is necessary to use removers, mandrels, ac-
commodations, drill drifts and hammers made of copper.
At disassembling of bearing mount assemblies the force at a release of bearings should be applied on a
face-end of an outer ring in case of a release of the bearing from the case and to a butt of an inner race in
case of removal from the shaft.
Parts which have passed combined processing on the factory – manufacturer, are not subjected to can-
nibalization when disassembling.
Besides it is necessary to remember, that any disassembling and assembling of unit or an aggregate
even if it did not expose to repair, results to drop of its operating cycle owing to violation of joints and interposi-
tion of the earned surfaces of mating parts. Therefore, disassembling of aggregates and units is necessary to
perform only in the event that it is caused by emergency after determine the probable cause and method of its
removal. To provide the correctness of assembling and setting of parts on the places it is necessary to provide
cerite-top, marking with a color or drawing of marks on mated parts when disassembling a unit.
3.2 Fault detection
At fault detection monitoring of parts is carried out first of all an external examination, if necessary - with
application of the measuring tool.
At visual inspection presence of visible damages, such as cracks, holes, breaks, fins, nick, risks,
scratches, sags, twisting, hoggings, color tarnishing, shell, spandings and other damages of mechanical and
corrosive character and deformation of parts must be determined.
Parts of a steering system, brake actuator, and also other main parts influencing traffic safety, are nec-
essary to be inspected with the help of special defectoscopes.
For dimension inspection of parts the special measuring tool - limiting impassable mail gages, female
gages, stencils are applied. Thus application of complete plugs or gauge rings is inadmissible.
Along with the special instrument the universal measuring tool: slide caliper, gear depth caliper, gear
tooth caliper, micrometers, internal dial gauges are applied. An adjustment of display instruments is made on
standard rings. Sizes of parts are inspected in cross-sections and directions of the greatest deterioration.
Monitoring of threads is made by visual inspection, inspection of interfaces by a part with a suitable
thread or in responsible cases by the threaded impassable gauges.
All parts be received on assembling, should be washed carefully out and cleaned of a carbon, incrusta-
tion, and mud. The corrosion-resistant coating used at parts storage, should be eliminated. Oil channels and
openings in parts should be cleaned, washed out under pressure and blown-through by compressed air.
All cavities of lubricating systems, cooling system, and also the units working under pressure are neces-
sary to be tested on leakproofness before assembling.
Parts and units subjected to balancing, are necessary to balance. Working edges of stuffing box seal
should not have breaks, cracks, traces of a exfoliation of rubber. Besides rubber parts should not have signs of
swelling and traces of a residual deformation.
3-1
General instructions repairing
7513-3902080 RM
3.3 Assembling
Assembling sections should be equipped with the work benches, special tools and test benches for dis-
assembling – assembling of units and aggregates. At assembling work cleanness of unit assembling should be
provided and assembling places should eliminate hit of a mud, dust, water, emulsion and abrasives on assem-
bling parts. It is forbidden to dispose places of assembling near to grinders and to use open compressed air dur-
ing assembling.
The details fed on assembly, should not have corrosion, a shavings in ports and deepenings, dents and
nicks on mated and mounting surfaces. The corrosion-resistant coating used at storage of details, should be
deleted. Oil galleries and openings in details should be cleaned, washed out under pressure and blown
throuhg by compressed air.
Before feeding on assembly the internal raw surfaces of cast and forged details should be cleaned of
a calxes, and all blind holes, bins and drillings should be blown through by compressed air.
At assembly it is necessary to use the standard or special instrument. It is allowed to use hammers and
planers of non-ferrous metals and alloys when setting details and gears.
The bearings installed during assembling, should be kept and be delivered on assembling section in
packaging of manufacturer and be unpacked directly before their. In case of damage of packaging, bearings
should be washed out in the petroleum oil heated to temperature 95 – 100 0С. Package is moved of only from
mounting surfaces. Mounting surfaces on bearings are necessary to be washed in kerosene, white spirit, to be
cleaned napless material and to be dried. Before mounting the bearing it is necessary to check conformity of
appearance, identification mark, to be convinced of ease of twirl, absence of gaps.
Surfaces mated to the bearing should be washed by kerosene, white spirit, rubbed, dried and greased
with a thin film of oil ТАП-15В, ТСп-15к or equivalent greases.
During assembling, mated surfaces and technological facets are necessary to smooth out, not disturbing
admissible sizes.
It is necessary to remember, that when setting bearings on the shaft, the pressing force should be ap-
plied through the carrier sleeve on an inner ring, and at mounting into the case – to an outer ring. At setting
bearings simultaneously on the shaft and in the case the simultaneous application of force through carrier
sleeve to external and inner rings. Application of force of a press fitting through solids of revolution and separa-
tors is not admitted. To press bearings use hydraulic, screw and others presses.
A T T E N T I O N : IT IS STRICTLY FORBIDDEN TO STRIKE ON THE BEARING RING BY THE HAMMER
When mounting bearings on shafts, their heating in oil till 80-90 0С, for exclusion of closed bearings with
one-time lubricant is admitted.
At execution of fastening operations apply the trig instrument to make a necessary force of torque and in
required cases apply torque spanners. At stopping use only new pin wire and splint pin.
When assembling do not use fasteners (bolts, nuts, splints, rivets, etc.) of non-standard sizes, bolts and
nuts with the worn out edges, screws with the hammered or worn out splines of heads. Fasteners should not
have damages of a thread.
At assembling of units and aggregates of a dump truck it is necessary to use a new package general
mechanical rubber goods (ring gaskets, packing glands, linings).
Collecting the joints having rubber seals (packing glands, sealing ring and cuffs), watch that there were
no undercuts and twistings.
Before setting sealing rubber rings and cuffs should be greased, and in cavities between a working edge
and a duster of a cuff and between the doubled cuffs should be filled approximately on two – third of volume
with lubricant Литол-24 or Фиол-2.
At assembling it is necessary to replace all linings by new ones, preliminary having greased them with
sealant.
3-2
Safety precautions and fire-prevention require-ments when repairing the dump truck
7513-3902080 RM
4 SAFETY PRECAUTIONS AND FIRE-PREVENTION REQUIRE-

MENTS WHEN REPAIRING THE DUMP TRUCK
4.1 Safety Precautions
When mounting, operating, servicing and repairing the dump truck, observe the general safety precau-
tions prescribed for transport vehicles, and follow the “Unified Safety Regulations to Be Observed in Opencast
Mining”, “The Rules of Operation of User’s Electric Machines”, the “Safety Precautions to Be Observed During
Operation of User’s Electric Machines”, “Rules of Arrangement and Safe Operation of Pressurized Vessels”
and “The Rules of Operation of Large Dimension Tires”.
Besides, observe also the following requirements conditioned by the design of the dump trucks:
4.1.1 Maintenance of the dump truck must be performed by mechanics and electrcians familiar with the
dump truck design, the rules of its operation and the safety and fire precautions to be observed during opera-
tion.
4.1.2 Trailing of a defective dump truck should be carried out by the special recovery tractor. In case of
dump truck trailing when the dump truck is fastened for bumper, it is necessary to unbrake the gear of a park-
ing braking system.
4.1.3 Before a service and repair of a dump truck it is necessary not to allow spontaneous driving of a
dump truck from a place. The service and maintenance are necessary to perform only at the stopped en-
gine, wit the exception of operations on adjustment of the traction electric drive, foreseen in « The Instruc-
tion of regulation of the traction electric drive”.
4.1.4 Before leaving the cab, make sure that the reverser switch and the electric drive control switch
are in OFF “Выключено” position and the dump truck is braked with the parking brake system.
4.1.5 At service and repairing of a dump truck, the raising of a body is required, it is necessary to unload
it and to stop it in the raised position by two towing pivots, having combined openings in links on a body with
openings in brackets on a frame. Operations under the raised and stopped platform are not permitted, if there
are more than 3 t the stuck ground or speed of a fair wind (when repairing outside) is more than 6,5 m/s.
A T T E N T I O N : LOCK ТРОСС IT IS CALCULATED ON LATCHING ONLY THE EMPTY PLATFORM.
It is impossible to stand near to a dump truck at rise of a platform in avoidance of injury a ground.
It is impossible to go out a cabin at omitting and at rise of a platform.
It is not supposed to begin driving at the lifted platform.
4.1.6 For safety dump truck is equipped with ladders, footboards, handrails and platforms.
When operating without fences and handrails it is necessary to use a safety belt, and also portable ladders
(ladders) and supports. Doing so follow Safety Precautions.
4.1.7 When moving along ladders and upper working flats (fenders, hoods), hold on to the handrails
available on the ladders, fenders, hoods and cab, so that three supporting points are constantly provided for
(with two hands and one leg or two legs and one hand). clean the ladders and flats of dirt, snow and ice. When
moving along ladders be always facing to the dump truck.
4.1.8 When use hydraulic jacks, hoists, and also other elevating means to lift the dump truck, it is nec-
essary to install rigid metal supports under the lifted part of a dump truck. Start maintenance only after the
dump truck is in steady positions on supports.
4.1.9 Rules of an Electric Safety Rules to be observed at an adjustment of traction electric drive are given
in Operation Manual of the traction electric drive.
4.1.10 It is not allowed to dismantle and disassemble elements of braking systems and steering system,
which are under pressure of working fluid.
Release of pressure in front and rear circuits of service brake system, a parking brake system, steering
system is made by unscrewing shutoff needles on the brake valve.
Release of pressure of a working fluid in a hydraulic system of steering and a parking brake of dump
truck BELAZ-75131 and its modifications is made automatically after scheduled shutdown of the engine during
80 s.
4.1.11 Prior to removing the suspension cylinder from a dump truck, it is necessary to release gas from
its space. For complete removal of gas from a space it is necessary to open the charge valve at list three
times, with intervals of 3 - 5 minutes.
4.1.12 Prior to disassembling the suspension cylinder, it is necessary to be convinced that there is no an
excessive pressure of gas in the space for what open charge valves.
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7513-3902080 RM
When check up a level of a working fluid in the suspension cylinder the control fuse should be turned out
slowly to remove an excessive pressure of gas in a space. Do not stay opposite the fuse when doing this op-
eration.
4.1.13 Prior to charging the suspension cylinder with gas make sure that charge accommodating is trig
and that the mark on the compressed gas cylinder is correct. The gas cylinder must bear an inscription
"NITROGEN" and should carry a brown circular marking strip.
ATTENTION: IT IS STRICTLY FORBIDDEN TO PRIME THE SUSPENSION CYLINDERS WITH OXYGEN AS IT

WILL CAUSE AN EXPLOSION!
4.1.14 Release completely air from the tire before unfastening on a dump truck. For rear double wheels
it is necessary to release air from both tires.
Prior to assemble a wheel, it is necessary to examine carefully condition of rims, bead, landing and lock
rings.
Приступая к сборке колес, необходимо тщательно осмотреть состояние ободьев, бортовых,
посадочных и замочных колец.
Before mounting of a wheel, inflate a tire the up to pressure 0,1 МPа and to be convinced of correctness
of setting of locking ring. To inflate the tire up to required pressure is possible only after fixing a wheel on a
nave. There should be no people near to the inflated tire.
4.1.15 Fuse of expansion vessel of engine cooling system is necessary to screw out cautiously - steam
in the vessel is under pressure.
4.1.16 It is necessary to remember, that low-freezing cooling liquid is toxic and may cause poisoning if
the rules of sanitary are violated.
4.1.17 When servicing and repairing a storage batteries remember, that electrolyt, having got on a body,
can cause strong burns.
4.1.18 Введение конструктивных изменений в схемах электрооборудования без согласования с
заводом-изготовителем категорически запрещается.
4.1.19 Disassembly of the cylinder of a parking braking system should be done in the special accommo-
dating, providing fixing of springs in the compressed condition and smooth their release up to a free state.
4.1.20 It is forbidden to perform repairing, to disassemble an armature, to perform welding jobs in sys-
tem of pneumostart and the pneumatic system of a dump truck which are under pressure.
The pressure release in system of pneumostart is made through the valves of condensate drain, thus
the shut-off cock on air vessels should be opened.
The pressure release in pneumatic system of a dump truck is made through the valves of condensate
drain, installed in a receiver.
4.1.21 Adjustment and operation of system of pneumostart and pneumatic system with out-of-order ma-
nometers and the broken seals on safety valves are forbidden.
4.1.22 Maintenance of airvessels, manometers, safety valves, armatures (including engineering survey
and repair) should beperfofmed according to the requirements and the orders given in “Rules of Arrangement
and Safe Operation of Pressurized Vessels” (ПБ 10-115-96).
4.1.23 Combustive-lubricating materials, working fluids and other operation materials should be applied
only according to recommendations of operation manual. Application of other brands of oils and fuel is forbid-
den.
4.1.24 When carrying out of welding jobs on a dump truck automatic switches SF1, SF2, SF3, SF4, QF2 of
control circuits and auxiliary circuit in the control should be switched off.
It is not admitted to connect the welding unit wire to the wheel hubs, since local heating of parts may
cause damage to the bearings.
The mass wire of the welding apparatus should be connected near to a place of a welding.
4.1.25 It is forbidden to carry out the welding jobs near to the charged pneumohydraulic accumulators
and pipelines, connected to them.
4.1.26 Prior to carry out of welding jobs near to accumulative containers it is necessary to follow neces-
sary precautions.
4.1.27 It is forbidden to fasten electric motorized wheel for the case (housing) in order to prevent its con-
tortion.
4-2
7513-3902080 RM
4.2 Fire-Prevention Rules

In order to prevent a fire on a dump truck observe the general fire prevention rules in handling inflam-
mables and also the following requirements:
4.2.1 Constantly check tightness of fuel and oil pipelines of engine systems, hydromechanical transmission,
steering gear, brake systems and dumping gear. When carrying out repairing works protect pipelines of these sys-
tems from mechanical damages.
4.2.2 It is impossible to leave a dump truck when engine starting preheater is operating.
4.2.3 The dump trucks must be furnished with fire extinguishers for the cause of fire.
For a fire extinguishing use the combined fire-extinguishing system, previously having stopped the en-
gine.
It is forbidden to use solution line for a fire extinguishing of alive electrical equipment and fuel and oil
overflows.
It is forbidden to use a powdered line if there are people.
4.2.4 In order to prevent ignition accumulating in the engine cooling system of gases it is forbidden to use
open fire when checking a level of a cooling liquid in the expansion tank.
4.2.5 It is forbidden to use open fire when examining the storage batteries.
4.2.6 In order to prevent flash of fuel it is forbidden to switch on the thermoelectric heater if there is fuel
less then a half of its capacity.
4-3
7513-3902080 RM
4-4
Engine systems
7513-3902080 RM
5 ENGINE SYSTEMS
Service and repair of the engine systems consists in supporter all external threaded joints, washing of
an integral cooling system and removal of an incrustation, the filter of preliminary of combustible clearing
washing, the dust clearing and inspection of the filter element condition, the tightness inspection and adjust-
ment of the pneumatic drive of management by a fuel feed (dump trucks with the pneumatic drive), inspection
and adjustment of the drive of management by a fuel feed (power-driven dump trucks), washing of the breather
filter of the fuel tank, and also in execution of a maintenance on the engine according to the maintenance en-
gine instruction .
5.1 Removal and mounting of the diesel generator
For the remomal of the diesel generator it is necessary:
- install the dump truck on the even horizontal platform, brake it by parking brake system and lay under
all wheels the stops;
- lift the platform in the extreme upper position and jammed it by special rope, which both end take in
lugs on the axle housing and fixed by tow pivot;
- remove from systems the oil and cooler fluid ;
- remove from dump truck front and rear jakets
- disconnect and remove the radiators block, air filter, control drive of the fuel feed;
- disconnect from the engine the exhaust system
- disconnect and remove cooling pipes of the traction generator and motor- wheels
- disconnect pipelines from the receivers (for dump trucks BELAZ-7514-10, 75132);
- disconnect hoses and pipelines of the engine external system
- disconnect pipeline of the pneumatic system running to the compressor;
- disconnect and remove the engine cable assembly and cable assembly building on the traction gen-
erator;
- disconnect output wires of the traction generator;
- disconnect the box cardan shaft of the power take-off from the hub of the ventilation wheel;
- remove the cross beam and screw off the fastening of underframe to the shock absorber ;
- disconnect diesel generator from the frame;
Figure 5.1 — Fastening diagram diesel generator of the dump truckсs BELAZ-7514-10
and BELAZ-75132 by suspension 7808-7598
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Engine systems
7513-3902080 RM
- fasten diesel generator behind underframe (Figures 5.1 и 5.2) and slowly move forward by dump truck
motion up to contact of the arm rear branches with upper cross frame;
- sink diesel generator and install it the underframe on the bumper and bearing pipes, welded to the-
frame longeron;
- throw the arm rear branches through cross-arm install it in the socket which are located on the end of
the cross-arm. Fasten the lower parts of the rear arm branches behind longeron lug of the underframe.
- lift by crane the diesel generator to give it forward on the dump truck motion and install on the support.
The diesel generator installation on the chassis to make in the return sequence.
Figure 5.2 — Fastening diagram of the diesel generator of the dump truckсs BELAZ-75145
and BELAZ-75131 by suspension 7808-7059
At the installation the upper part of the vibroinsulators rubber pad should be situated near the dump
truck longeron frame. The flatness tolerance of the upper surfaces the four vibroinsulators should be no more
1,5 mm, test to diesel generator installation and adjust by gasket, installed between lower vibroinsulator fittings
and dump truck arm frame. No more than two gaskets is installed under one vibroinsulator. The adjustment it
is possible execute by vibroinsulators selection at the height
In case of the traction generator emergency the dismantling can to make without engine removal.
For the generator removal it is necessary :
- install the dump truck on the plane horizontal ground to brake it by parking brake system and put under
all wheels supports;
- lift the platform in the extreme upper position and to stop it by special rope which the both ends install
in the lugs on the axle crank case and fixing by tow pin
- dismantle pipelines of the exhaust system ;
- disconnect the cardan shaft of the power takeoff drive from the hub of the fan wheel;
- disconnect and removal the cooling pipelines of the traction generator and motorwheels;
- disconnect power cable from the clamps of the traction generator;
5-2
Engine systems
7513-3902080 RM
For the dump trucks BELAZ-7514-10 and BELAZ-75132:

- knock out pins and turn off the generator fastening bolts to the underframе;
- take off locking rings from the half-coupling fingers
- take off the half-coupling fingers and with the help fastening device to remove the generator .
Figure 5.3 – Fastening diagram of the traction

generator by suspension 7808-8551
For the dump trucks BELAZ-75145 and BELAZ-75131:

- cut and remove pneumatic starter and oil pump from engine block.
- through hole in the flywheel housing, formed after the pneumatic starter removal, turn off one of
adapter fastening bolts of the generator rotor to the flywheel (Position 5 Figure 5.7);
- with the help of the drive shafting device, turning the flywheel turn off bolts(12 pieces);
- turn off bolts 3, connecting the starter adapter and generator case;
- turn off generator fastening bolts to the underframe ;
- with the help of the fastening device lift the generator on the 1 – 5mm and move it in the side of power
takeoff;
- after making the enough between generator case and the starter adapter to remove generator and in-
stall on the support ;
- from rotor generator remove rotor adapter , by turning off bolts 7 (18 pieces).
At the removal draw attention on the gaskets under generator supports between rotor and rotor adapter,
between flywheel and rotor adapter.
5.2 Engine connection with the traction generator

Engine connection with the traction generator for dump trucks BELAZ-7514-10 and
BELAZ-75132 to carry out according to «Operating manual» of the engine.
Engine connection with the traction generator on the dump trucks BELAZ-75145 and BELAZ-
75131.
Lift engine, remove transportation arms and instead of it to install the arms
75125-1001150, fixing their be eight times bolts S123 3/4" 10UNCx2,5" with spring lock washers. The bolts
tightening torque (380±20) N.m. It is supposed to use arms, acting with the engine, together with plates
75125-1001079.
At the lifting and travel the engine and also generator should be in horizontal position.
Install the underframe on the stand. Lower on it engine and bolts with springs and washers. Tighten two
bolts М18-6gх80 with spring washers on the front engine support by moment (280±10) N.m.
Tighten four bolts М20х1,5-6gх60 with plane spring washers on the rear engine arms by moment
(380±10) N.m.
In the case of necessity install under rear engine arms no more than four adjustment gaskets
75145-1001448.
In the engine accompanying documentation should be specified size (С) axial (horizontal) movement of
5-3
Engine systems
7513-3902080 RM
the engine crank shaft .

This size it is necessary control. Turn off three bolts strengthening starter to the flywheel casing and two
bolts strengthening starter to the arm. Take off starter and arm supporting starter. Turn off four bolts and take
off oil pump. Turn off the arm of the oil pump and others bolts. Take off the cover opening access to the crank
shaft.
The device, crowded to the crankshaft web move out the engine crankshaft in the end position up to the
stop and hold in this position. In front of the engine where possible near to the crankshaft to install indicator
and expose on the “0”. Then displace the crankshaft in the reverse side up to the stop and holding it to fix the
indicator indices. This is axial(horizontal) movement (backlash)of the engine C crankshaft which must be быть
С=0,305 – 0,508 mm.
Displace the crankshaft in the extreme front position and install on the former place the engine cover
Install and fasten adapter of the stator 3 (75145-1001102, Fig-

ure 5.4) with sixteen bolts 4 (1/2" 13UNCх1,5") with spring washers to
the fly-wheel casing of the engine engine 2, previously having in-
stalled four bolts М16х1,5-6gх75 in the holes of the stator adapter (to
two with each side ) near rear engine arms. To fasten sixteen bolts by
moment (0±5) N.m.
Figure 5.4 – Connection of engine with traction alternator engine

1 – engine flywheel; 2 – engine flywheel jacket; 3 – adapter of stator; 4 – bolts
А1, Л, Д1 – sizes; И, Ж - surfaces
By test ruler measure in fourth points: 3 and 9, 6 and 12 hours

of the clock dial distance between disk face of the elastic coupling
(surface Ж) and stator adapter, fixed on the engine (surface И). To
find mean value (Д1+Л).
The size determine: A1=Д1+Л-1/2C.
To move the generator in the horizontal position. To take off from engine four covers. With the adjust-
ment help to install the front end of the generator rotor coaxial the stator (around). The shaft generator to move
out in the limitimg position. The indicator to install in front. near to the generator axle and install it on the«0».
Then move the generator shaft in the underside to stop and keeped it fixed registration of the indicator. This
size (Е) is the axial (horizontal) movement of the generator shaft.
Е=0,8 – 1,4 mm.
Move the generator shaft in the end rear position. With the help of the straight edge measure in four
points accordingly: 3 and 9, 6 and 12 hours of the clock dial the distance between the generator case 1 (Figure
5.5, surface И1) and the rotor flange 2 (surface Н).
To find an average value. It is size "Г1".
To define size Гпр=Г1 – 1/2Е.
To measure in the adapter of the rotor 75145-1001104 size "K" (Figure 5.6) between adjoining surfaces
Ж1 and Н1.
To calculate an amount of adjusting shims 5 (75145-1001428 and 75145-1001429), necessary for deriv-
ing the size "P" between adjoining surfaces Н (look Figure 5.5) and Н1 (look Figure 5.6). Р=А1+Гпр-M-K.
5-4
Engine systems
7513-3902080 RM
At setting adjusting shims the size of the typed package should not exceed the size "É", and this vari-
ance of sizes should be less than 0,5 mm.
Package of layer pads to install on the shaft of the shaft generator and to press the adapter of the rotor.
Bolt eighteen bolts М24х160. Gradually and serially to tighten bolts by the moment (500 + 50) N.m. The bolts
cotter by the plates it installed under the head of bolts.
With the help of device to install the fast-head butt of the rotor of the generator coaxially to the stator
(approximately).
Figure 5.5:
Figure 5.6:
1 – generator body; 2 – generator shaft;
Г1 - size И1, Н - surfaces 1 - generator body; 2 – rotor body; 3 - bolt
М24х160; 4 – generator rotor; 5 - adjustment gasket s;
И1, Ж1, Н1 - flatnesses; F, К, Р, М - sizes
With the help of the levelling rule to measure in 4 points accordingly: 3 and 9, 6 and 12 hours of a hour
dial distance between docking surfaces of the generator body (surface И1) and the rotor adapter (surface Ж1).
To find an average value. It is the size "F". To define size В1=F+1/2Е.
Obtained size В1 necessarily should be less size А1. The maximum difference of these sizes П=А1-В1
should not exceed 1,5mm.
To define an amount of layer pads N installed on an engine flywheel (surface Ж). The amount of layer
pads should be selected with exactitude N=П±0,1.
With the engine, from the left and right sides to remove the covers closing access covers, timbered one
bolt.
To screw in the adapter of the rotor generator two technological studs in points accordingly 3 and 9
hours of a hour dial. To move the generator forward along axle.
To turn an engine flywheel so that two pins on a cushion disk were opposite to bores under pins in the
adapter of the generator rotor, and bores in the fly wheel were opposite to the engine access cover.
Cautiously to give the generator to the engine as it is possible more precisely having combined their ax-
les. Technological studs should enter the corresponding bores of the disk of an elastic clutch.
To install two technological layer pads of equal width (3-5 mm) in points accordingly 3 and 9 hours of a
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hour dial and bolt four bolts from above and from below layer pads from each side between the adapter of a
stator (surface И) and the case of the generator (surface И1) according to Figures 5.4 and 5.6. To tighten four
bolts the moment 10 - 20 N.m, thus displacing the generator in the necessary horizontal direction.
To adjust overlapping generator axles and the engine in a vertical plane, measuring by a probe a spac-
ing between the case of the generator and the adapter of the stator in points accordingly 6 and 12 hours of the
hour dial and establishing adjusting shims under each claw of the generator until the variance in spacings no
more than 0,1 mm will be reached. The spacing in point of 12 hours should differ in the smaller side, than in
point of 6 hours.
To bolt but to not torque, four bolts М30x2-6gx70 with flat and the spring lock washer fastening the
claws of the generator to the underframe.
To remove the lifting tackle of the generator.
To release four fastening bolts in points accordingly 3 and 9 hours of a hour dial and to delete two tech-
nological layer pads. To test a spacing in points accordingly 3 and 9, 6 and 12 hours of the hour dial which
should not vary at removal the lifting device.
To install the bolts fastening the stator adapter to the generator body (16 pieces, four of which are in-
stalled preliminary). Under six bolts to install a visor bracket and to tighten all bolts the moment (220±10) N.m.
The spacing between adjoining planes should not be.
Turn off and to remove technological studs. With the help of the barring gear the installed in engine ac-
0
cess cover to turn an engine flywheel through everyone 30 and tinstall bolts М16-6gx70 (12 pieces with lock-
washers from two sides of the engine in access cover simultaneously. To mark the first torqued bolt and to
tighten bolts the moment (220±10) N.m.
To tighten four bolts М30x2-6gx70, fastening generator claws to the underframe, the moment
(700±50) N.m.
Validation of assembly.
Inspection of engine backlash.
In a place where the starter motor is removed to remove a cover of a manhole of the engine. To move a
bent shaft of the diesel-generator set back against the stop. Ahead of the engine, whenever possible is closer
to a shaft of a bent shaft to install the indicator and to expose it on "zero". To shift a bent shaft forward against
the stop and, keeping to fix the observation on the indi-
cator. To compare an obtained value to a value to the
accompanying documentation on the engine and with
obtained as a result of sampling a size of C. This value
of size C should coincide with a size in the deed on the
engine with an exactitude ±0,13 mm.
Inspection of the generator radial runout.
To fix bar indicator on thread М14х1 executed in
the case of the adapter in a point of 3 or 9 hours of a
hour dial. The indicatorleg to install on surface Т (Figure
5.7) of the rotor adapter. To expose the indicator on
"zero". The barring gear to turn crankshaft of the Diesel-
generator set on 3600, registering an outrun on the indi-
cator.
Preferable magnitude of the runout is 0,08 mm.
The maximum permissible value of the runoutis 0,13
mm. If magnitude of the runout is more than 0,13 mm,
necessary to lead disassembly of the Diesel-generator
set, to turn an engine flywheel on 1800 and again to
manufacture process of assembly.
Figure 5.7 – Diesel-generator assembly:

1 – generator body; 2 – visor bracket; 3,5 – bolts; 4 – engine
fly-wheel casing; 6 – generator rotor;
F – size of the pads thickness; Т – surface metering of the ra-
dial runout
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To test tightening torque of the bolts fastening the adapter of the stator to the generator body and cotter
of them.
To test tightening torque of the bolts installed through engine access covers, fastening the adapter of the
generator rotor to an elastic clutch of the engine. To install on the place access covers from two sides of the
engine.
Additional indications.
To fix the removed cover of the engine with the layer pad, bracket of the starter motor and bracket of the
oil injected pump by bolts, having tightened the moment (44±3) N.m.
To install the starter motor and to fix three basic bolts to the fly-wheel casing of the engine by the mo-
ment (220±10) N.m. To tighten two bolts, fastening the starter motor to the bracket by the moment (44±3) N.m.
To connect the hoses connected to the starter motor, on the former place. To fix oil injected pump on the
bracket.
To install four covers on the generator, closing air ports in the generator.
5.3 Repair and service of the cooling system
Index of a normal operation of the engine cooling system is maintenance of temperature of a cooling
fluid in nominal limits. The aberration from the specified temperature condition while in service a dump truck
can be caused a series of the reasons.
Most typical of them the following:
- insufficient amount of the cooling fluid;
- big adjournment of an incrustation in an integral cooling system;
- pollution of an external surface of radiators;
- failure of thermostatically controlled chambers;
- failure of a louvers or their drive gear;
- failure of a water pump.
Washing of the cooling system, descaling, substitution of a cooling fluid is necessary for carrying out ac-
cording to the use specification of the engine and indicatings of a maintenance manual of the dump truck.
Remarks - At the filling of the cooling system at cooling fluid it is necessary to turn out dummy
plug on the boiler of the engine starting preheater.
Arrangement of drain cranes:

On dump trucks BELAZ-7514-10, 75132:
- on pumps of the cooling system (two);
- on cooling system connections (three);
- on the pre-launch preheater of the cooling fluid (one);
- on the furl defroster (one);
- on the heat exchanger (two).
On dump trucks BELAZ-75145, 75131:
- on the engine block under intake manifolds (four), approximately at the axle level of the crankshaft : on
a left side two, on right - two;
- on an output tube from the radiator (one);
- on the case of a water pump (one);
- on a nipple of the head of the compressor (one);
- n boxes of thermostatically controlled chambers (on two);
- on a defroster of fuel (one);
- on the pre-launch preheater of the cooling fluid (one);
- on tubes of the preheating system of the cooling fluid (two), (75131 - one);
- water filters (4pieces.) have no drain cranes, but a cooling fluid to merge it is necessary for prevention
of collapse of filters. After the water drain it is recommended to replace the filter, as it is unsuitable for the fur-
ther maintenance.
By practice it is established, that on the engine after the water drain of the cooling fluid through all
above-stated cranes, because of design features of the engine it is not ensured full drain of cooling fluid from
the upper part of cases of thermostatically controlled chambers and accordingly the water tubes connecting
thermostatically controlled chambers with the radiator as the thermostatic valve in an enclosed position her-
metically closes drain port in the case and does not pass the cooling fluid on sink. For full removal of the cool-
ing fluid from boxes of thermostatically controlled chambers it is necessary to disconnect from them water
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tubes and through unblocking bores to delete the cooling fluid or to merge it with disassembly thermostat
boxes on the connector.
ATTENTION: IN THE COOLING SYSTEMS INSTEAD CRANES THE PLUG INSTALLATION IS POSSIBLE.
Removal and installation of the radiators blocks

- before removal of the radiators blocks from the dump truck it is necessary to merge the cooling fluid
from cooling system through drain cranes and (for engines DM) oil from an oil cooler;
- disconnect and remove with the help of the hoisting crane a fast-head jacket;
- disconnect pipe ducts and hoses from blocks of radiators, water and lubricated systems of water-
lubricated heat exchangers, heater hoses;
- weaken a anchor band of strengthening of a weather strip to the fan housing ;
- disconnect the pneumoswitch of the drive gear of radiators louvers from the overhead line;
- disconnect an electricity cable from temperature-sensitive elements;
- turn off strengthening bolts of the radiators block to frame brackets and a pull-rod of strengthening of ra-
diators;
- install on blocks of radiators affixed in spare parts ring bolt. Using the hoisting crane and pull device
fasten radiators motor blocks of and disconnect from both sides of the strengthening pull-rod of of the radiators
block ;
- remove the radiators block from the dump truck and to install it on a jamb
Setting of the radiators blocks on the dump truck is made in inverse sequence.
Disassembly of radiators block
Establish and fix radiators block on the assembly and disassembly of the radiators (Figure 5.8).
Figure 5.8 - the Stand - turner for assembly - disassembly of the radiators block:
1 - frame; 2 - stopper; 3 - reducer; 4 - fast-head support; 5 - fast-head arm; 6 - back arm; 7 - end support bearing
Disassembly of the radiators block is carried out in the following sequence:

- disconnect draft from the pneumoswitch of the louvers management ;
- disconnect and remove the pneumoswitch, fans casings, louvers and shock -absorbers;
- turn nuts of the bolts of radiators fastening to each other to move apart them, to take out distance
sleeves from racks;
- fasten in succession radiators and to remove them from the stand;
- disconnect upper and lower radiators tank, turn fastening bolts to radiator racks and strips. Remove
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upper and lower radiators tank, two linings, four strips;

- disconnect the upper and lower radiators frame, turn off nuts and the bolts connecting two frames,
racks of the radiator and strip through the prorate in an average part of the radiator. Remove two frames, two
linings, four racks, four strips.
Assembly of radiators blocks is made in inverse sequence.
Radiators Repair
After disassembly radiators are necessary for examining carefully.
The basic imperfections of radiators are:
- leak in places of the soldering;
- leak of handsets;
- damage tank and cooling plates;
- pipe choking and tanks depositions of the mud and an scale.
Tightness test will be carried out after clearing an outside radiators surface from mud and scale removal
which, filling in pores and flaws, can hide defects.
Radiators tightness is tested by compressed air in water bath (Figure 5.9). Apertures of bringing and as-
signing connecting pipes preliminary should be enclosed by rubber fuses (Figure 5.10), through one of which is
fanned under pressure 0,3 МPа. Tests will be carried out within 5 minutes.
Figure 5.9 – Installation diagram for

the radiators tests:
1 – feeding compressed air
crane; 2 – manometer; 3 – pressure air
control crane; 4 – air receiver ; 5 – con-
densate sink crane; 6 – hose; 7 – connec-
tive flange; 8 – water bath; 9 – radiator.
Figure 5.10 – Expanding fuses for radiator sockets:

a – with the tube for air delivery; b- deaf with cam clamp
For detection of the defective tube located inside the radiator check up each tube separately. For this
purpose remove upper and lower tanks, place a core of the radiator in water bath, muffle one end of the mus-
tered tube by fuse, to other end by means of accommodating (Figure 5.11) connect the hose for the intake of
compressed air. The radiator leak is eliminated by the tube soldering by tin solder ПОС-40 or ПОС-30. Tubes
which soldering is hampered or impossible, it is necessary to replace new or to solder them from both cleaning
cloth on depth 10 mm. It is supposed to kill no more than 1,5 % tubes.
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Figure 5.11 – Tube test on the tightness:

1 – radiator tube; 2 - tip; 3 – rubber fuse ; 4 - hose for
air delivery
The radiators undergoing to repair by means of the soldering, it is necessary to wash out an alkaline so-
lution for neutralization of an acid with consequent washing by hot water for removal of an alkaline solution.
Cooling radiator plates at repair to correct so that they did not touch.
The repaired radiator after corresponding subassembly with tanks should be tested on the contaiment
above within 5 minutes.
Regulation plates louvers position
The louvers plates position is regulated by change of length of the free draft end or its installation in
other aperture in the lever. For regulation to disconnect draft (from one end), turn off the lock nut to turn the
fork on 0,5 - 1 turnover and to stop by nut. To install draft on the place.
To open - enclose the louvers and to test the thickness of plates adjacency.
At the louvers opening the plate should open completely, and at close there the plates should be the
dense adjacency.
Maintenance of the oil-water heat exchangers
The most typical the heat exchanger inaccuracies :
- violation of the soldering at grate;
- oil deposition on outside surfaces of tubes of the heat exchanger;
- big scale deposition in tubes of the heat exchanger.
Washing of water and oil cavities of the heat exchanger is made separately.
Removal of the scale and washing of the water cavity of the heat exchanger is necessary for manufac-
turing on special installation with use of the solution used for removal of an incrustation in radiators.
Test of the section of the water-oil heat exchanger for tightness will be carried out at the removed upper
cover by compressed air pressure 0,5 МPа within 5 minutes in water bath. Air should move through oil chan-
nel. It is necessary to replace defective tubes by new or to damp from both cleaning cloth, but no more than 5
tubes. After the tubes replacement and the block heat exchanger soldering wash out it in an alkaline solution
for acid neutralization, and then in hot water test for tightness.
Pneumoswitch repair
At the tightness violation of the pneumoswitch it is necessary to replace joint rings.
Pneumoswitch disassembly: - to turn off bolts and to remove cover 1 (figure 5.12) to extract from the
case 2 piston 4 together with stock 7 to remove the retaining ring 5 and to disconnect stock and piston, to re-
move joint rings
Figure5.12-Pneumoswitch:
1- cover; 2 - case; 3, 6, 8 - joint rings; 4 - piston; 5 - retaining ring; 7 - stock
Assembly to manufacture in inverse sequence. Before as-

sembly ring gaskets and body work surface to grease with lubri-
cant ЦИАТИМ-221. After assembly the bucket with rubber rings
should displace freely without jams in both directions
To test the collected switch for tightness air under pressure
0,4 МPа. Air to bring serially in both cavities. The air pressure de-
crease should not exceed 0,05 МPа within 5 minutes.
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5.4 Fuel systems service

Fuel systems priming.
If tightness of system dislocated and air has got in it, it cause abnormal engine.
start-up and operation.
In the beginning it is necessary to remove systems leakage, and then to priming it manual by
fuel pumping pump as follows:
- delete air from fuel filters for what to turn off (not completely) a hose, from fuel filters to the fuel pump
(for engines KTA) or to turn out the fuse of fuel filters (for engines of DM), and to pump over by the fuel pump-
ing pump, before fuel appearance;
- turn out a fuse on the fuel pump body of the high pressure, to install a bar of the drive gear of steering
of the fuel delivery in the maximum feeding position and to pump over system by the fuel pumping pump (only
for engines of DM).
Disassembly and washing of fuel heater with the filter.

Disassembly and washing of fuel heater with the filter (Figure 5.13) to manufacture as follows:
- turn off four butterfly nuts to remove cover 1 and ring gasket;
- extract from the case rod 2 with filter cartridges and to dismantle it;
- all details of the filter, and also the body 5 to wash out in a diesel fuel and to blow compressed air.
To assemble the filter in sequence, inverse disassembly. Injured filter elementes to replace new.
Before setting of a cover to pay attention to a condition of a rubber ring gasket.
Figure 5.13 – The Defroster of fuel with the filter:

1 - cover; 2 - rod; 3 - coil; 4 - filter element; 5 - body; 6 - intermediate washer; 7 - protective washer; 8 - connection nipple to an in-
tegral cooling system; 9 - bleed hole fuse
I - fuel inlet opening; II - fuel discharge point; III - fuel discharge point to the engine starting preheater
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5.5 Air filter cleansing

For cleansing the basic filter element iit is necessary:
- turn off strengthening nut of the filter element (at nut turn off the element will gradually go out from the
body of an air filter);
- extract filter element from the body;
- blow an element compressed air for a dusting from a surface. The air pressure in system should be
0,2 - 0,3 МPа. It is necessary to direct a current of air under an acute angle to a surface, and an air pressure
on a surface to regulate change of distance between a hose and an element;
- after each clearing a filter element and at setting new to test a condition of an element, brightening
from within a lamp.
ATTENTION IT IS NOT SUPPOSED PRESENCE THE BOARD BREAKS AND DAMAGE OF SEALING ELE-
MENTS
- test presence of the joint ring under the nut;

- clear the inner case cavity of the air filter from dust and muds with the help of the rags cloth moistened
in the washing solution;
- install the filter element 12 in the case of the air filter. The nut to tighten at the twisting moment
30 - 40 N.m.
Basic element cleansing to manufacture at each wear of a transmitter of a contamination of an air filter.
Replacement of the basic air filter element to manufacture in the following sequence:
- turn off the fastening nut of the filter element ;
- extract the filter element from the case;
- mechanically to destroy the upper cover of the filter element 6 (Figure 5.14) for deriving access to the
retaining ring;
- remove the retaining ring 5 and the thrust washer 2;
- extract the fastening nut 1 of the filter element in assembly with sealing gasket and the thrust washer
from the front cover of the air filter. At damage of the sealing gasket to replace by new;
- screw in the nut 1 the arbor 3 and to be convinced available washers 2 and gaskets 7;
- the nut in assembly with the arbor, the washer and the gasket to insert into the hole of the front cover 6
of the filter elements, preliminary having installed the element on the hard surface (the surface should touch
only the nut face end, not touching the front cover of the filter element);
- install on the nut 1 thrust washer 2 and to put on on arbor 3 retaining ring 5;
the arbor for the press fitting, as the pipe with the inner diameter 20,5 - 21 mm and length 650 - 700 mm
to press on the retaining ring, and to install it in groove on the nut;
- turn out with the screwdriver help the arbor from the nut;
- install the filter element in the case of the air filter.
Approximate life cycle of the basic filter element is 500 hours.
After triple clearing of the basic element to manufacture substitu-
tion of the safety filter element by new.
Figure 5.14 – Accommodating for setting of the retaining ring

of the basic air- filter element:
1 - nut of strengthening of filter element; 2 - thrust washer; 3 - arbor; 4 – arbor for
press fitting; 5 - retaining ring; 6 - front cover of filter element; 7 - sealing gasket
Substitution of the filter element is made in the following sequence:

- turn off strengthening nut of a safety element, to remove sealing gasket 5 (figure 5.15) and to extract a
filter element;
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Figure 5.15 – Air filter:

1 - air filter body; 2 - basic filter element; 3 - safety filter element; 4 - header of the filter element; 5, 10 - sealing gaskets; 6 - header
of the cyclone separator; 7 - cyclone nipple; 8 - cover; 9 - cyclone cap; 11 - sealing; 12 - retaining ring; 13 - thrust washer; 14,
16 - strengthening nut of the filter element; 15 - gasket; 17 - cyclone compactor
E - hole in cyclone cap for dust blowout
- install a new element;

- install a rubber gasket under a nut. A nut to tighten by the twisting moment 20 – 30 N.m (force of
the arm).
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5.6 Service and repair of the pneumatic starter engine system
ATTENTION: SYSTEM DISMANTLING AND ITS ELEMENTS( PNEUMATIC STARTER, SHUT-OFF

COCKS, CRANES OF RESET OF A CONDENSATE, ETC.), REMOVAL OF AN ARMATURE AND PIPE
DUCTS, ALSO HOLDING OF PREVENTIVE AND WELDING OPERATIONS IT IS SUPPOSED TO MANU-
FACTURE DISASSEMBLY OF SYSTEM AND ITS ELEMENTS ONLY AFTER AIR PRESSURE DECREASE
IN SYSTEM UP TO ATMOSPHERIC. AIR REMOVAL FROM SYSTEM IS MADE THROUGH CRANES OF
RESET OF A CONDENSATE, THUS SHUT-OFF COCKS OF AIR-SLAKED BULBS SHOULD BE OPEN.
In case of need holdings of repair of the pneumatic starter are necessary for executing the following op-
eration.
Pneumatic starter dismantling

Pneumatic starter dismantling (Figure 5.20) should be carried in the following consecution:
Figure 5.20 — Pneumatic starter:

1, 5, 14, 21, 25, 29 - bolts; 2 - bearing cap; 3 – pneumoengine cover; 4 - barrel; 6 - pinion shaft; 7 - drive pinion; 8 - case; 9 – drive
case; 10 - restoring spring; 11 - breather; 12, 20, 22, 23, 28, 30 - bearings; 13 – starter pinion; 15 - cuff; 16, 17 - half-couplings; 18 – drive
shaft of; 24 - retaining ring; 26 - pinion shaft; 31 - rotor; 32 - plate;
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Engine systems
7513-3902080 RM
- disconnect the pneumatic engine from the reducer, for what turn off four bolts 29;
- cautiously tapping with a hammer from the soft material to separate the pneumatic engine from the
case of the reducer;
- turn off bolts 1 of the cover fastening 2 pneumatic engine, and then the bolt of 5 of the pinions
fastening 7;
- put the pneumatic engine in the verticality position and easily striking on the cover 2 to extract the shaft of
the pneumatic engine;
- for the disconnection of the reducer case 27 from the drive case 9 turn off bolts 21;
- easy percussion on the drive case to disconnect the reducer case ;
- turn off the bolt 25 of the bearings fastening 23 and the bolt 14 pinions fastening 13 then through the hole
in the shaft pinion to remove the retaining ring 24;
- with the help of special accommodating it is cautious turn off two screws of the case fastening 8 with the
drive case 9 as the restitution spring of the piston is strongly compressed;
- cautiously releasing restoring spring 10 to remove the reducer from the drive case ;
- to put the drive case in the verticality position and, tapping with the hammer from soft material on the
shaft end face 18 to beat out it from the bearing 12.
After disassembly all parts at which imperfections detected, it is necessary to replace.
Pneumatic starter assembly

Pneumatic starter assembly will be carried out in the following sequence:
- install shaft 18, molded in in the bearing 12 of the drive cases 9;
- insert spring 10 into the drive case and with the help of special accommodating to install the case 8, hav-
ing fixed its two screws;
- install the bearing 23 and pinion 13, having fixed their bolts 25 and 14, then to install the retaining ring 24;
- connect the reducer case 27 to the drive case 9 by means of bolts 21;
- manufacture assembly of the pneumatic engine for what to fix on the shaft of the pneumatic engine the
pinion 7 with help the bolt 5, install the shaft of the pneumatic engine in the pneumatic engine case, install cover
2, having fixed its bolts 1;
- connect pneumatic engine with the reducer by means of bolts 29.
At assembly it is necessary to execute the following demands:
- assembly to manufacture only by clean hand;
- use the corresponding instrument and accommodatings;
- put lubricated film on useful barrel areas, rotor and plates of the pneumatic engine;
test form and sizes of the pneumatic rotor plate. The plate sizes should be correspond the indicated
on the Figure 5.21;
Figure 5.17 – Pneumatic engine rotor plate
- not clean the parts by rags leaving fibers;

- not suppose hit of the mud in the pneumatic starter.
Pneumatic starter assembly to manufacture by assembly of three units in the following sequence:
pneumatic engine, reducer, drive.
Table 5.1 – Possible inaccuracies of the pneumatic starter and ways their removal
Faultiness Possible cause Remedy
The pneumatic starter does not turn to
the engine crank shaft though the
The engine crank shaft is not turned. The
pneumatic starter pinion has come in Fined reason. The engine blocking is elimi-
engine is blocked.
gearing with the flywheel, and to the nated.
pneumatic engine compressed air is
brought.
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Continued table 5.1

After engine start the starter pinion Dismantle the pneumatic starter, to eliminate
does not go out gearing with flywheel The drive piston of the pneumatic starter has the reason of the piston wedging, to wash
rim. jammed. out and grease the piston with the drive
parts.
The pneumatic engine turn slowly The pneumatic starter system of the engine To remove an air leakage in pneumatic
does not explicate starting turns. start is leakage. Lubricant of heightened vis- starter system of the engine start. To provide
cosity is applied. lubricant of the corresponding viscosity.
Pneumatic engine is turn, but not The wear of half-couplings. The break of the Half-couplings, the spring are substituted. To
transmit the moment on the pneumatic spring the pressing half-couplings. The fric- adjust the moment transmitted by the friction
starter pinion. tion coupling is not adjusted. coupling (400 N.m).
The big wear of the pneumatic starter plates.
Air consumption is heightened The wear of the useful area of the pneumatic Replace worn-out parts.
starter barrel
The pneumatic engine plates are damaged. The damaged plates are substituted on new.
The pneumatic starter suddenly has
Ingress of dirt on the useful area of the Pneumatic engine parts are washed out, put
stopped.
pneumatic starter barrel. on useful areas the thin layer of greasing
The rubber ring providing condensation of
There is no force to entry in gone the piston with the drive case is damaged.
To replace the rubber ring. To increase air
gearing of the pneumatic starter with The pressure of compressed air providing
pressure in the pneumatic starter system .
flywheel rim. pulling out of the pneumatic starter shaft is
lowered..
After the engine start the shaft of the The return spring of the piston is broken.
To replace spring. To clean and wash out
pneumatic starter with pinions is not The ventilation breather of the drive case is
the breather.
reset. littered.
At the opening the crane on the air Dismantle the starting valve, if necessary to
tank is the pneumatic engine rotor ro- The starting valve is not tight.. replace worn-out parts, to wash out in kero-
tation. sene and to grease useful areas.
5.7 Service of the engine preheater

At preheater maintenance it is necessary to watch, that was not leaking of the cooling fluid and fuel
through of the pipelines and hoses connections. It is necessary periodically test and tighten fastening bolts of
the preheater and the pumping unit.
After everyone 100 - 150 start-up to clear from scale the glow plug, the nozzle and burner and also to
wash out the filter of the electromagnetic valve and to clean the drain port of the fuel pump.
Sequence of the nuzzle clearing:

- disconnect the solenoid valve, turn out the nuzzle and to dismantle it;
- wash out the filter, clean the central aperture of the nuzzle;
- collect the nuzzle and to fix it on the valve;
- not attaching the solenoid valve to the boiler to switch on the pumping unit and to open the solenoid
0
valve. Combustible should be sprayed by the nuzzle as a fog-like cone with an angle not less than 60 C.
The possible troubleshooting of the starting preheater and the methods their removes are in the
table 5.2.
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Table 5.2 The possible troubleshooting of the starting preheater and the methods their removes
Preheater fails to start because of no fuel de- Electromagnetic valve filter clogged Wash or replace filter, blown down
livery with compressed air before mount-
ing
Electromagnetic valve fails to open (no click Check reliable connection of wire
heard in working position) lugs to terminals and serviceability
of 2A fuse. Replace fuse if needed
Nozzle centre orifice choked Remove and disassemble nozzle,
wash all parts in diesel fuel, clean
chamber hole and casing centre
orifice. Energize preheater and
check spray cone of nozzle not
screwed into burner
Air entrapped into fuel line Unscrew pump fuel supply pipe, let
air locks out, then screw pipe back
into place
Heater electric motor is inoperative Check reliable connection of wire
lugs to terminals and check electric
circuit with the aid of pilot lamp.
Push fuse button on control board
Glow plug does not operate Control board check spiral burnt Replace spiral
Glow plug spiral burnt Replace glow plug
Glow plug spiral heat insufficient Check connection of wire lugs to ter-
minals. Check storage battery
charge. Recharge, if necessary
No contact between wire lug and plug Tighten up wire lug attachment
Preheater is smoky Air delivered by blower insufficient because Charge storage batteries
of low motor speed
Nozzle orifice choked Disassemble nozzle, wash parts in
diesel fuel and clean orifice. Check
assembled nozzle for spray cone
Air intake blower screen or outlet pipe Clean outlet pipe or air intake screen
clogged with dirt
Combustion chamber carbonized Disassemble and decarbonize com-
bustion chamber. Clean chamber and
blow down with compressed air
Engine warming up period is too long Clogging of valve and nozzle filters causes Clean filters of solenoid valve and
insufficient delivery of fuel nozzle. Increase fuel consumption by
turning fuel pump pressure-reducing
valve screw
Fuel pipelines leaky Eliminate leakage
Electromagnetic valve fails to shut off fuel feed Dirt got under check seat Screw valve out of base, wash in die-
sel fuel and blow down with com-
pressed air
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Traction electric drive
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6 TRACTION ELECTRIC DRIVE
6.1 General data on traction electric drive

Traction electric drive of dump trucks is intended for:
- creation of regulated traction forces on driving wheels of dump truck by transformation of mechanical
power of diesel engine to electric power, and also for automatic regulation of electric power and its reconver-
sion in mechanical power;
- creation of regulated braking powers on driving wheels at standard and forced electric braking.
At standard electric braking force is formed at expense of regulated transformation of kinetic energy ac-
cumulated by dump truck during driving, in electric power. Transformation of kinetic energy is carried out by
shifting of traction motors in generator operation mode and creation of braking torques on their shafts. Electric
power oscillated by electric motors is transformed in brake resistors into thermal energy with consequent dif-
fusing in circumambience.
Forced electric braking operation is carried out for raising of braking efficiency at dump truck speeds be-
low 20 - 25 km/h and for providing full shut-down of dump truck. Braking powers at forced electric braking op-
eration, except for specified for standard electric braking operation, are formed at expense of additional power
consumption from diesel-generator set.
The electric drive is intended for operation in two modifications of dump truck distinguished by reduction
ratio of electric motorized wheel reducer.
The electric drive comprises following principal components:
- traction synchronous alternator which is rotated by engine. Stator winding of traction alternator consists
of two electrically not connected three-phase windings, each of which is connected in star. On stator of traction
alternator is situated single-phase self-excitation winding that is connected through external adjuster and slip
rings to exciting winding, placed on its rotor;
- two direct-current traction motors of electric motorized wheels with series excitation, forced pressure
ventilation and built-in sensors of rotary speed and monitoring of thermal condition;
- two power three-phase bridge incontrollable rectifier to which input cramps stator three-phase windings
of traction alternator are connected;
- setting of ventilated brake resistors with individual brake resistors for each traction motor and common
motor-fan;
- current regulator of excitation of traction alternator, which power part represents half-controlled single-
phase bridge rectifier to which input cramps self-excitation winding of traction alternator is connected, and to
output its exciting winding is connected;
- common current regulator of excitation of traction motors (adjuster of smooth field reduction of electric
motors). Power part of adjuster comprises steered three-phase zero rectifier, powered in parallel circuits, con-
taining anode group of one of power rectifiers and two sequentially joint exciting windings of traction electric
motors;
- power switching equipment consisting of contactors, providing power circuits commutation, circuits of
excitation and reversing of traction motors.
Except for listed electric machines, settings and apparatuses basic components of electric drive com-
prise automatic control system (САУ), which comprises two subsystems: system of program control (СПУ) and
system of automatic regulation (САР). Adjusters of alternator excitation and electric motors are also included in
САУ subsystems.
The automatic control system is intended for control of power switching equipment and of operation
modes of system of automatic regulation.
The system of automatic regulation is intended for forming of traction and braking performances of dump
truck by means of comparison of assigning signals and feedback signals acting from sensors of electric and
mechanical parameters. It is intended also for regulating of exciting currents of traction alternator and traction
motors in function of error signals between specified signals. Besides, system of automatic regulation executes
functions of guard of electrical equipment from emergency operation modes.
The signalling of electric drive operation is carried out by indication devices – indicating lamps located
on control panel in cab, and indicators on front panels of blocks with microelectronic elements.
Indicators on front panels of blocks are intended for diagnosing operation of blocks, other devices of
system of automatic regulation and of some aggregates and devices of electric drive. In particular, indicators
signal about receipt of source voltages on inputs of blocks with microelectronic elements, about operation of
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ports of system of automatic regulation and together with lamps signal about turning on of safety devices.
Mechanically power rectifiers, adjusters, power switching equipment, and devices of program and auto-
matic control are integrated in control cabinet.
Operation modes of electric drive can be divided into two groups:
- modes set by operator;
- modes set automatically by means of system of automatic regulation.
In first group it is necessary to divide basic and additional modes.
Basic modes comprise:
- traction mode at forward and backward motion;
- mode of electric braking operation at forward and backward motion, implemented in two alternatives -
mode of standard electric braking operation in all speed range of driving and mode of forced electric braking
operation only in range of low speeds.
Additional operation modes of electric drive comprise:
- traction mode with emergency excitation of traction alternator (at out-of-order system of automatic
regulation or thyristors of adjuster of excitation of traction alternator);
- mode of emergency control (at out-of-order system of program control);
- mode of driving at power supply from external current source in garage;
- mode of manual or automatic control of exciting currents of traction alternator on braked dump truck at
inspection of technical condition of electric drive and regulating of parameters of external characteristic of in-
jection diesel-generator set at imitation of traction mode.
Second group of electric drive operation modes, set by system of automatic regulation, comprise:
- operation mode of traction motors with slackened magnetic stream of excitation (slackened field) in ba-
sic traction mode at forward motion:
- mode of dump truck speed limitation (of maximum rotary speed of traction motors).
Besides in traction electric drive safety of electrical equipment is ensured in case of overflow of accept-
able values of voltage and current of power circuit, shorting of power circuit on body of dump truck, short-circuit
of power rectifier, skidding of electric motorized wheels and others.
6.2 Description and operation of electric drive components

6.2.1 Electric machines
6.2.1.1 Traction alternator

On dump trucks non-collector one-basic or two-point traction alternator is installed. Alternator is intended
for power supply of traction motors through rectifying installation, and also for power supply of exciting winding
of alternator rotor through system of automatic regulation.
Alternator ГС-525А
The alternator (figure 6.1) is eight-polar synchronous electric machine of guarded construction. It con-
sists of following main bodies: stator, rotor and end bracket.
The alternator is made with one end bracket with frictionless bearing. Case of stator of alternator is
rested with claws on absorbers and by flange is cemented immediately to diesel engine case. On part of slip
rings rotor of alternator has free conic end of shaft, allowing to produce power takeoff up to 200 kW at rotor
speed of 1900 rpm, on which hub fan wheel of cooling fan of traction machines is installed. From side opposite
to slip rings, alternator has flange for connection to shaft of diesel engine through semihard clutch.
The alternator is equipped with centrifugal exhaust fan, which is installed on flange 33 at joint of alterna-
tor with diesel engine.
Air cleared of ectogenic admixtures moves in butt of end bracket on part of slip rings. Further air passes
through air channels of alternator (through vent holes in stator sheets, spacing between poles of rotor and
spacing between poles of rotor and stator). Having passed through spacings, air goes out of alternator through
windows protected by grids in case of stator from side opposite to slip rings.
The system of cooling air supply to alternator ensures fence of cooling air through air-slaked cyclonic fil-
ter built on power cabinet, and through suction duct air moves in upstream end of traction alternator. Part of air
is used for cooling of traction alternator, other air on forcing air vent moves by fan in crankcase of rear axle and
on special ports in cases of reducers of electric motorized wheels for cooling of traction motors. Air goes out
through air-vent windows of traction motors and bores in cover of crankcase manhole of rear axle.
Excitation of alternator is carried out from special self-excitation winding located in chases of its stator,
through regulating system.
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Figure 6.1 - Traction alternator ГС-525А:

1 - internal bearing cap; 2 - plug; 3 - internal sealing ring; 4 - bearing; 5 - shaft; 6 - external sealing ring; 7 - ring of internal bearing
cap; 8 - ring of external bearing cap; 9 - rubber sealing ring; 10 - external bearing cap; 11 - demountable hub; 12 - slip ring; 13 - brush-
holder; 14 - suspension; 15 - insulator; 16 - pad; 17 - board; 18 - greaser; 19 - rod; 20 - tube of lubrication input; 21 - end bracket; 22 - ring;
23, 25, 27, 34 – pressure washer; 24 - pad; 26 - winded case of stator; 28 - sheet of stator; 29 - stud; 30 - case of stator; 31 - coil of basic
stator winding; 32 - coil of self-excitation winding; 33 - flange; 35 - inductor sheets; 36 - grid; 37, 44, 57 - covers; 38, 41 - pole; 39 - tab;
40 - tire; 42 - web; 43, 58 - cleat; 45, 46, 47, 48, 53, 54, 55, 56 - output leads; 49, 50, 51, 52 - wires
Maintenance and repair of internal components of alternator (slip rings, brush-holders, sweepers and
others) is made through access hatches of board closed by folding covers.
Output leads from outputs of basic stator winding, wire from exciting winding of rotor and from outputs of self-
excitation winding are located in heel of board at left and right of vertical axis.
The end bracket 21 is welded skeleton structure, fixed by bolts to case 30 of stator. In central part of end
bracket demountable hub 11, providing opportunity of replacement of bearing 4 without removal of end bracket
from alternator and without removal of alternator from dump truck, is fixed by bolts.
On brackets of end bracket by means of insulators 15 two suspensions 14 are installed, to each of which
three brush-holders 13 and current carrying wires of sweepers are fixed, and also wire, connecting circuit of excit-
ing winding of rotor with system of automatic regulation, is connected.
In alternator radial one-clip brush-holders (figure 6.2) are applied in which force of pressure is created
and transmitted to sweeper by pressure bar 3 consisting of spring, bar and cock, which is intended for rise of
bar from sweeper.
The construction of brush-holder ensures fixed force of pressure to sweeper irrespective of its wear.
Therefore, while in operation additional readjustment of force of pressure on sweeper is not required.
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Sweepers, installed in cartridge clips of brush-holders, are supplied with shock-absorbing strap.
In alternator spherical roller double-row bearer is applied for support and for free rotation of rotor 4 (see
figure 6.1), closed with covers 1 and 10 from two sides.
Cavities between bearing 4 and covers 1 and 10 form internal and external chambers of lubrication ac-
cordingly. Besides, as result of press fitting of ring 7 in internal bearing cap, backup chamber of lubrication,
which is filled by lubricant at assembly of cover 1 is formed.
Lubricating grease, which brand is specified in certificate of alternator, is applied in bearing.
The construction of bearing mount assembly ensures reset of completed lubrication in special chamber
formed by external cover 10 of bearing, its ring 8 and external sealing ring 6. Reset of debris-contaminated lu-
brication in chamber occurs through spacing between ring 8 of cover 10 and external sealing ring 6.
Labyrinth and groove sealings are applied in order to prevent outflowing of lubrication from bearing out
or in inside of alternator and penetration into bearing of dust and moisture.
Figure 6.1 (continuation) - Traction alternator ГС-525А
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Figure 6.2 - Brush-holder:

1 - case; 2 - restrictive shaft; 3 - pressure bar; 4 - lever
pin; 5, 6 - barrels; 7 - shaft of spring
External and internal covers are con-

densed with rubber sealing rings 9. Labyrinth seals are formed by sealing rings 3 and 6, and protuberances in
covers 1 and 10 of bearing, and groove sealings are formed by grooves of covers 1 and 10 and corresponding
surfaces of shaft of rotor.
Lubricant in bearing is added by pressure gun through greaser 18, screwed in tube 20. Added lubricant
moves in backup lubrication chamber of internal cover 1 of bearing.
Housings are installed on perimeter of cylindrical part of end bracket. Upper housing from horizontal shaft
has folding covers 37 that are intended for access to slip rings and brush-holders for maintenance. In cavities of
two lower housings, cleats 43 and 58, timbered to end bracket are located. After assembly of alternator output
leads from corresponding outputs of basic stator winding are fixed in cleats, as well as wire from exciting winding
of rotor and from outputs of self-excitation winding. Cavities of housings are closed by covers 44 and 57.
The stator of alternator consists of cylindrical welded case 30 and winded stator that is timbered in it.
On side of slip rings in case tapped holes under bolts of end bracket fastening are made, and from side
opposite to slip rings case has cylindrical sharpening and tapped holes for flange fastening to diesel engine,
and also windows for blowout of cooling air. Claws are welded on case of stator in parallel with its horizontal
shaft from two sides for mounting of alternator on absorbers. Perpendicularly to claws, for raising their stiff-
ness, ribs with eyelets, intended for rise and transportation of alternator, are welded to case of stator.
The winded stator consists of following main parts: case 26, sheets of stator 27, pressure washer 23,
forming not winded stator in assembly, and also coils 31, 32, webs, clinches, tires and output leads, that are
forming stator winding.
The case 26 of winded stator is executed as cylinder of welded construction. Between disk of case and pres-
sure washer 23 by coupling studs 29 sheets of stator in pressed condition are clamped.
On inner diameter of sheets of stator chases for stacking coils of winding, and on external diameter -
bores under handrail bolts and for creation of axial air channels are stamped-out.
Coils 31 with webs and tires form wave two-layer basic stator winding executed under circuit of two in-
dependent three-phase stars with shift in thirty electrical degrees with output of origins.
Outputs of phases and origins of basic stator winding are executed as flexible tires, output leads, to
which corresponding output leads 45, 46, 47, 48, 53, 54, 55, 56 are connected in assembled alternator.
Coil 32 with clinches and tires form single-layer wave single-phase special self-excitation winding.
Outputs of self-excitation winding are executed as tires, webs, to which wires 49, 52 are connected in
assembled alternator.
Coils 31, 32 are fastened in chases by chocks from insulation substance. Frontal parts of coils 31 are
fixed by cord to isolated rings 22, and frontal parts of coils 32 fixed by cord to frontal parts of coils 31.
The winded stator is soaked in varnish КО-916К ТУ 6-02-1-012-89 and enamels КО-935
ТУ 16-50.4.021-77.
The rotor of alternator consists of following main parts: shaft 5 and flange 33 put on it, pressure washers
25, 27 and 34, inductor sheets 35, poles 38, 41, slip rings 12, interpolar webs 42, connective tires 40 and pads
24.
The shaft and flange in assembly form case and in assembly with pressure washers and inductor sheets
- case of rotor.
Two packages inductor sheets are burdened and pressed on shaft between three pressure washers or
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package is selected from pressure washers. On outer diameter of inductor sheets and pressure washers
chases in shape of "dovetail" are made, in which poles of single-block construction are fixed with wedge keys
39. Each of poles consists of core hub and coil.
The core of pole is typed from sheets, pressed and strap with two cheeks and polar rivets, and has spe-
cial protuberances in shape of "dovetail" for fastening in chases of case of rotor.
The single-layer coil of pole is reeled up on rib from copper ribbon of rectangular cross-section. Between
coils of coil layer pads from insulation substance are stamped in shape of coil. Coil in assembly with core of
pole is impregnated in epoxide compound, by which cast-in-place construction eliminating conveyance of coil
concerning core is ensured.
Each coil has two output leads to which interpolar joints are connected.
From eight coils of poles which form exciting winding of rotor, four are executed with intercrossed output
leads, and other four are direct (open). Полюсы with intercrossed and direct output leads of coils are installed
on case of rotor through next nearest one.
The series connection of coils of poles is executed by means of webs 42 fastened with output leads of
coils to case of rotor through pads 24.
The beginning and finishing of winding of excitation 40 are connected by tires to slip rings 12.
Slip rings are produced of antirust steel and pressed on isolated cylinder landed on shaft with tightness.
As contact output, stud, to which corresponding connective tire from exciting winding is connected, is
fixed in each ring.
The surface of rotor (except for working surface of slip rings of shaft and flange) is covered with enamel
Эп-91 GOST 15943-80.
The wiring scheme of joints of windings of alternator is specified in figure 6.3.
Alternators in different climatic modifications differ in brands of used constructive materials, paint and
varnish and metal plating.
Figure 6.3 - Scheme of electric joint of windings of alternator ГС -525A (view from side of slip rings):
F1, F2 - beginning and finishing of winding of rotor excitation; S1, S2 - outputs of self-excitation winding (from third harmonics);
1U, 2U, 1V, 2V, 1W, 2W - outputs of phases of stator winding; 1N, 2N - outputs of origins of stator windings; H, K - beginning and end of
polar coils of rotor
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Traction alternators СГД, СГД2.

Alternators are of horizontal modification with flange on case of stator from side of diesel engine, with
two running ends of shaft. Alternator СГД is executed with one end bracket, and alternator СГД2 - with two
end brackets. End of shaft for connection to bent shaft of diesel engine at alternator СГД is of flange typr, at al-
ternator СГД2 - taper.
The end of shaft on part of slip rings is of taper type and is calculated on drive of power 200 kW for all
alternators.
Fanning of alternators is axial and is carried out on open loop by means of centrifugal exhaust fan 3, 9
(figures 6.4 and 6.5 accordingly), rotor of alternator is installed on shaft on side of diesel engine. Cooling air
moves on side, opposite to diesel engine, then passes through alternator and is rejected by fan in windows.
Excitation of alternators is carried out from special winding located in chases of stator, through regulat-
ing system.
The basic stator winding is connected in two three-phase stars to space phase lag on angle that is equal
to 30 electrical degrees.
Figure 6.4 - Traction alternator СГД:

1 - grid; 2 - flange; 3 - fan; 4 - stator; 5 - rotor; 6 - slip ring; 7 - brush-holder; 8 - end bracket; 9 - pipe duct of lubrication of roller
bearer; 10 - beam; 11 - cap; 12 - roller bearer; 13 - external cover of bearing; 14 - nut; 15 - shaft of rotor; 16 - internal cover of bearing;
17 - sealing ring of bearing
The beginnings of phases and origins are inferred through bores in heel of board from side opposite to
diesel engine. Lead-out tires are closed by protective demountable housings 4, 17 (figure 6.6).
The stator of alternator is of cylindrical shape and consists of core, windings and case.
The case is welded of sheet steel, consists of sheeting and flanges connected among themselves by ribs.
The core of stator is blended from isolated by varnish segments of electrotechnical steel with width of
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0,5 mm, divided on length into separate packages by glass fiber plastic segments. Core is pressed with pres-
sure flanges, coupling studs and nuts.
In open chases of stator three windings are stacked - two basic three-phase winding and single-phase
self-excitation winding. In chases they are fixed by glass fiber plastic chocks. Frontal parts of windings are fas-
tened to retaining rings.
The rotor consists of shaft, skeleton put it, poles with windings and fan blower.
Cores of poles are burdened. Poles are fastened to skeleton by T-shaped shanks with chocks.
The current supply to rotor winding is carried out through slip rings.
Coils of poles are produced from tire copper bent on rib. Interturn isolation of coils is made of glass rib-
bon or fiber glass on epoxide cementing material.
Interbobbin joints are executed by non-isolated tires, which are timbered with bolts on isolation pads.
Figure 6.5 - Traction alternator СГД2:

1, 23 - sealing rings of bearings; 2, 22 - internal covers of bearings; 3, 20 - nuts; 4, 19 - external covers of bearings; 5, 18 - bear-
ings; 6, 15 - tubes of lubrication of bearings; 7, 14 - end brackets; 8 - greaser; 9 - fan; 10 - stator; 11 - rotor; 12 - slip ring; 13 - brush-
holder; 16 - beam; 17 - cap; 21 - shaft of rotor
In end bracket of alternators СГД and СГД2 on side, opposite to diesel engine, spherical double-row
roller bearing is installed. For protection from emersion of bearing currents, end bracket is executed with iso-
lated cap.
Internal and external bearing caps are produced with grooves for protection of outflowing of lubrica-
tion. In addition from interior of bearing ring is installed, which forms labyrinth device in pair with cover. For
washing of bearing and feeding of lubrication two tubes are screwed in internal cover. Cavities of external
and internal covers are connected by bore in cap.
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Figure 6.6 - Traction alternator СГД (view from side of slip rings):
1 - lock of cover; 2 - cover of access hatch; 3 - greaser; 4, 17 - housings; 5, 6, 7, 8, 13, 14, 15, 16 - output leads; 9, 12 - wires;
10 - pipe duct of lubrication; 11 - plug
6.2.1.2 Traction electric motor

On dump trucks direct-current traction electric motors are installed. Electric motors are intended for drive
gear of wheels of dump truck as part of alternating-direct-current electric drive.
The traction electric motor ДК-722Е.
The electric motor (figure 6.7) is of direct-current and series excitation. It is intended for transformation
of electric power of traction alternator in mechanical and for transmitting it to driving wheels of dump truck.
Electric motor is fastened to case of reducer of electric motorized wheel and together with case of reducer is
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fastened with bolts to crankcase of rear axle.

The armature shaft of 1 electric motor is connected by one end with torsion shaft of drive pinion of re-
ducer of electric motorized wheel, and on second end (on side of collector) brake gear drum of parking braking
system is fastened.
The traction electric motor has four principal 17 and four additional 18 poles. Principal poles serve for
creation of basic magnetic stream, and additional poles serve for better commutation. Winding of armature is of
o
lap type, with equalizers. All windings have isolation of class "F" and "H", supposing heat up to 180 C.
Principal and additional poles are fixed on support 14. Brush-holders 10 are fixed on fornt end bracket
11. Brush-holders are equipped with special devices for regulating pressure force of finger on sweeper.
The collector 8 has steel grounding strapped with bolts. Manholes are available in case of electric motor
for visual inspection and maintenance of collector and sweepers. Manholes are closed by steel ribbon 15 tight-
ened by bolts. Motor armature rests on bearings 4 and 26 installed in front and rear end brackets. Bearing
mount assembly from drive end is made with devices for adding lubrication.
Figure 6.7 - Traction electric motor ДК - 722Е:

1 - armature shaft; 2, 6, 27 - nuts; 3 - spline barrels; 4 - ball bearing; 5, 25 - covers; 7 - internal cover; 8 - collector; 9 - sweeper;
10 - brush-holder; 11, 22 - end brackets; 12 - series winding of excitation; 13 - bolt of end bracket fastening; 14 - frame; 15 - steel ribbon;
16 - winding of principal pole; 17 - principal pole; 18 - additional pole; 19 - winding of additional pole; 20 - winding of armature; 21 - com-
pensating winding; 23 - bolt; 24 - greaser; 26 - roller bearing; 28 - flange; 29 - bolts
Fanning of electric motor is of forced type. Cooling air moves from side of collector through collector
manhole and goes out from opposite side through bores in rear end bracket. Lead-out wires go out through
bores with rubber inserts in end bracket on side of collector.
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Traction electric motor ЭД136.

The electric motor is four-pole, reversive electric direct-current machine of series excitation.
The electric motor is executed on two end brackets with frictionless bearings and has two free cylindrical
ends of shaft with slots. One end of shaft is connected to reducer of electric motorized wheel, and another -
with brake gear.
Sensors of thermal mode are installed in electric motor. All lead-outs of electric motor and sensors are
inferred on side of collector.
The system of cooling air input to traction electric motor ensures fence of cooling air through air-slaked
cyclonic filter built on power cabinet. Part of air is used for cooling of traction alternator, other air on forcing air
vent moves with fan in crankcase of rear axle on special ports in cases of reducers of electric motorized
wheels.
Cooling air moves in electric motor through ventipane in side part of magnetic system (from side of col-
lector), and is blown through armature and magnetic system in two streams. First stream passes through air
channels of armature and goes out from side opposite to collector through four axial bores in end bracket.
Another stream passes through spacing between poles and armature and goes out from side opposite
to collector through radial bores in case of magnetic system.
End brackets 12 and 18 (figure 6.8) are produced cast of steel. End brackets are fastened with bolts to
case 15 of magnetic system.
In bearing mount assembly on side of collector radial-thrust ball bearing 4 is installed. Bearing is set
on armature shaft in heated mode. Bearing is closed by external cover 6, which forms with ring 5 external
chamber of lubrication. Internal chamber of lubrication is formed by internal cover 9 and ring 3. For security
of leakproofness of bearing mount assembly expanders 1 serve with split collars 2 and rubber sealing rings
7 and 8, installed in covers.
In bearing mount assembly from side opposite to collector radial roller bearing 23, perceiving only radial
loads, is installed. Inner ring of bearing is set on armature shaft in heated mode. Bearing is enclosed by exter-
nal cover 21, which forms with ring 22 external chamber of lubrication. Internal chamber of lubrication is
formed by end bracket 18 and inner ring 24. Sealing of bearing mount assembly is executed analogously to
sealing of bearing mount assembly on side of collector.
Maintenance of internal components of electric motor (collector, brush-holders, sweepers) is made
through access hatches (upper, lower and two side-cut), located on side of collector and enclosed by covers.
The arrangement of manholes enables to examine all brush-holders and collector on all round.
Covers 1 (figure 6.9), 2 and nipple 3 of access hatches are executed as quick-detachable ones. Covers
have rubber seals intended for prevention of penetration of moisture and dust inside of electric motor.
The armature 25 (see figure 6.8) consists of not winded armature, coils, equalizers, winding-holder and
sealing rings. Not winded armature powers up shaft, armature sheets, two pressure washers, collector and
winding-holder. Armature shaft consists of shaft and barrel pressed on it. Such construction allows to squeeze
damaged shaft without disassembly of armature.
On barrel of shaft armature sheets, chucked between pressure washers, are burdened.
On outer diameter of armature sheets chases for stacking armature coils are stamped-out, and in aver-
age part two lines of bores for creation of axial air channels are made.
In armature collector of arch type, consisting of package of collector bars isolated from each other by in-
sulating spacers, two pressure tapers and collector tube, is applied.
Plates of collector are stamped-out as a whole with risers, in which slots ends of armature coils are
stacked. Package of collector bars is isolated from pressure tapers and collector tube by electro insulation
cuffs and gasket. Collector tube on side of pressure washer has one series of bores for creation of axial air
channels of armature.
Assembled collector after dynamic forming is pressed on barrel of shaft.
The appearing end of cuff of collector on side of its external pressure taper after assembly of armature is
protected from exposures by bandage from special glass-strip ribbon, covered with electro insulation enamel.
Winding-holder it intended for fixing equalizers and increase in heat sink from current carrying parts of
armature.
Coils and equalizers are produced of wire, insulated by polyamide insulation or composition from poly-
amide film with fluoroplastic sublayer and form lap winding of armature with equalizer joints.
Equalizers are located under frontal parts of coils on side of collector.
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Figure 6.8 - Traction electric motor ЭД136:

1 - expander; 2 - ring; 3, 24 - inner ring of bearing; 4 - ball bearing 5, 22 - outer ring of bearing; 6, 21 - external bearing cap; 7, 8,
20 - sealing ring; 9 - internal bearing cap; 10, 19 - tubes of lubrication; 11 - brush-holder; 12, 18 - end brackets; 13 - outputs of sensors of
thermal mode; 14 - winding of series excitation; 15 - case of magnetic system; 16 - principal pole; 17 - winding of armature; 23 - roller
bearing; 25 - armature; 26 - winding of additional pole; 27 - additional pole
Chases in armature sheets before stacking of coils are covered by film from fiber glass fabric. Armature
coils in chases of armature sheets are fixed by insulation chocks, and frontal parts of them are fixed with bind-
ings from special glass-strip ribbon.
Joint of equalizers and armature coils with collector bars is executed by welding.
The head of coils from side opposite to collector are protected from mechanical damage by winding-
holder. Besides, winding-holder serves for separation of streams of cooling air moving out of electric motor.
Sealing rings of bearings 3, 5, 22 and 24 are set on shaft in heated mode. On their external surface, there
are grooves for setting sealing split collars with expanders.
Magnetic system consists of case 15, brush-holders 11, principal 16 and additional 27 poles, connective
tires and wires.
The case of magnetic system serves for assembly of all electric motor and simultaneously is its mag-
netic conductor.
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Figure 6.9 - Traction electric motor ЭД136 (view from side of collector):
1, 2 - covers of access hatches; 3 - nipple;
Д1, Д2 - outputs of winding of series excitation (Д1 - beginning of circuit, Д2 - end of circuit); А1, В2 - outputs of winding of
armature (А1 - beginning of circuit, В2 - end of circuit)
With purpose of best use of internal space for seating principal and additional poles, case is executed in
lateral section as scalene octahedron that allows to receive least outline dimensions of electric motor at four-pole
modification.
There are welded gusset plates on case from above and from below, which serve for fixing electric mo-
tor on dump truck.
In butts of case borings (necks) are available, through which assembly of magnetic system is executed.
End brackets with armature are installed in borings.
Four brackets are welded to internal face wall of case against principal poles, which serve for fastening
of brush-holders. Case on side of collector has four manholes, on one of which nipple for feeding of cooling air
in electric motor is installed. Other manholes serve for maintenance and repair of internal components of elec-
tric motor. From side opposite to collector, in case there are windows for exit of cooling air.
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The magnetic system has four radial brush-holders. Case 4 of brush-holder (figure 6.10) has two car-
tridge clips in which split brushes 2 are installed.
Figure 6.10 - Brush-holder:

1 - bolt; 2 - sweeper; 3 - spiral spring; 4 - case;
5 - clamper; 6 - splint; 7 - shaft; 8 - finger; 9 - rivet
Thus in one cartridge clip one sweeper is

installed, and in another – two sweepers. Sweep-
ers are equipped with taking up shock insulation
straps. Current carrying wires of sweepers are at-
tached by bolts to case 4. System of brush-holder
pressure consists of clamper 5, spiral spring 3,
shaft 7 and protuberance in case 4 of brush-
holder. Clamper 5 is executed as tooth gear, tim-
bered on barrel. Teeth of tooth gear are bent aside
springs. In sawcut of barrel internal end of spring
is fixed. From free rotation on shaft 7, installed in
bores of case 4, in assembled brush-holder clamper is stopped by protuberance, enveloped by two next teeth
of tooth gear, ensuring fixing of spring in “On” position. If necessary, changes and visual inspection of sweep-
ers, assembly and disassembly of brush-holder, and also adjusting of force of pressure on sweeper, free
folded end of spring thrusting on sweeper, is displaced aside from tooth gear and installed on any of teeth of its
upper part.
Necessary force of pressure of spring is adjusted with axle 7 removed from dump truck by turning
movement of clamper in both directions with consequent locking by protuberance in case 4 and mounting of
shaft on place.
Fastening of brush-holder to bracket of case of magnetic system is carried out by means of fingers 8,
pressed in case 4 of brush-holder and arrested in it by rivets. Fingers are insulated from case by stratum of
press-material on which barrel from fluoroplastic is dressed on.
In magnetic system principal poles 16 (see figure 6.8) are located on horizontal and vertical shafts (on
large edges) of case, and additional poles 27 - under angle of 45o to vertical and horizontal shafts (on small
edges).
Poles consist of cores and coils, joint in one-piece single housing by dense mounting attachment and
impregnation in compound with consequent caking, which ensures humidity resistance, stability to vibration
and temperature effects.
The core of principal pole is made from extruded sheets of low-carbon steel, which are chucked by ex-
treme thicker sheets (cheeks). All sheets of core with cheeks are strapped under press with rivets.
On surface, that faces armature, along shaft of core rectangular chase for mounting of rod is stamped-
out. Core of additional pole is produced of plate steel and has on side of armature not magnetic nosepieces for
maintenance of coil.
Coils of poles are executed from copper tires of rectangular cross-section, which have been winded up
flatwise (coils of principal pole) or on rib (coils of additional pole). Coil of principal pole is executed as two-
layered, and coil of additional pole - single-layered one.
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Each of coils has two output leads for fastening tires or wire joints between poles. Output leads of coil of
additional pole for toughness are rested on steel insulated plates inserted between coils. From four coils of
principal poles, two are executed with cross output leads, and two others – with direct (open) ones. Coils with
cross and direct output leads are installed in magnetic system through one, what enables to interlace polarity
of poles and to simplify construction of connective tires at series connection of coils of principal poles.
Principal poles are fastened to case of magnetic system by means of bolts rolled in tapped holes of rod.
Additional poles are fastened to case of magnetic system by means of through passage square-head
bolts and nuts. Heads of bolts are placed in special chases of cores on side of armature.
Joints between coils of principal poles are executed from insulated tires and located on side of collector.
Tires are fixed by means of bolts to output leads of coil and by means of steel ribbon and rubber shock-
absorber to clinches welded on case.
The wiring scheme of joints of windings of electric motor is shown in figure 6.11.
Figure 6.11 - Wiring scheme of joints of windings of electric motor ЭД136:

а) - communication chart of winding of series excitation; б) - communication chart of winding of armature and windings of sensors
of thermal mode
Д1, Д2 - outputs of winding of series excitation (Д1 - beginning of circuit, Д2 - end of circuit); А1, В2 - outputs of winding of arma-
ture (А1 - beginning of circuit, В2 - end of circuit); 1Т1, 1Т2, 2Т1, 2Т2 - outputs of windings of sensors of thermal mode
Joints between coils of additional poles, between brush-holders of one polarity, between circuits of addi-
tional poles and brush-holders are executed by flexible wires (cables) and located on side of collector. Fixing of
wires is similar to fixing of tires between coils of principal poles.
Magnetic system has four wires for connection of electric motor to power circuits of dump truck. Wires of
winding of armature and winding of series excitation, and also wire of sensors of thermal mode are inferred from
case of magnetic system through bores in its upper part on side of collector. Bores are condensed with rubber in-
serts precluding hit of moisture inside of electric motor and protecting insulation of lead-out wires from fault.
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Traction electric motor ЭК-420А

Electric motor (figure 6.12) is four-pole, reversive electric direct-current machine of series excitation.
For better commutation electric motor has additional poles and compensating winding. Compensating
winding is dropped in slots of cores of principal poles and fixed by fiber-glass plastic chocks.
The electric motor is executed on two end brackets 6 and 9 with frictionless bearings and has two free
cylindrical ends of shaft with slots. One end of shaft is connected to reducer of electric motorized wheel, and
another one – to brake gear.
Winding of armature is of lap type with equalizers. In grooving part winding is fastened by fiber-glass
plastic chocks, on frontal parts – by glass treads. Joint of conductors of winding of armature with collector bars
is carried out by welding in neutral medium.
Figure 6.12 - Traction electric motor ЭK-420A:

1, 2 - covers; 3 - nuts; 4 - sweepers; 5 - brush-holder; 6, 9 - end brackets; 7,10 - bolts; 8 - frame; 11 - armature; 12 - bearing cap;
13 - armature shaft
Collector of electric motor is of arch type, on steel modular grounding. Electric motor is made with four
brush-holders 5. Each brush-holder has three split brushes. Force of pressure to sweepers is regulated by
turning movement of screw. For maintenance of brush device and collector there are windows in end bracket.
In electric motor on side of collector ball bearing is installed, from opposite side - roller bearing. Lubricant
Литол-24 GOST 21150-87 is applied to bearings.
Bearing mount assemblies ensure opportunity of lubrication refill without dismounting of electric motor.
On side of collector on electric motor tubes for feeding lubrication in bearing mount assemblies are located.
Fanning of electric motor is independent. Cooling air moves from side opposite to collector through
bores in rear end bracket, and is rejected on side of collector through bores in front end bracket.
Lead-out wires of windings of electric motor go out from side opposite to collector, and are fastened in
cleats installed on board.
Each electric motor has plate on frame, on which motor’s serial number, extent of safety, operation
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mode, mass of electric motor, class of insulation and other ratings are specified.
The serial number of electric motor is also plotted on flange of frame. Number of armature is plotted at
butt of shaft on side of collector.
The wiring scheme of joints of windings of electric motor is shown in figure 6.13.
Я 1 is out through coil of additional pole
Direction of rota-
tion (from side of Joint of lead-out ends
collector)
Figure 6.13 - Wiring scheme of joints of windings of electric motor ЭK-420A
Traction electric motor ТЭД-6УХЛ2

The electric motor with rated voltage of 840 V is intended for drive gear of dump trucks operating in cold
climate conditions.
The engine ensures reliable operation under following conditions:
- temperature of ambient air from minus 50 up to 50 °С;
- relative humidity of air up to 100 % at temperature of 25 °С;
- circumambience is not explosive, not fire-hazardous;
- height above sea level is no more than 1200 m;
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- engine is resistant to effect of vibration loads over range frequencies from 1 up to 80 Hz with maximum
speedup of 50 мс2 for degree of stiffness "6" in accordance with GOST 16962.2-90;
- angles of bank and trim are no more than 20 °.
Main parts of engine include: magnetic system, armature, end brackets with covers of bearings, brush-
holders.
The traction electric motor (figure 6.14) is four-pole electric direct-current machine with series excitation
with two running ends of shaft. As support of shaft 1 of armature serves single-row ball-bearing 30 located on
side of collector, and single-row roller bearer 40, located on opposite side. Change of direction of armature
shaft rotation in both sides is carried out by switching exciting winding according to scheme (figure 6.15).
System cooling is of forced-circulation type. On air vent, which is fastened to window of nipple 34 (see
figure 6.14) in case on side of collector, cleared cooled air moves in engine. Blowout of air is carried out
through windows located on face surface of end bracket 8, on side of opposite to collector. At mounting of en-
gine on dump truck, reinstallation of nipple 34 and closing 45 on opposite side face of case is supposed.
Choke tubes located on closing 45 and nipple 34 should be placed on side of butt of frame case.
Magnetic system. In frame, executed by steel welded both being case and magnetic conductor of en-
gine, four principal and four additional poles are fixed by bolts 11, 14. Frame has two basic platforms, with the
help of which engine is fastened on dump truck. For visual inspection and maintenance of collector, brush de-
vice and replacement of sweepers four manholes, enclosed by covers 33, are made in frame.
Cores of principal and additional poles 12, 13 are executed blended of sheet electrotechnical steel. Be-
tween cores of additional poles and frame sets of magnetic and not magnetic gaskets 15 providing operation of
engine in zone of safety commutation are installed. Between cores of principal poles and frame adjusting
shims are installed. Coils of principal 7 and additional 16 poles are executed from copper ribbon of rectangular
cross-section and fixed on cores of poles. Between coils of poles and frame there is air gap that augments
area of convective heat exchange from surface of coils.
Heat, produced by windings of poles, is sinked from surface of coils by cooling air coming through en-
gine.
Windings of poles are interconnected by copper tires according to scheme (see figure 6.15), by means of
hard soldering. Lead-out ends 43 (see figure 6.14), and joint of windings of poles with brackets are executed
from multifilament wire with rubber insulation. Each output consists of two wires, joint in parallel. Lead-out wires
go out through bores in frame and rubber inserts 44, and are fixed by pad 42 to clinch 21. Identification mark of
outputs is executed on cable lugs.
From butts of frame bores for mounting end brackets, tapped holes for fastening working end bracket 8
and body-size holes for fastening collector end bracket 27 are executed. On face surface of case on side of col-
lector brackets with brush-holders 18 are fixed. brackets are installed on neutral on factory-manufacturer. Cases
of brush-holders are executed of brass cast, in each of which two sweepers are installed that are held down to
collector by pressure gears 46 of brush-holders with roll springs.
Armature. Basic components of armature is winding consisting of armature coils 6 and equalizers 17,
armature core 39, shaft 1, collector 37 and winding-holder 5. Simple lap winding of armature is executed from
insulated copper wire of rectangular cross-section and stacked in chases of armature core.
Outputs of armature coils and equalizers are joined to collector bars by argon-arc welding. Armature core
is executed blended of sheet electrotechnical steel. Round bores in sheets form two lines of axial ports for pass
of cooling air.
The collector 37 is of arch construction and ensures current lead through sweepers to winding of armature.
Collector ring 38 and taper collector 23, executed of forged steel, at tie with studs 35 and nuts 32 create neces-
sary arch thrust (pressure) holding collector and insulation plates from offset. Between taper and nuts Belleville
springs 25, providing stability of shape of collector at maintenance, are installed. For insulation of collector bars
from barrel and pressure taper two insulation cuffs 20 are installed. In collector ring there are bores which form
with bores of armature core ports for pass of cooling air.
Heat produced in winding and in armature core is taken away from external cylindrical surface of arma-
ture core and from surface of internal ports by cooling air. Winding-holder is of welded steel, and serves for ar-
rangement and fixation of frontal parts of armature coils and security of solidity of armature core.
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Figure 6.14 - Traction electric motor ТЭД-6УХЛ2:

1 - shaft; 2 – thrust ring; 3, 29 - cover; 4, 9, 11, 14, 24, 26, 28 - bolts; 5 - winding-holder; 6 - armature coil; 7 - coil of principal pole;
8 – end bracket; 10 - eye bolt; 12 - core of principal pole; 13 - core of additional pole; 15 - gaskets; 16 - coil of additional pole; 17 - equal-
izer; 18 - bracket with brush-holders; 19 - sensors; 20 - cuff; 21 - clinch; 22 - bracket; 23 - taper collector; 25 – Belleville spring; 27 - end
bracket; 30 - ball-bearing; 31 - thrust ring; 32 - nut collector; 33 - cover of collector manhole; 34 - nipple; 35 - stud; 36 - placard; 37 - collec-
tor; 38 - collector ring; 39 - armature core; 40 - roller bearing; 41, 45 - closing; 42 - pad; 43 - output; 44 - rubber inserts; 46 - pressure gear;
47 - strap; 48 - ledge of brush-holder; 49 - tube of lubrication supply
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Figure 6.14 (continuation) - Traction electric motor ТЭД-6УХЛ2
Direction of rotation Connection of outputs at reversal

From side of drive
From side of drive
Note: Connection B2-D1 or B2-D2 is carried out by control

equipment of dump truck drive
Figure 6.15 - Communication chart of windings

of electric motor ТЭД-6УХЛ2
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End brackets and covers are of bearing type. End brackets 8 and 27 are steel welded. Supporting bear-
ings 40 and 30 are installed in them, bearing 30 perceives axial loads on shaft. On hubs of end brackets bear-
ing covers 3 and 29, defending together with stop rings 31 bearings from hit of dust and mud and forming
chambers for confinement of lubrication, are fixed. Lubricant moves in bearing chambers through oil pipe 49
located on external surface of case, near to lead-out wires, and connected by system of handsets and bores in
case, end brackets and covers. As matter of convenience access to greasers, their reinstallation with plugs lo-
cated on opposite side of case of engine is supposed. Bearing mount assemblies are filled by lubricant
ЛИТОЛ-24. In nodes of bearings 2,5 kg of lubrication is applied.
Temperature, vibration and rotary speed sensors. Engine is equipped with sensors for monitoring tem-
perature of windings of additional poles, bearings, sensor of rotary speed. Output of sensors of 1 m cables in
length with connectors are inferred from upper part of case.
Temperature sensors - thermistors СТ 14-2А-160 (for additional poles) and СТ 14-2А-105 (for bear-
ings). Sensors are connected in sequence.
The sensor of rotary speed - cutout retract non-contact switch, is installed inside engine on bracket in-
stalled on face part of case of engine. Sensors (designation on scheme BR1 and BR2) are intended for feeding
signal about current values of rotary speed of armatures of traction electric motors on electronic blocks.
The sensor is fastened to case of traction electric motor. On external belt of taper of collector, there are
two diametrically located chases at transmitting of which under sensor pulse will be selected. Spacing between
+1
sensor and belt of taper of collector is 2 mm.
At operation of engine, reinstallation of bracket with sensor of rotary speed on diametrically opposite
side of case is supposed.
As speed sensor non-contact retract switch ЭВИ-151 is used. The switch is electric inductance-type trans-
ducer working on closure.
Appearance of speed sensor and scheme of its connection are shown in figure 6.16.
The technical data of speed sensor ЭВИ-151 is specified in table 6.1.
Table 6.1 - Technical data of speed sensor ЭВИ-151
Range of operating voltage, V 10 – 30

Admissible pulsations of supply voltage, % 15
Frequency of switching, kHz 0.6
The maximum current of loading, мА 200
о
Range of working temperature, С From minus 25 to 70
Power consumption no more, V 0.5
Figure 6.16 - Sensor of rotary speed and scheme of its connection:

1 - case; 2 - ring; 3 - nut; 4 - connection; 5 - wires
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6.2.2 Electric apparatuses
6.2.2.1 Control cabinet

The cabinet is intended for rectification of AC voltage, commutation and guard of power circuits and cir-
cuits of excitation of traction alternator, traction electric motors, mounting of ventilated brake resistors, and also
automatic regulation of exciting currents of traction alternator and traction electric motors in composition of
electric drive.
The control cabinet has four demountable cargo bolts and is fastened on dump truck in horizontal plane with six
bolts М16.
The control cabinet Ш9013-48ДК has frame modification with one-sided maintenance of electrical
equipment located in it, contains three consistent doors with weather strips and deputies. On trailing wall of
cabinet stuffing boxes for lead of main leads are located.
On each side wall of cabinet one stud is installed for connection of wires "case" to framework. Besides, on
right side wall cramp "case" for joint of cabinet with case of dump truck is installed. On right side wall socket con-
nections XS20, XS21 for connection of external power supply in mode of driving are installed at garage power
supply.
The control cabinet consists of four chambers. Arrangement of electrical equipment in chambers of con-
trol cabinet is shown in figure 6.17.
In first chamber are located:

- control packages БУ-06 (А1), БУ-09 (А2), БУ-10 (А3) with electronic equipment;
- automatic switches SF1-SF4, QF2 of circuits of steering and auxiliary circuits;
- tubular electric heaters R12, R13 and contactor КМ10 of circuit of heating of cabinet;
- block БПРР1;
- сontact cramps XT1, XT2 for connection of external low-current circuits of cabinet control;
In second chamber are located:

- gate block of adjuster of excitation of alternator;
- power contactors KM4, КМ5, КМ7;
- blocks of voltage dividers БДН2.1. БДН2.2, БДН2.3;
- blocks of reinforcement of power БУМ1, БУМЗ and block of transformers БT1.2;
- resistor R8 of degaussing of alternator;
- tire switches QS1, QS2, QS3.
In third chamber power gate blocks БСВ1 and БСВ2 are located, power rectifiers UZ1, UZ2, diodes
VD1, VD2, thyristors VS6-VS8 of adjuster of excitation of traction electric motors and thyristors VS4, VS5 of
safety against skidding of electric motorized wheels. Third chamber is executed as upcast providing opportu-
nity of operation of power semiconductor devices located in it with forced cooling. Air take-in for fanning is per-
formed through nipple with filters from front side of cabinet. Blowout of air is carried out in air pipe-line, con-
nected to flange on rear wall of cabinet.
In fourth chamber are located:

- power contactors KM1, КМ2, КМ6, contactor КМ3 of excitation of traction electric motors;
- contactor КМ8 and automatic switch QF1 of circuit of excitation of alternator;
- switch QS4 of emergency excitation of alternator;
- relay of maximum current KА1, КА2;
- relay of duplicating of guards KV1;
- contactor КМ9, resistor R9 and diode VD5 of circuit of additional charging;
- current limiting resistor R7 of circuit of adjuster control of excitation of traction electric motors;
- measuring shunt RS1; additional resistance R10, R11 in circuit of voltage meters PV1, PV2;
- socket connections XSZ1 of garage power supply.
The electronic control equipment is located by electric drive in three identical control packages on con-
struction БУ-06, БУ-09 and БУ-10. Each of blocks represents framework with socket connections of connec-
tors on rear wall into which forks of connectors of draw-out blocks moving on guiding framework are inter-
posed. On left side wall of block forks of plug-and-sockets for joint with external electric circuits are fixed.
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The control cabinet 75131-2112010 has frame modification with one-sided maintenance of electrical
equipment located in it, contains four consistent doors with weather strips and locks. On rear wall of cabinet
stuffing boxes for lead of main leads are located. Control cabinet consists of four chambers. Arrangement of
electrical equipment in chambers of control cabinet is shown in figure 6.18.
In first chamber are located:

- power contactors KM4, КМ5, КМ6, КМ7;
- contactor КМ8 and automatic switch QF1 of circuit of excitation of alternator;
- contactor КМ3 of excitation of traction electric motors;
- relay of maximum current KА1, КА2;
- thyristors VS1, VS2 and diodes VD3-VD6 of adjuster of excitation of traction alternator;
- resistor R8 of degaussing of alternator, resistor R9 and diode VD5 of circuit of additional charging;
- switch QS4 of emergency excitation of alternator;
- current limiting resistor R7 of circuit of adjuster control of excitation of traction electric motors;
- measuring shunts RS1, RS2.
In second chamber power gate blocks БСВ1 and БСВ2, into which power rectifiers UZ1, UZ2 are con-
nected, blocking off diodes VD1, VD2, thyristors VS6-VS8 of adjuster of excitation of traction electric motors and
thyristors VS4, VS5 of safety against skidding of electric motorized wheels are located.
The third chamber is executed as upcast providing opportunity of operation of power semiconductor de-
vices located in it, both with natural, and with forced cooling. In latter case take-in of air for fanning is carried
out through nipple with filters from front side of cabinet. Blowout of air is carried out in air main pipe-line, con-
nected to flange on rear wall of cabinet.
In third chamber are located:

- blocks of voltage dividers БДН2.1. БДН2.2, БДН2.3;
- blocks of reinforcement of power БУМ1, БУМЗ and block of transformers БT1.2;
- additional resistance R10, R11 in circuit of voltage meters PV1, PV2;
- relay of duplicating of guards KV1;
- contactor КМ9 of turning on of circuits of initial excitation of traction alternator;
- power contactors KM1, КМ2;
- tire switches QS1, QS3.
In fourth chamber are located:

- control packages БУ-06 (А1), БУ-09 (А2), БУ-10 (А3) with electronic equipment;
- automatic switches SF1-SF4, QF2 of control circuits and auxiliary circuits;
- block of switch of operation modes БПРР1;
- tubular electric heaters R12, R13 and contactor КМ10 of circuit of heating of cabinet;
- contact cramps XT1, XT2 for connection of external low-current circuits of cabinet control;
- kiloammeter PA2.
The electronic control equipment is located by electric drive in three identical control packages on con-
struction БУ-06, БУ-09 and БУ-10. Each of blocks represents framework with socket connections of connec-
tors on rear wall into which forks of connectors of draw-out blocks moving on guiding framework are inter-
posed. On left side wall of block forks of plug-and-sockets for joint with external electric circuits are fixed.
Construction, principle of operation and parameters of electronic draw-out blocks, are explained in tech-
nical description ДЖТИ.656116.003 ТУ "Consistent electronic control equipment for traction electric drives for
dump trucks BELAZ with payload capacity up to 200 t".
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6-24
Figure 6.17 - Arrangement of electrical equipment in control cabinet Ш9013―48ДК

6-25
Figure 6.18 - Arrangement of electrical equipment in control cabinet 75131-2112010

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6.2.2.2 Contactors
Direct-current electropneumatic contactors ПК-1-02 (figure 6.19) are intended for turning on and cutting
off of power circuits of electric drive.
The contactor consist of following basic units: mobile 4 and motionless 5 contact pieces, pneumatic
drive 12, extinguishing chamber 9 and electric blocking 14. All units and parts of apparatus are built on insula-
tion rod 1. Unit of fixed contact consists of bracket 6, arcing ground suppressor 7, principal contact piece 5 and
arcing contact 8. On bracket 2 of movable contact bar 3, carrier contact clip with principal contact piece 4 and
arcing contact 10 are hingedly installed. Principal contact pieces have straps from composition silver-cadmium
oxide and are intended for long transiting of current through them. Arcing contacts have straps from composi-
tion copper-tungsten and are intended for commutation of power current. Bar 11 is connected by insulation
pull-rod 3 to stock of pneumatic drive 12. Drive gear includes cylinder, cutting off spring, stock, bucket and
electromagnetic valve 13. Piston seal is executed by rubber cuff.
For arc control contactor has one-slotted chamber executed as two premolded side members from arc-
resistant material. On exit of extinguishing chamber arc chutes are installed.
Figure 6.19 ― Direct-current electropneumatic con-

tactor ПК-1-02:
1 - insulation rod; 2 - bracket of movable con-
tact; 3 - bar; 4 - principal movable contact; 5 - princi-
pal fixed contact; 6 - bracket; 7 - arcing ground sup-
pressor; 8 - motionless arcing contact; 9 - extinguish-
ing chamber; 10 - mobile arcing contact; 11 - insula-
tion pull-rod; 12 - pneumatic drive; 13 - electromag-
netic valve
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Electropneumatic contactors ПК-753Б9 connects power circuit of electric motors to traction alternator.
Contactor consists of fixed contact 3 (figure 6.20) with arcing ground suppressor 2 and extinguishing chamber
4, movable contact 5, retaining contacts 8 and pneumatic drive controlled by electropneumatic valve 13. All
units are built on insulation panel 1. Technical data of contactor is shown in table 6.1.
Table 6.1 - Technical data of contactor ПК-753Б9

Type ПК753-Б9
Ratings of principal contact pieces:
current, А 830
voltage, V 750
spacing, mm 12 - 19
undershooting, mm 13 - 15
contact pressure, Н 539 - 617
Drive:
voltage of control circuit, V 24
resistance of coil, Ohm 28
Air pressure in pneumatic drive, МPа:
rated 0,5
operating minimal pressure 0,37
Weight, kg 30
At energizing on coil of valve core of electromagnet displaces and connects drive gear of contactor to
pneumatic drive of parking braking system. Compressed air moves in cylinder 12 of drive gear, effects on bucket
and sets in stock 10 which displaces bar 7 with movable contact 5, which completes circuit. At stress relief from
coil of valve turnpike of pneumatic drive is
unhooked from drive gear of parking braking
system, compressed air goes out in aero-
sphere, and contact pieces under operation
of restoring spring are unlocked. Electric arc
originating at contact breaking is blown off
from them by magnetic field formed by arc-
ing ground suppressor, and dies away in
extinguishing chamber.
Figure 6.20 - Electropneumatic contactor ПК-

753Б9:
1 - panel; 2 - arcing ground suppressor;
3 - fixed contact; 4 - extinguishing chamber; 5 - mov-
able contact; 6 - arc-suppressing horn; 7 - bar; 8 - pad
of interlocking device; 9 - block fingers; 10 - stock;
11 - spring; 12 - air cylinder; 13 - electropneumatic
valve;
I - port of input of compressed air
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The electromagnetic contactor SU-610 Ts – dry open contactors with electromagnetic DC-drive. Con-
tactors of this type can be used instead of electropneumatic contactors. Technical data of contactor is shown in
table 6.2.
The contactor consists of fixed contact 11 (figure 6.21) with arcing ground suppressor 9, arc-
suppressing groove chamber 10 arranged with pole shoes, movable contact 13, forcing circuitor 3, magnetic
system (core 17, armature 4, coil of drive gear 2 and forcing resistance 1) and block of free contact pieces.
The movable contact is connected to lead-out tire 14 by flexible connection 15. System of principal con-
tact pieces is built on plastic grounding 6. Contactor is installed in horizontal position on claws 5.
At maintenance it is enough to remove only arc-suppressing chamber for inspection of its condition and
condition of principal contact pieces.
Figure 6.21 - Electromagnetic contactor SU-610 Ts:

1 - forcing resistance; 2 - coil of drive gear;
3 forcing circuitor; 4 - armature; 5 - mounting foots of
contactor; 6 - plastic grounding; 7 - upper connecting
cramp; 8 - spring of contact piece; 9 - arcing ground sup-
pressor; 10 - arc-suppressing chamber with pole shoes;
11 - fixed contact; 12 - catch of chamber; 13 - movable
contact; 14 - lower connecting cramp; 15 - flexible con-
nection; 16 - armature core; 17 - bolt fastening coil;
18 - aluminium washer; 19 - grounding bolt; 20 - bar of
drive gear; 21, 24 - mounting screws of bar of drive gear;
22 - mounting screws of circuitor; 23 - free contact pieces
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Table 6.2 - Technical data of contactor SU-610 Ts
Rated mode of operation long-lasting

Sort of current direct
Principal circuit:
nominal long current, А 630
Rated voltage, V 800
Rated voltage of insulation, kW 5.5
Spacing of contact pieces, mm 13 - 15
Undershooting, mm 4.5 - 7.5
Contact pressure, kg 8.5
Supplementary contact pieces:
rated current, А 10
rated voltage, V 110
Retractable coil, rated voltage, V 24
The electromagnetic contactor МК-6 is intended for commutation of resistors shunting windings of se-
ries excitation of traction electric motors and for connection of exciting winding of traction alternator. Contactors
are installed in control package of control cabinet.
Construction of contactors is of single-block type. All parts are installed on clinch 5 (figure 6.22). Mag-
netic system is of two-bobbin type. Twirl of armatures 2 and 8 occurs on shafts 4 fixed in pads, shock absorb-
ing is performed by springs 3.
The contact system of principal circuit consists of terminal block 7 on which motionless base rings 1 are
installed. In pad 7 there are snapping clinches 9, intended for confinement extinguishing chamber 10. Contact
system of auxiliary circuit consists of two interlock contacts 6 which are fastened motionlessly on clinch 5.
The technical data of contactor is shown in table 6.3.
Table 6.3 - Technical data of contactor МК-6
Contact pieces of principal circuit (closing): Retractable coil:

number of contact pieces 1 voltage:
rated voltage, V 220 rated, V 24
rated current, А 400 retractable (concerning nominal), % 7 - 11
Interlock contacts: resistance, Ohm 8,2
number of contact pieces (closing and unlocking) 4 (2+2) power, W 70
voltage, V 110 Insulance, MOm:
current, А: in cold condition 100
powered up at 110 V 25 in heated condition 20
disconnected at 110 V 2,5 at test on moistureproofness 1,0
nominal (on heat) 10 Weight, kg 6
Figure 6.22 - Electromagnetic contactor МК-6:

1 - base ring; 2, 8 - armatures; 3 - spring; 4 - shaft; 5 - clinch; 6 - interlock con-
tact; 7 - pad contact; 9 - clinch snapping; 10 - chamber
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6.2.2.3 Mounting of ventilated brake resistors

Mounting of ventilated brake resistors is intended for transformation of electric power, which is worked
out by traction electric motors in mode of electric braking operation, in thermal and its diffusings in circum-
ambient. It comprises electrodynamic brake resistance with forced air cooling.
Unit of ventilated brake resistors УВТР2х750 (figures 6.23 - 6.25) consists of two blocks of resistors
and fan, which is driven with electric motor. Each block of resistors consists of two sections in which it is in-
stalled on five elements. Element comprise fechral ribbon curved in sinuous shape and timbered between insu-
lators.
Blocks of resistors are installed in framework 8 (see figure 6.23) on draw-out rollers, which allow to draw
them out for maintenance. Blocks of resistors are fixed in framework by bolts.
Figure 6.23 - Unit of ventilated brake resistors УВТР 2х750:

1 - housing; 2 - guiding; 3 - panel; 4 - protection enclosure; 5 - fan; 6 - air vent; 7, 9 - covers; 8 - framework
Figure 6.24 - Unit of ventilated

brake resistors УВТР 2х750
(left-side view):
1, 2, 3 - main leads; 4, 6,
9 - tires; 5 - lower block of resis-
tors; 7 - upper block of resistors;
8 – framework
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Figure 6.25 - Section of resistor:

1 - plate; 2 - rod with insulators; 3 - resistor; 4 - header; 5 - shaft of roller; 6 - roller; 7 - bracket
The stream of cooling air from fan 5 acts in zone of arrangement of resistors through air vent 6. In front
and rear parts of framework are installed guiding 2 for regulating streamline of cooling air.
On side of exit of air framework is enclosed by protective lattice for prevention of hit in zone of blocks of
resistors of mud and ectogenic subjects.
Accumulation of mud and dust on resistors at continu-
ous exploitation call aggravation of fanning that can serve as
reason of excessive heating. Besides adhesion of mud and
dust to insulators results in aggravation of electrical insula-
tion.
In case of pollution remove cover, put forward blocks
of resistors and delete mud and dust by wood putty knife or
other wood tool.
The axial fan 9 (figure 6.26) is driven by electric motor
of 4 direct-current series excitations. Power supply of electric
motor is carried out from interior of brake mounting. For
power supply power failure on side of brake resistance is
used at leakage of current flow through it, therefore air sup-
ply is made only at connection of mounting in circuit, that is
at braking operation of dump truck.
Figure 6.26 - Fan of brake mounting with electric motor:

1 - plug; 2 - tube of exit of lubrication; 3, 8 - greasers; 4 - electric mo-
tor; 5 - housing; 6 - support; 7 - insulation ring; 9 - wheel of fan; 10 - nut;
11 - lock washer
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Each traction electric motor in mode of electric braking operation is connected to one bank of resistors.
The frame of electric motor has mounting surfaces to pinion point for fastening in housing 5 of fan. For
access to collector and to brush device in frame there are windows enclosed by housing.
The end of motor shaft is cylindrical, with tab and thread part for landing and fastening of axial fan. On
frame, coils of principal and additional poles are fixed.
The electric motor has four brush fingers, mica-insulated by plastic. Fingers are chucked in beam, which
has opportunity to be pivoted on surface of front end bracket.
Lubrication of frictionless bearings is carried out through tubes brought to end brackets.
Mounting of ventilated brake resistors УВТР2х600 (figure 6.27) consists of two banks of resistors 1
and motor-fan 8. Each bank of resistors consists of four elements. Each element represents fechral ribbon
curved in sinuous shape and timbered between insulators. Technical data of mounting is shown in table 6.4.
The axial fan is driven by direct-current electric motor of series excitation. Power supply of electric motor is
carried out from interior of resistor. For power supply power failure on side of brake resistance is used at leakage
of current flow through it, therefore air supply is made only at connection of mounting in circuit.
The frame of electric motor has mounting surfaces to pinion point for mounting in fan casing. For access
to collector and brush device there are windows enclosed by housing in frame.
The end of motor shaft is cylindrical, with tab and thread part for landing and fastening of axial fan. On
frame coils of principal and additional poles are fixed.
The electric motor has four brush fingers, mica-insulated by plastic. Fingers are chucked in beam, which
has opportunity to be pivoted on surface of front end bracket. Technical data of fan is shown in table 6.5.
Lubrication of frictionless bearings is carried out through tubes brought to end brackets.
Figure 6.27 - Mounting of ventilated brake resistors УВТР 2х600:

1 - section of resistor; 2 - framework; 3, 7 - upper covers; 4, 6 - loose straps; 5 - nipple; 8 - motor - fan; 9, 11 - side covers;
10 - plate; 12 - insulator; 13 - tire
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Table 6.4 - Technical data of УВТР 2х600
Sort of current direct

Amount of banks of resistors 2
Nominal resistance of each group, Ohm 1,05
Rated current, А 800
о
The maximum temperature of ribbon, С 750
Weight, kg 550
Table 6.5 - Technical data of electric motor
Type of engine ЭТВ-20М3

Nominal output, kW 18,9
Rated current, А 100
Nominal rotary speed, rpm 3100
Number of brush-holders 16
Mark of sweepers ЭГ74
Sizes of sweeper, mm 10х12,5х35
Maximum permissible height of sweeper, mm 25
Force of pressure to sweeper, Н 3,2 - 3,8
6.2.2.4 Running control unit

The running control unit is intended for turning on of circuits of traction mode. It is installed on grounding
of floor of cabin from below.
The control unit consists of case 4 (figure 6.28) in which are fixed cam elements 1 and shaft 21 with
cams 17. On shaft bar 13, which is connected by pull-rod to drive gear of fuel delivery control is installed.
Cams have figurate excisions for cam elements control.
By pressure accelerator pedal bar 13 is pivoted and pivots shaft 21 with cams 17. If at turning movement
of shaft roller of cam element gets in excision of washer contact pieces 11 become insulated, and on contrary,
contact breaking occurs at hit of roller on protuberance of washer.
The spacing in contact pieces 11 of cam elements in open mode should be (7 ± 3) mm.
Overlapping of rollers of cam elements with washers is made by conveyance lath 3 in axial direction of
shaft.
Regulating of extreme positions of bar and pull-rod of drive gear of running control unit is shown in Op-
eration manual of dump truck.
6.2.2.5 Brake control unit

The brake control unit (figure 6.29) in construction is analogous to running control unit and differs from it
in configuration of cams and scheme of connection of wires. Besides, on shaft of cam drum of brake control
unit selsyn-sensor of БД-160А is installed. Brake control unit is installed on grounding of floor of cabin near to
running control unit.
The bar of control unit 9 is connected to shift pedal of supplementary braking system located in driver's
cab. By pressure treadle bar of control unit is pivoted and pivots shaft 16 with cams, which close and unlock con-
tact pieces of cam elements.
Adjustment of spacing in contact pieces of cam elements, magnitude of spacing in contact pieces is
made in the same way as and in running control unit. Adjustment of drive gear of brake control unit is made by
change of length of tractions 2 and 6 (figure 6.30).
For adjustment disconnect pull-rod 6 from bar 9 of brake control unit and adjust its length so that at con-
nected pull-rod in extreme position of bar 9 restricted to front thrust block of bracket 10, angle between ground-
0
ing of treadle and floor of cabin is (60 ± 5 ). Adjustment of drive gear is supposed to be produced by pull-rod 2.
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6.2.2.6 Probing devices

On control panel in cabin of dump truck three gears for monitoring of operation of power circuits are in-
stalled: two voltage meters М42300.0-1000 B-1.5 for measurement of voltage of traction alternator and amme-
ter М42300.1-0-1кА-1.5, which sum of observations represents current of loading of traction alternator.
Figure 6.28 - Running control unit:

1 - cam element; 2, 7, 23 - bolts; 3 - lath; 4 - case; 5 - wiring harness; 6 - sealing ring; 8, 12 - covers of manholes; 9 - contact bolt;
10 - screw; 11 - contact bridge; 13 - bar; 14 - lock washer; 15, 20 - covers of bearings; 16 - ring; 17 - cam; 18 - insulating washer; 19 -
bearing; 21 - shaft of cam drum; 22 - bracket
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Figure 6.29 - Brake control unit:

1, 7 - cam elements; 2 - case; 3 - wiring
harness; 4 - sealing ring; 5, 8 - covers of man-
holes; 6 - lath; 9 - bar; 10 - cover; 11 - sensor;
12 - flange; 13 - bearing cap; 14 - cam drum;
15 - bracket; 16 - shaft of cam drum
Figure 6.30 - Drive gear of brake control unit:

1 - control pedal of electric braking system; 2, 6 - pull-rod; 3 – protective cap; 4, 5 - bars; 7 - spring; 8 - brake control unit; 9 - bar of
brake control unit; 10 - bracket
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6.2.3 System of fanning and cooling of traction electric drive
System of fanning and cooling is intended for maintenance of optimum temperature operation mode of
components of traction electric drive.
The system of input of cooling air ensures input of air from least dusty zone of dump truck and through
air-slaked cyclonic filter built on power cabinet and cyclone separators, built on front wall of power cabinet (for
dump trucks BELAZ-7514-10/75145), through cyclone separators built on front wall of power cabinet (for dump
trucks BELAZ-75131/75132), air cleared of ectogenic admixtures on suction air duct acts in upstream end of
traction alternator on side of slip rings.
The part of air is used on cooling of traction alternator, passing through air channels (through vent holes
in stator sheets, spacing between poles of rotor, poles of rotor and stator). Passing through spacing air goes
out of alternator through windows protected by grids in case of stator, from side opposite to slip rings.
Other air acts in cooling fan of traction engines and through forcing air vent moves in crankcase of rear
axle and on ports in cases of reducers of electric motorized wheels acts for cooling traction electric motors. Air
goes out through air-vent windows of traction electric motors and bores in cover of manhole of crankcase of
rear axle.
The cooling fan of traction electric motors

Fan wheel in assembly consists of front disk 20 (figure 6.31) and rear disk 15. Between disks on studs
18 aluminium blades 17 (24 units) are installed. Fastening of vanes is carried out by nuts 19. Plate 16 is in-
tended for locking of nuts.
Fan wheel with hub 5 is installed on tab 3 on conic shank of shaft of rotor of traction alternator 2. Hub is
landed on shaft of alternator with tightness and tightened by round split nut 6 with torque 882 - 980 H.m. From
unscrewing nut is arrested by bolts 9, which are among themselves stopped by splint-wire 10. Housing of fan 4
is fixed on end bracket of traction alternator. Gasket 1 between traction alternator 2 and housing of fan 4 and
gasket 13 between cover 8 and housing of fan 4 are installed on adhesive 88 СА ТУ 38.105.1760-89.
Fan wheel in assembly with hub is dynamically balanced. Unbalance should not exceed 24 g.cm in
plane of front disk and 40 g.cm in plane of rear disk. Positional relationship of components is arrested by pins 7
(2 pieces).
Technical condition of product of fan is determined in operation by:
- external examination;
- hearing (noise of operations, vibration).
External examination makes it possible to reveal fault and emersion of cracks of housing with air main
pipe-line 4 or covers 8, fault or wear of gasket 11. By hearing noise of operation and vibrations violation of bal-
ancing fan wheels can be detected.
Repair of cooling fan of traction machines

Repair of cooling fan of traction machines consists in welding up of cracks, replacement of gaskets in
case of fault or wear, replacement of fan wheels.
Disassembly of fan is to be performed as follows:
- lift and lock platform;
- unscrew bolts of propeller shaft fastening from hub of fan wheel 5 and disconnect propeller shaft;
- unscrew bolts 14 of cover 8 fastening and remove cover and gasket 13;
- unscrew nuts 12 and remove gasket 11;
- unsplint and turn out bolts 9;
- turn out nut 6;
- by device squeeze fan wheel in assembly with hub;
A T T E N T I O N : IT IS FORBIDDEN TO PERFORM DISMOUNTING OF FAN WHEEL ON COMPONENTS AS

THUS POSITIONAL RELATIONSHIP OF DETAILS OF BALANCED PACKAGE IS DISTURBED, THIS AT CONSE-
QUENT ASSEMBLY RESULTS IN INCREASE IN UNBALANCE OVER SPECIFIED NORMS AND OWING TO THAT TO
HEIGHTENED VIBRATION OF ALTERNATOR AND DECREASE OF RESOURCE OF ITS BEARINGS.
- take out tab 3 of rotor chase of alternator;

- in case of need unscrew bolts of housing 4 fastening and remove housing and gasket 1.
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Assembly of fan is to be performed as follows:

- install on end bracket of traction alternator 2 housing with air main pipe-line 4 and gasket 1 and fix it
with bolts. Gasket is to be installed on adhesive 88 СА ТУ 38.105.1760-89, bolts – on sealer Унигерм 9 ТУ 6-
01-1326-86;
- install in rotor chase of alternator tab 3;
- press, screwing up nut 6 (torque 882 - 980 N.m) fan wheel in assembly with hub 5 on conic shank of
rotor of alternator. Before landing of wheel with hub on conic shank of rotor reseat and test firmness of fit of ta-
per of rotor to nave boss, surface of fit should be not less than 75 % of all surface of taper;
- lock nut 6 by bolts 9 and splint bolts with splint-wire 10;
- install gasket 11 between hub and cover 8 and tighten nut 12;
- install cover 8 with gasket 13 to housing of fan 4 and fix with bolts 14. Gasket 13 is to be installed on
adhesive 88 СА.
Figure 6.31 - Cooling fan of traction electric motors:

1, 11, 13 - gaskets; 2 - traction alternator; 3 - tab; 4 - housing with air main pipe line; 5 - hub of fan wheels; 6, 12, 19 - nuts; 7 - pin;
8 - cover; 9 - bolt; 10 - splint - wire; 14 - bolt; 15 - rear disk; 16 - plate; 17 - blade; 18 - stud; 20 - front disk
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6.3 Repair of electric machines and apparatuses of traction electric drive

The list of characteristic failures of traction electric drive as whole, alternator, electric motor, electric ap-
paratuses, blocks of resistors and methods of their elimination are shown in Operation manual of traction elec-
tric drive ДЖТИ.655133.029 ИЭ.
6.3.1 Repair of electric machines

Disassembly and assembly of electric machines (traction alternators and electric motors) should be per-
formed with application of standard instruments and special devices.
6.3.1.1 Repair of traction alternators

The principal causes triggering violation of serviceability of alternator are drop of insulance of windings,
breakdown of insulation of winding on case, excessive arcing under sweepers and heightened heat of slip
rings, heightened heat or collapse of bearing.
Besides, reasons of violation of serviceability of alternator can be arrangement of soldered connections
of stator winding in frontal part or outputs of winding, and also arcing of outputs of coils or webs between coils
of poles of rotor, arcing or abruption of connective tire between exciting winding and slip rings. Elimination of
majority of listed failures and faults needs disassembly of alternator and replacement or repair of its compo-
nents.
Repair of alternator is executed by highly skilled mechanics in special locations equipped with necessary
equipment for holding of maintenance jobs.
Before unhooking of alternator from diesel engine lay gaskets (to fill in spacing) between lower poles of rotor
and stator sheets, lift sweepers and envelop slip rings with pressboard, disconnect electric cables and harnesses
from alternator and snug, tie up them with help of rope to frame of dump truck with purpose of prevention from faults
at removal and mounting of alternator.
The order of dismounting and wiring of traction alternator on chassis of dump truck, alignment of traction
alternator with engine is explained in "Systems of engine» chapter.
The order of maintenance:

- remove alternator from underframe and install it on jamb;
- clear external surface of alternator, unhooked from diesel engine, of dust and mud, blow alternator out-
side and inside with dry clean air, clear external surface of assembly unit and parts of pollution.
Air for dusting of separate parts and of alternator as a whole should be dry, cleared of ectogenic admix-
tures and moved under pressure of 0,18 - 0,2 МPа, hose for dusting should not have metal nosepiece.
Clearing of contact or other metal and insulated surfaces of alternator is to be produced by clean dry
pileless napkins (if necessary moistened in benzine or spirit) at powered exhaust ventilation.
For removal of mud, which is densely stuck to component of alternator, use rigid hair sweepers, and
wood or fibre scratchers.
A T T E N T I O N : IT IS STRONGLY FORBIDDEN TO PERFORM CLEARING OF LOW-PURITY SURFACES

OF COMPONENTS AND ALTERNATOR BY CAUSTIC SUBSTANCES.
- clear surfaces of windings, slip rings, brush device of pollution and dust. For removal of stuck mud it is
necessary to use rigid hair sweeper, and also dulled wood or fibre scratcher. If pollution is easily cleared me-
chanically, insulation surfaces should not be sprayed and washed out with any fluid. During clearing or flushing
out it is necessary to ensure sufficient aeration.
If pollution is not cleared mechanically, clearing of alternator, which has arrived on repair, and its com-
ponents from operation pollution is to be performed in washing mounting by washing fluid for which dilute solu-
tions of one of following washing-up liquids are to be applied:
- 0,1-percent solution of МЛ-80 ТУ 84.509-1-82;
- 0,5-percent solution of waste products of "Синтамида 5" ТУ6-02-09-04-82;
- 0,5-percent solution of "Термос" ТУ6-0,2-15325-80;
- 0,1-percent solution of "Термос" ТУ6-02-15325-80 with 0,2-percent solution sodium tripoliphosphate of
GOST 13493-86.
0
Clearing is to be produced at temperature of 70 С for washing fluid with solution of MЛ-80 and waste
0
products of "Синтамида 5" and at 50 - 60 С with solutions of " Термос".
It is supposed to apply to flushing out of alternator in assembly cleaning solution "Лабомид-101" or
"Лабомид-102";
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- after clearing or flushing out produce drying at temperature of 130 - 150 0С before restoring required
values of insulance of units. Thus from moment of termination of clearing or flushing out prior to beginning of
drying should pass not less than 0,5 h.
Insulance of circuits of alternator regarding to case and between windings is to be measured with me-
gohm meter by voltage on 1000 V.
At doing so level of insulance should be:

- not less than 10 MOm in practically cold condition before mounting on dump truck new or past operat-
ing repair and factory repair of alternator;
- not less than 1,0 MOm at stator windings and not less than 0,5 MOm at armature coils\ in practically
cold condition in operation and before putting of dump truck into operation after long parking (more than 15
days);
- not less than 1,0 MOm at stator windings and not less than 0,5 MOm at armature coil in heated condition.
For measurement of insulance of circuits of alternator in assembly concerning case connect output of
gear "GROUND" with any unpainted part of case of stator, and output "CIRCUIT" - to one of output leads «1N,
1U, 1V, 1W» (circuits of first star of stator winding). Winding of other star «2N, 2U, 2V, 2W» and self-excitation
winding should be connected to grounded case. After measurement disconnect winding «2N, 2U, 2 V, 2W»
from case.
Then connect winding of first star « 1N, 1U, 1V, 1W » to grounded case; connect output "GROUND" of
gear to any unpainted part of case, and output "CIRCUIT" - to one of output leads «2N, 2U, 2V, 2W». After
measurement disconnect all outputs from case.
For measurement of insulance of self-excitation winding concerning case connect output "GROUND" of
gear to any unpainted part of case, and output "CIRCUIT" - to one of output leads of self-excitation winding.
At measurement of insulance of rotor in assembled alternator concerning case lift all sweepers (or lay
insulating spacers under sweepers) and connect output "GROUND" of gear with shaft of rotor, and output
"CIRCUIT" - to one of slip rings.
At measurement of insulance of circuits of brush-holders in assembled alternator concerning case lift all
sweepers and connect output "GROUND" with any unpainted part of case of stator or end bracket, and output
"CIRCUIT" - serially to nosepieces of wires "F1" (circuit of brush-holders of one slip ring) and "F2" (circuit of
brush-holders of other slip ring).
In case of detection of insulance decrease due to moistening, perform drying of insulation of windings.
Drying is to be performed by:

- blowing off through alternator of dry hot air (for example, from hot-air heater or special defroster);
- external heating up (for example, in furnace or drying chamber).
Produce measurement of insulance during drying every 30 minutes, and at installed one – every hour.
During drying by both modes value of insulance is depressed owing to evaporation of moisture, then
raises. At kickdown of insulance drying should not stop. After reaching the installed insulance drying should be
continued for 2 - 3 hours more.
0
At drying by blowing off with air its temperature should be no more than 120 - 130 С. During drying
cover of access hatches should be enclosed.
For drying by external heating up dismantle alternator, disassemble it and place separately stator and
rotor in ventilated drying chamber or furnace. Temperature in drying chamber or furnace should be no more
than 100 - 110 0С. During drying temperature should be raised for not more than on 10 0С within one hour.
Before drying of insulation blow alternator (and its components) with compressed air to clear disposable
sections of stator, rotor, brush-holders, suspenders and their insulators of dust, oiling and other pollution. At
drying stator winding and rotor heat gradually (raise temperature for not more, than on 10 0С within one hour).
At sweeping heating up variance in fixed time of heat and in coefficients of linear expansion of winding and ac-
tive steel, and also constructive parts of alternator, can cause faults (ruptures) of insulation.
The traction alternator ГС-525А
Disassembly of traction alternator

Disassemble alternator as follows:
- disconnect and remove from alternator sensor of monitoring of thermal mode of bearing (only on alter-
nator equipped with sensor of monitoring of thermal mode of bearing);
- turn out bolts, remove rod 19 (see figure 6.1) and pad 16, fastening tube of input of lubrication 20 to
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end bracket 21;

- turn out from internal bearing cap 1 tube for lubrication supply;
- unscrew bolts and disconnect from end bracket of cleat 43 and 58, fastening output leads 45, 46, 47,
48, 53, 54, 55, 56 and wires of alternator 49, 50, 51, 52;
- deinsulate and disconnect output leads and wires from outputs of stator winding (it is necessary to re-
member, that bolts of output leads fastening to outputs of stator winding are saved from self-unfastening by
leaf springs and lock washers);
- turn out bolts of fastening and remove external bearing cap 10 by means of bolts rolled in its squeezing
bores. Measure radial clearance in bearing, which should be no more than 0,06 - 0,12 mm;
- install and fix on shaft of rotor 5 clinch for output of rotor from stator;
- output rotor from stator, being careful not to damage slip rings 12, winding and grooving chocks of sta-
tor and lay it on jamb with soft facing;
- turn out bolts of fastening of end bracket and squeeze end bracket 21 by means of bolts turned in its
squeezing bores (it is necessary to support end bracket with crane or other hoisting device);
- lay end bracket on jamb with brush-holders 13 up;
- turn out bolts of fastening of current carrying wires to suspenders 14 and take out sweepers from
brush-holders.
The further disassembly of alternator is to be produced only at detection of any failures of parts of bear-
ing and end bracket.
Disassembly of end bracket is to be carried out as follows:

- turn out bolts, nuts and remove brush-holders 13 from suspenders 14, suspenders from insulators 15,
insulators from brackets;
- turn out bolts and squeeze hub 11 of end bracket by means of bolts turned in its squeezing bores;
- crimp bearing 4 and sealing rings 3 and 6 (only in case of need) by means of remover (bolts of re-
mover should be screwed in bores of internal bearing cap).
At disassembly of end bracket it is necessary to wash out bearing mount assembly and to produce full
re-lubrication. Type of lubrication and its amount is specified in Operation manuals or lubrication charts.
Disassembly of brush-holder is to be carried out as follows:

- unsplint shafts (see figure 6.2);
- extract from case restrictive shaft 2, shaft of spring 7 and lever pin 4;
- remove from case 1 pressure lever 3;
- remove barrels of shafts 5, 6 from lever.
Assembly of traction alternator

Before assembly of alternator perform following operations:
- assemble brush-holders (see figure 6.2) in case of replacement of components;
- assemble end bracket (see figure 6.1) and paint its internal surface with enamel ГФ-92ХС GOST 9151-
75 or ГФ-92ГС GOST 9151-75, and external surface with enamel ПФ-115 GOST 6465-76 or enamel of МЛ-12
of GOST 9754-76;
- measure insulance of windings in cold condition, which should be not less than 10 MOm;
- test electric strength of insulation of windings concerning case by test voltage of 50 Hz within one
minute (see «Trials of alternator after repair» section);
- wash out bearing mount assembly, put in lubricant and assemble internal bearing cap 1 (only in case
of its removal and disassembly);
- put on shaft of rotor internal bearing cap (only in case of its removal or replacement), preliminary hav-
ing laid in groove of cover rubber sealing ring 9;
- put against stop preliminary picked up internal sealing ring 3 (only in case of its removal or re-
0
placement), preliminary heated up to temperature of 120 - 150 С. Before installation of sealing ring cor-
responding mounting surface to pinion point of shaft is to be greased with thin stratum of petroleum oil,
excluding cases when heat is made in lubricated bath;
- heat preliminary picked up bearing 4 to temperature of 100 - 120 0С in lubricated bath and put it on
shaft against stop in shoulders (only in case of removal or replacement of bearing);
- put lubricant in bearing after its cooling (fill in unconfined space of bearing on level with edges of rings)
according to lubrication chart of alternator (lubricant should be pressed through between rollers and separator
between separator and outer ring of bearing);
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- put against stop in bearing external sealing ring 6 (only in case of its removal), preliminary picked up
and heated up to temperature of 120 - 160 0С (before installation of sealing ring corresponding mounting sur-
face of shaft is to be greased with thin stratum of petroleum oil, excluding cases when heat is made in lubri-
cated bath);
- wrap up working surface of slip rings with board or other dense material for protection from mechanical
damages during assembly of alternator;
- grease thread surfaces of bolts and bores, and also mounting surface of case of stator 30 under end
bracket with lubricant ЖРО ТУ32 ЦТ520-83;
- install sweepers in brush-holders so that they did not appear from cartridge clips aside slip rings (bar
on sweepers is not to be installed, but sweeper from side should be propped up by them).
Assembly of alternator is to be carried out as follows:

- moor end bracket for ribs so that inflow for fastening cleats 43, 58 were below from two sides from axis
of yaw;
- bring end bracket 21 to case of stator 30, having combined bores for fastening in board with bores in
case;
- fix with bolts end bracket to case of stator;
- fix on flange of rotor device for mounting rotor in stator;
- lead rotor in stator;
- turn two guiding studs M16 in diametrically located bores of internal bearing cap, pass them through
bores of hub;
- screw nuts М16 on guiding studs;
- press hub on bearing of end bracket by means of guiding studs;
- remove from slip rings electrical insulating board;
- turn out guiding studs from bore of internal bearing cap;
- install and fix with bolts external 10 and internal 1 bearing caps to hub 11, preliminary having laid in ex-
ternal cover rubber sealing ring;
- make gaskets (fill spacing) between lower poles of rotor and stator sheets;
- remove device from flange of rotor;
- install pressure bars of brush-holders on sweepers;
- test by dynamometer pressure of bar of sweepers (on sampling basis);
- screw in internal bearing cap tube for adding lubrication 20 and to fix it to end bracket by means of pad
16, rod 19 and bolts;
- screw greaser 18 in tube for adding lubrication;
- connect output leads and wires to outputs of stator windings;
- fix output leads 45, 46, 47, 48, 53, 54, 55, 56 and wires 49, 50, 51, 52 to end bracket by means of
cleats 43 and 58;
- install and fix sequentially lower and upper housings of board to end bracket;
- install and fix covers 44, 57 of lower housing.
At assembly of alternator bolts of fastening of end bracket and covers of bearings should be tightened
by a little serial screwing of diametrically opposite bolts.
After assembly of alternator perform inspection by visual examination of condition of working surface of
slip rings and barrels, sweepers and brush-holders, correctness of identification mark and arrangement of out-
put leads and wires and also make sure of absence of ectogenic subjects in alternator.
Traction alternator СГД

Disassembly and assembly of traction alternator is to be carried out according to figures 6.4 and 6.6 analo-
gously to alternator ГС-525A.
Traction alternator СГД2

In alternator СГД2 (in contrast to alternator СГД) on side of diesel engine additional bearing is installed.
Construction of bearing mount assembly is analogous to unit from side opposite to diesel engine.
Disassembly of alternator is to be carried out according to figures 6.5 and 6.6 analogously to alternator
ГС-525A, observing additional rules (in connection with presence of two end brackets):
- disconnect tubes 6 and 15 of lubrication of bearings;
- remove external bearing covers 4 and 19 of both bearing mount assemblies;
- remove both end brackets 7 and 14;
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- remove beam 16;

- remove cap 17;
- put pressboard or board on stator bore;
- output rotor 11 aside from drive gear and put on wood bars.
Assembly of traction alternator is made in sequence analogously to alternator ГС-525A, observing addi-
tional rules that are mentioned above and saving air gaps.
The requirements to assembled alternators.

The assembled alternator should match following requirements:
- working surface of slip rings should be without pollution combustive-lubricating and paintwork materi-
als, without burrs, agnails and other mechanical damages;
- barrel between slip rings should be without pollution and faults;
- sweepers should match to brand specified in certificate of alternator, should be preliminary grounded in
on drum, local spallings of crimps at contact area of sweeper of its cross-section should be no more than 10 %,
current carrying wires should be braided on two revolution, bars of brush-holders should be lowered on
sweepers;
- identification mark and arrangement of output leads and wires should match to wiring scheme of joints
and assembly drawing of alternator (see description of alternator).
Inspection of technical condition of alternator parts and methods of their restoring

Sequence of inspection of technical condition of alternator parts:
- after disassembly of alternator is to be blown through with clean compressed air and cleared of pollu-
tion of its components, pay special attention to parallax purity of surfaces of coils of poles;
- test condition of insulation of stator in cold condition by visual inspection and megohm meter. Insulation
should not have cracks, stratifications, coalification, mechanical damages and pollution. Insulance should be
not less than 10 MOm (it is measured after drying in drying chamber by megohm meter on 1000 V).
At mechanical injury of insulation of frontal parts and tires of stator winding produce insulating of
damaged place (tires of stator winding – by ribbon ЛСЭП-934 ТПЛ 0,13х20 GOST 13184-78 and ribbon
ЛЭС 0,1х20 GOST 5937-81, coils – by polyamide film ПМ-A 40х20 ТУ6-19-121-85 and ribbon ЛЭС 0,1х20
GOST 5937-81). Cut insulation in place of its fault, and edges should be cut off on taper. Overlap new insu-
lation sequentially from one edge of cut section to another densely, without folds, blanking of 1/2 width.
Each stratum of insulation should be varnished. General width of overlapped stratums should be not less
than width of basic insulation. At insulance in cold condition less than 10 MOm produce drying insulation by
external heating. After drying it is necessary to cover surface of stator winding with enamel KO-935.
At impossibility of restoring of damaged sections of insulation, at detection of breakdown of insulation on
0
case, and also if insulance gauged at temperature 100 - 110 С (after drying), less than 1,0 MOm send stator
on major repair;
- test by visual inspection condition of soldered joints of stator. There should not be faults and traces of
excessive heating (change of color of enamel). At fault detection and traces of excessive heating test quality of
brazing of stator winding by method of power failure. Places of unsoldering are to be soldered.
At impossibility to solder winding in conditions of garage deliver stator on major repair;
- test by visual inspection and tap test condition of grooving chocks of stator. There should not be
cracks, having chopped off and slackenings of chocks (rattling sound at tap test by hammer at length more
than one third of length of chocks). Replace damaged chocks;
- enamel internal surfaces of stator (except for contact areas of outputs of winding). Surfaces, covered
with enamel, should be equal (without rolls and smudges). Use enamel KO-935 ТУ16-50.4.021-77;
- wash out bearing, internal and external sealing rings, internal and external bearing cap with kerosene,
white spirit or diesel fuel with help of hair brush and napkin. Examine condition of bearing. Replace bearing at
presence of cracks, wears, strain of separator, shelling-out, indents on tracks of rolling and rollers, cracks of
rings;
- test by visual inspection condition of rotor. At fault of shaft and flange send rotor for major repair;
- test condition of insulation of coils of poles in cold condition by visual inspection and megohm meter.
There should not be cracks, stratifications, mechanical damages and pollution. Insulance should be not less
than 10 MOm. Measurements are to be produced by megohm meter on 1000 V.
Cracks, spallings and places of surface blankings of insulation of poles and slip rings are to be removed
with help of epoxide composition of cold curing, which consists of hundred parts of epoxidian pitches ЭД-20
GOST 10587-84, fifteen parts polyethylene-polyamine ТУ6-02-594-80, twenty five parts of oligoether-acrylate
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ТГМ-3 ТУ6-16-2010-82, hundred thirty parts of talc GOST 19729-74 or hundred sixty parts of quartz sand.
Damaged insulation of tires between slip ring and exciting winding should be restored similarly to restor-
ing of insulation of tires of stator. Thus each stratum of insulation should be covered with glueing air-drying
varnish. At insulance in cold condition less than 10 MOm produce drying of insulation by external heating. After
drying it is necessary to enamel surface of rotor.
At detection of breakdown of insulation on case, and also if insulance gauged at temperature of 100 -
110 0С (after drying), less than 0,5 MOm, deliver rotor on major repair. Before sending on repair remove bear-
ing, internal sealing ring and internal bearing cap from shaft;
- test by visual inspection and tap test condition of bolt contact joints of rotor and if necessary tighten
them. At burning of nosepieces of tires of webs and output leads of poles replace them. At impossibility of re-
placement of poles under operating conditions deliver rotor to major repair. After replacement of poles pierce
and balance rotor;
- test by visual inspection, ruler and probe condition of slip rings. Slip rings should have smooth working
surface without traces of flashing off, burnings and pollution. Development under sweepers is to be defined by
measuring by probe light slot between ruler and slip ring. Development under sweepers should be no more
than 0,25 mm.
At radial development more than 0,25 mm pierce and ground working surface of slip rings. There should
not be traces of blanking on surface of barrel between slip rings. After propoint and grinding work of slip rings
blow rotor with compressed air.
Enamel surface of rotor (except for surface of shaft, flange and working surface of slip rings). Surface
covered with enamel, should be equal (without rolls and smudges);
- test by external examination condition output leads and wires of alternator. Restore damaged insulation.
Replace wires and tires at burning of nosepieces, abruption of more than 10 %;
- test by visual inspection condition of brush-holders. Replace out-of-order (damaged) details. Remove
file rolls disturbing free conveyance of sweepers in cartridge clips;
- test retorque fastening of brush-holders to suspenders, suspenders to insulators, insulators to brackets
of end bracket. Slackening of fastening is not supposed;
- enamel internal and external surfaces of end bracket (except for tapped holes, mounting surfaces to
pinion point, suspenders, brush-holders). Surfaces covered with enamel, should be equal (without smudges
and rolls).
For internal surface it is necessary to apply enamels ГФ-92ХС or ГФ-92ГС GOST 9151-75, to external
surface – enamel ПФ-115 GOST 6455-76 or enamel of МЛ-12 of GOST 9754-76;
- install package of new sweepers. Again installed sweepers preliminary should be reseated on special
drum (with diameter equal to diameter of slip rings) on which surface emery paper by speckle of 8 - 10 pres-
sure face to sweepers is installed. Install only sweepers of brand, which is specified in certificate of alternator.
Sweepers should not have chopped off crimps at contact area of more than 10 % of cross-section and should
displace freely in brush-holders. Current carrying wires of sweepers should be braid on 2,5 revolutions;
- wash out and blow with air tube for adding lubrication. Test by visual inspection condition of tube and
greaser for adding lubrication. Tube having cracks, fault of thread and others failures should be replaced;
- test by visual inspection condition of housing, covers of lower housings. Weld cracks in details of hous-
ings, and also in weld seams with consequent square-wave stripping. Smooth out weld seams flush with par-
ent metal. Remove warping of details by editing on plate;
- replace components of board at presence of cracks not permitting reparation and warping;
- enamel internal and external surfaces of housings, covers of lower housings. Restore color image of
warning sign of safety on covers of lower housings. Surfaces covered with enamel, should be equal (without
smudges and rolls).
Trials of alternators after repair

After repair and assembly works carry out following trials of alternator:
- measure insulance of windings in cold condition by megohm meter;
- measure by method of voltmeter and ammeter the resistance of windings to direct current in practi-
0
cally cold condition. Resistance of windings to direct current, shown to temperature of 20 С, should not dif-
fer from shown in certificate more than on 10 %;
- test electric strength of insulation of windings concerning case of alternator and between windings
within one minute at voltage Uисп. of frequency of 50 Hz (voltage at trial is to be applied to each winding seri-
ally, other winding and case of stator or rotor should be grounded):
Uисп. = 2U + 1000, V
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Where U for stator windings is equal to greatest voltage of alternator at durating condition of power, for
exciting windings and autoexcitation U is equal to rated voltage of these windings.
After trial cover external surface of alternator with enamel ПФ-115 GOST 6465-76 (modification УХЛ) or
enamel MЛ-12 GOST 9754-76 (modification Т), and also cover greaser and screw of external bearing cap with
red enamel ГФ-92ХС GOST 9151-75.
In case of storage necessity produce rust-preventive treatment of alternator.
The joint of alternator with diesel engine

At joint of alternator and its centre-drilling with diesel engine:
- inspect spacing between poles of rotor and stator on shaft of poles probe in length not less than 400
mm and width no more than 5 mm;
- open external bearing cap and measure radial clearance in bearing which should be not less than 0,06
mm and no more 0,22 mm;
- install and fix external bearing cap;
- test spacing between brush-holders and working surface of slip ring (under midpoint of brush-holder);
- test on fit on color the surface of conic end of shaft (alternator СГД2) and half-couplings. If imprint is
less than 75 % of mating, or unfitting is present produce mutual abrading of shaft and half-coupling by means
of emery powder;
- test operation of alternator in time of running-in of diesel engine idling at rheostatic trials. Bearing
should work without knock with uniform noise, and surface of abrading of sweepers to slip rings before turn-
ing on of loading of alternator should be not less than 75 % of cross-section. After inspection of operation
blow internal surfaces of alternator with dry compressed air.
After rheostatic trials of dump truck alternator should meet following requirements:
- slip rings should have smooth working surface without traces of flashing off, without burnings and mud;
- radial runout of working surface of slip rings in hot condition should be not more than 0,08 mm;
- sweepers should not have one-sided development of edges, traces of burning, fault and traces of ex-
cessive heating of current carrying wires;
- stator should not have traces of violation of brazing;
- insulation of windings should not have traces of mechanical or electric faults;
- bolted joints should be tightened and have no slackenings.
After rheostatic trials of dump truck apply 0,05 kg of fresh lubrication in each tube for adding lubrication.
Replacement of bearing of alternator ГС-525А without removal of alternator from dump truck
At replacement of bearing it is necessary to wash out bearing mount assembly and to replace lubricant.
Type of lubrication and amount is specified in Operation manual or lubrication charts.
Replacement of bearing should be performed in following sequence:
- clear alternator outside of dust and mud;
- remove from conic end of shaft hub of fan wheel;
- disconnect from end bracket 21 (see figure 6.1) and turn out tube of input of lubrication 20;
- lift sweepers;
- swept shaft of rotor 5 between bearing and slip rings with rope of necessary length with hempen armor
and hinge strains on ends;
- put on hinge strains of rope on hook of hoisting crane;
- stretch rope with help of crane and suspend rotor for removal of loading from its mass on details of end
bracket mated to bearing;
- unscrew bolts and remove external bearing cap 10 by means of bolts screwed in its squeezing bores;
- unscrew bolts, squeeze hub 11 of boring end bracket by means of bolts screwed in squeezing bores
and remove it;
- press bearing 4 and sealing rings by means of mechanical remover (bolts of remover should be screwed in
bores of internal bearing cap), wash out bearing mount assembly;
- test by visual inspection absence of cracks of sealing rings and covers of bearings, absence of burrs,
nicks, agnails on them, absence of burrs on mounting surfaces of shaft (it is supposed no more than three lon-
gitudinal marks by depth up to 0,1 mm);
- measure diameters of corresponding mounting surfaces of shaft of rotor and pick up on them (or use
removed) internal 3 and external 6 sealing rings, and also pick up new bearing. At selection provide tightness
no more than 0,035 mm (or spacing no more than 0,03 mm) for internal sealing ring, 0,013 - 0,055 mm for in-
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ner ring of bearing and 0,01-0,073 mm for external sealing ring;

- install on shaft of rotor internal cover 1 of bearing, preliminary having laid in groove rubber sealing ring
and having filled fresh lubricant in it;
- install against stop internal sealing ring 3, preliminary heated it up to 120-160 0С;
- heat in lubricated bath to temperature 100 - 120 0С preliminary picked up bearing and put it on shaft
against stop;
- put lubricant in bearing (after its cooling) according to lubrication chart;
- put against stop in bearing external sealing ring 6 preliminary heated to temperature of 120 - 160 0С;
- put on bearing, install and fix hub 11 in end bracket 21;
- test radial clearance in bearing, which should be not less than 0,06 mm and no more than 0,12 mm (for
new bearing) or 0,22 mm (for used bearing);
- install and fix external bearing cap 10, preliminary having laid in its groove rubber sealing ring and lu-
bricant;
- screw tube 20 for input of lubrication in internal cover 1 of bearing and fix it;
- install housing and cover on end bracket;
- test operation of alternator idling at least rotary speed of bent shaft of diesel engine. Bearing should
work without knock with uniform noise;
- apply 0,05 kg of fresh lubrication in tube for adding lubrication.
Before installation of sealing rings corresponding mounting surfaces of shaft should be greased with thin stra-
tum of petroleum oil, excluding cases when heat is made in lubricated bath.
Replacement of bearing without removal of alternator СГД, СГД-2 from dump truck is carried out accord-
ing to figures 6.4 and 6.5 analogously to alternator ГС-525A.
6.3.1.2 Repair of traction electric motors
The principal reasons for violation of serviceability of traction electric motors are: drop of insulance of
windings, breakdown of insulation of windings on case, spring coil closure in windings, transfer on collector of
electric arc, violation of commutation (heavy sparking under sweepers, violation of glossy surface of collector,
burning of crimps of sweepers), rupture and drum-out glass-tread of winding of armature, excessive heating or
collapse of bearings, heightened outrun of collector.
For elimination of majority of listed failures and faults removal of electric motor from dump truck, disas-
sembly and replacement or repair of its components is required.
Repair of electric motors is executed by highly skilled mechanics in special locations equipped with nec-
essary equipment for holding of maintenance functions.
At detection of insignificant burnings of collector bars which are not eliminated by wiping by cleaning
cloth, it is necessary to grind collector. Grinding work should be performed by abrasive sticks specially in-
tended for this purpose. For deriving greater exactitude and tall surface smoothness it is necessary to fix sticks
in caliper. It is forbidden to apply to grinding work sand or carborundum paper.
In case of failure detection and faults which elimination needs disassembly of electric motor before its
repair perform following operations:
- clear external surface of electric motor removed from dump truck of dust and pollution, blow electric
motor outside and inside with dry clean air, clear external surface of assembly unit and details of pollution.
Air for blowdown of separate parts and as whole of traction electric motor should be dry, cleared of ec-
togenic admixtures and move under pressure of 0,18 - 0,2 MPa, hose for blowing should not have metal nose-
piece.
Clearing of contact or other metal and insulated surfaces of electric motor should be performed by clean
dry pileless napkins (if necessary moistened in benzine or spirit) at powered exhaust ventilation.
For removal of mud, densely stuck to components of electric motor, use rigid hair sweepers, and also
wood or fibre scratchers.
A T T E N T I O N : IT IS STRICTLY FORBIDDEN TO PRODUCE CLEARING OF LOW-PURITY SURFACES OF

COMPONENTS AND ELECTRIC MOTOR WITH CAUSTIC SUBSTANCES.
Clearing and drying of electric motor which has arrived on repair and its components from operation pol-
lution is to be carried out in washing mounting by washing fluid according to recommendations, specified in
Operation manual;
- measure insulance of circuits with purpose of detection of sections with reduced insulance (the insu-
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lance of windings should be not less than 1,0 MOm);

- test outrun of collector in cold condition which should be not more than 0,04 mm.
Insulance of circuits of electric motor concerning case and between windings should be measured me-
gohm meter by voltage of 1000 V.
Level of insulance should be:

- not less than 10 MOm in practically cold condition before mounting on dump truck of new or passed
operating repair and factory repair of electric motor;
- not less than 1,0 MOm in practically cold condition in maintenance and before lead of dump truck in
maintenance after long parking (more than 15 days);
- not less than 1,0 MOm in heated condition.
For measurement of insulance of circuits of electric motor in assembly concerning case connect output
"GROUND" of gear to any unpainted part of case of magnetic system, and output "CIRCUIT" - serially to
nosepiece of one of wires "Д1" or "Д2" (circuit of principal poles) and "А1" or "В2" (circuit of additional poles,
brush-holders and armatures).
For measurement of insulance of circuits of additional poles and brush-holders in assembled electric motor
concerning case lift all sweepers (or to lay insulating spacers under sweepers) and connect output "CIRCUIT" of
gear with nosepiece of one of wires "А1" or "В2", and output "GROUND" of gear – so, as at measurement of in-
sulance of circuits of electric motor in assembly. For measurement of insulance of circuit of additional poles in as-
sembled electric motor concerning case disconnect wire going from brush-holder to additional pole and connect
output "CIRCUIT" of gear with nosepiece of wire "В2", and output "GROUND" of gear – so, as at measurement of
insulance of circuits of electric motor in assembly.
For measurement of insulance of circuit of brush-holder in assembled electric motor concerning case lift
all sweepers (or to lay insulating spacers under sweepers), disconnect wire going from brush-holder to addi-
tional pole, and connect output "CIRCUIT" of gear with nosepiece of wire "А1", and output "GROUND" of gear
– same as at measurement of insulance of circuits of electric motor in assembly.
For measurement of insulance of separate pole in assembled magnetic system concerning case discon-
nect it from other poles and connect output "CIRCUIT" of gear with one of output leads of coil, and output
"GROUND" of gear – same as at measurement of insulance of circuits of electric motor in assembly. For
measurement of insulance of separate brush-holder in assembled electric motor or in assembled magnetic
system concerning case disconnect it from other brush-holders and connect output "CIRCUIT" of gear with
case of brush-holder, and output "GROUND" of gear – same as at measurement of insulance of circuits of
electric motor in assembly.
For measurement of insulance of armature in assembled electric motor concerning case lift all sweep-
ers, short-circuit collector of armature thin copper noninsulated wire or tire, and connect output "CIRCUIT" of
gear with any plate of collector (wire or tire), and output "GROUND" of gear to armature shaft.
For measurement of insulance between windings in assembled electric motor connect one of outputs of
gear with any of nosepieces of wires "Д1" or "Д2", and other output - to any of nosepieces of wires "А1" or
"В2".
After measurement of insulance unload winding (windings) association to lead-out wires of windings (to
plates of collector) grounded wire, and also remove from collector of armature copper wire (tire).
In case of detection of drop of insulance owing to its moistening carry out drying of insulation of windings
(as in assembled electric motor, and separately armature or poles of magnetic system) by one of methods,
shown for alternator.
Before drying of insulation blow electric motor (and its components) with compressed air to clear dis-
posable sections of armature and magnetic system, brush-holders and their fingers of dust, oiling and other
pollution.
0
At drying, winding should be heated gradually (raise temperature no more, than on 10 C within one
hour). At sweeping heat variance in fixed time of heat and in coefficients of linear expansion of winding and ac-
tive steel, and also constructive parts of electric motor, can cause faults (ruptures) of insulation.
In time of drying covers of access hatches should be closed, and sampling of insulance should be per-
formed by megohm meter with voltage of 500 V.
At each disassembly of electric motor produce washing of bearing mount assemblies and full relubrica-
tion. Type of lubrication and its amount is specified in Operation manual and lubrication charts.
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Traction electric motor ЭД136
Disassembly of traction electric motor

Disassembly of electric motor is to be carried out as follows:
- install electric motor horizontally;
- remove from case of cover of access hatches 1 and 2 (see figure 6.9) and lift sweepers;
- unscrew bolts fastening covers of bearings 6 and 21 (see figure 6.8), remove covers;
- unscrew bolts fastening end brackets 12 and 18, and squeeze uniformly without sidesways end
bracket 12 on side of collector by means of bolts, screwed in squeezing bores of end bracket;
- output armature 25 with end bracket 18 (from drive end) and ball-bearing 4 with bearing cap 9, advanc-
ing armature strictly horizontally in order to prevent fault of collector and winding of armature about brush-
holders, pole or neck of case;
- put armature with end bracket on jamb with soft facing;
- dismantle rings 2 with spring expanders 1 of bores of external sealing rings 5 and 22 on armature from
two sides and remove sealing rings;
- remove from armature shaft end bracket 18;
- heat inductor and remove inner ring of roller bearing 23;
- heat with inductor ball-bearing 4 and remove it;
- remove internal bearing cap 9 on side of collector;
- squeeze from end bracket external package of roller bearing;
- dismantle split collars with spring expanders from inner rings of bearing 3 and 24 on armature and re-
move inner rings with remover;
- disconnect from brush-holders 11 current-carrying wires of electric sweepers and pull out sweepers
from cartridge clips;
- put marks on both straps of fastening of each brush-holder, unscrew bolts of fastening and remove
brush-holders.
It is necessary to remember that straps from one bracket on another can be installed only two by two.
Amount of adjusting shims on each bracket should not vary.
Removal of additional pole is made only if replacement is necessary.
Removal of additional pole is made in following sequence:

- deinsulate and disconnect outputs of additional pole 27 from contiguous additional pole;
- install case of magnetic system 15 vertically with collector chamber up;
- unscrew and pull out average bolt of fastening of additional pole;
- supporting the pole that is being removed on round metal rod in length 1,5 - 1,6 m and diameter 20 -
22 mm, put pole into average bore and cases of electric motor, unscrew and pull out extreme bolts of fastening
of additional pole;
- remove metal rod and pull out pole from case by means of hoisting crane, having moved pole in mid-
point of magnetic system.
Removal of principal pole (only if replacement is necessary) is made in following sequence:

- deinsulate and disconnect outputs of coils and remove additional poles 27, located near to principal
pole 16 that is being removed;
- remove wires between principal contiguous poles;
- install case of electric motor vertically with collector chamber up;
- unscrew and pull out average bolt of fastening of principal pole;
- supporting pole that is being removed on round metal rod in length 1,5 - 1,6 m and diameter 20 - 22
mm, put pole into average bore and cases of electric motor, unscrew and pull out extreme bolts of fastening of
principal pole;
- move pole by means of round rod to midpoint of magnetic system;
- pass soft sling through upper bore in core of pole and pull out pole from case by means of crane.
Removal of brush-holder is made in following sequence (only if repair is necessary):

- disconnect wires from brush-holder 11;
- put labels of twoness on strap and bracket of brush-holder that is being removed;
- unscrew bolt of fastening of brush-holder to bracket and remove brush-holder.
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Disassembly of brush-holder is made in following sequence (only if replacement of out-of-order and

damaged components is necessary):
- unsplint shaft 7 (see figure 6.10);
- fix running end of spiral spring 3 for one of upper teeth of wheel of clamper 5;
- extract shaft from case 4 and remove from case spiral springs with clampers;
- remove spring from clampers.
Replacement of fingers of brush-holders of electric motor is to be carried out as follows:
- cut down one of rivet hands 9, arresting substituted finger 8 with insulator in case of brush-holder 4;
- beat out rivet from bore, squeeze finger from case;
- press new finger in bore of case;
- drill in barrel new bore and to install rivet with formation from both sides of heads.
Assembly of traction electric motor

Before assembly of electric motor perform following operations:
- assemble magnetic system (in case of replacement of poles, brush-holders, wires and tires) with con-
sequent painting its internal surface by enamel ГФ-92-ХС GOST 9151-75. Observe polarity poles. After final
torquering bolts of fastening of poles should not have vibration at tap test by hammer. Wiring of interbobbin
wires should be executed without sharp bends. Contingence of wires to case without insulating spacers and
conveyance of wires inside case is not supposed. Surfaces covered with enamel should be without rolls and
smudges;
- measure insulance of windings in cold condition which should be not less than 10 MOm;
- test electric strength of insulation of windings concerning case by test voltage Uисп. by frequency of 50
Hz within one minute:
Uисп. = 2U +1000, V
Where U is equal to greatest voltage of rectifier of traction alternator at durating power;
- install on armature shaft 25 against stop in butt of shoulder preliminary picked up and heated up to
0
temperature of 120 - 160 С internal sealing rings 3 and 24 (see figure 6.8) and inner ring of roller bearing 23
(in case of their removal or replacement). Before installation of internal sealing rings corresponding mounting
surfaces of shaft should be greased with thin stratum of petroleum oil, excluding cases when heat is made in
lubricated bath;
- install split collars 2 with expanders 1 in bores, preliminary having filled bores by lubricant;
- expose junctions of split collars of sealing in each sealing ring on 1600 and their common shaft ap-
proximately in midposition;
- wrap up collector abrasive paper (pressure face to sweepers) for protection from mechanical damages
in assembly time of electric motor and for consequent abrading of sweepers on collector (length of abrasive
paper should be more on 30 % of length of round of collector);
- fill fresh lubricant of chamber of lubrication and ports for adding lubrication in end brackets and cover
according to lubrication chart of electric motor;
- wash out in petroleum oil external package of roller bearing 23 (the outer ring with rollers), it is recom-
mended to turn multiply separator with rollers in outer ring of bearing and give oil to flow down during one - two
minutes;
- install external package of roller bearing in end bracket 18;
- install cover 9 on armature shaft (on side of collector);
- press ball-bearing 4 on armature shaft;
- install on armature end bracket 18 (from drive end);
- grease thread surfaces of bolts and bores, and also necks of case of magnetic system with thin stra-
tum of lubrication ЖРО ТУ32ЦТ 520-65.
Assembly of electric motor should be carried out as follows:
- install magnetic system horizontally;
- install in case of magnetic system 15 end bracket 12 on side of collector, preliminary having installed
rubber ring 8 for bearing seal. Press and fix board with bolts. Tightening torque of bolts is (700 ± 98) N.m.
Heat-up of neck of case is supposed by induction radiator;
- install sweepers in brush-holders 11 so that they did not appear from cartridge clips aside collector;
- install on armature transport clinch and to inject armature with end bracket into magnetic system, pre-
liminary having tested condition of armature and glass-treads;
- fix end bracket to magnetic system and remove transport clinch from armature shaft;
- install on shaft external sealing rings 5 and 22 from both sides, preliminary heat theim;
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- measure by probe radial clearance in bearings (between upper roller and outer ring of bearing) which
should be not less than 0,09 mm for bearing from drive end and not less than 0,05 mm for bearing on side of
collector;
- measure axial take-off run of armature, which should be 0,6 - 0,9 mm;
- measure face runout of outer rings of bearings which should be not more than 0,12 mm;
- mount split collars with expanders in external sealing rings 5 and 22, preliminary having lubricant in
bores, and expose junctions of split collars of sealing in each sealing ring on 1800 and their common shaft ap-
proximately in midposition;
- install and fix bolts of cover 6 and 21. Through body-size holes in board on side of collector turn, not
torquing, bolts to internal cover to fix bolts of external cover and after that fix internal bearing cap;
- remove board from collector;
- test and expose distance between brush-holder and working surface of collector (the distance should
match to the one specified in assembly drawing);
- reseat sweepers on collector, for that envelop collector with emery paper in length of 1,3 of length of
round of collector and in width that is equal to length of working surface of collector. Lower sweepers on collec-
tor and, twirling armature produce abrading of sweepers. After abrading of sweepers blow electric motor with
dry compressed air;
- test by dynamometer force of pressure of springs to sweepers. It should be 42 - 46 N;
- measure radial runout of working surface of collector in heated condition. Radial runout should be not
more than 0,04 mm at variance between outrun in cold and hot conditions no more than 0,02 mm;
- test absence of contingence of current carrying wires of sweepers to metal parts of electric motor;
- measure insulance of windings of electric motor in practically cold condition. Insulance should be not
less than 10 MOm.
At assembly of electric motor bolts of fastening of end brackets and covers of bearings should be tight-
ened by a little serial screwing of diametrically opposite bolts.
After assembly of electric motor perform visual inspection of condition of working surface of collector,
sweepers and brush-holders, correctness of identification mark and arrangement of wires, and also make sure
(by rotation of hand) of free rotation of armature and in absence of ectogenic subjects in electric motor.
Traction electric motor ТЭД-6УХЛ2

Possible failures and methods of their elimination, maintenance operation of traction electric motor ТЭД-
6УХЛ2 are specified in Operation manual ОБС.460.893 РЭ.
Disassembly of engine
Disassembly of engine is to be carried out as follows:
- disconnect output 43 (see figure 6.14), dismantle working half-coupling, brake and brake plate;
- open collector manholes 33 and extract sweepers from nests of brush-holders 18. Dismantle thermistor
located in external bearing cover 3;
- install engine in horizontal position, turn out bolts 9, 4, remove end brackets, having screwed bolts 9 in
thread squeezing bores of working end bracket 8;
- install engine on special jamb with collector downwards. Output end bracket 8 of lock, having screwed
bolts 9 in thread squeezing bores in bracket. Armature outputs together with bearing mount assemblies. Arma-
ture should be put on special rack storage or jamb with felt or rubber gasket;
- disconnect connecting leads from brackets, remove brackets 18. Delete putty, arresting head of bolts
11 and 14. Blow magnetic system with compressed air, delete accumulated mud and dust. Wipe internal sur-
face of magnetic system with cleaning cloth moistened in benzine;
- examine condition and security of attachment of coils of principal and additional poles, their outputs
and connective tires. Insulation of outputs, external surfaces of coils of principal and additional poles should be
clean, without mechanical damages and burnings. Veins of wires at nosepieces should not have abruptions.
Disassembly and assembly of bearing mount assemblies:

- remove bearing covers 3, 29. Output working end bracket 8 together with outer ring and rollers of bearing
40. Dismantle rings 2 of locking bearings. Dismantle ball-bearing 30 together with end bracket 27 and inner ring
of roller bearing;
- squeeze ball-bearing 30 from end bracket 27 and outer ring with rollers from end bracket8. It is forbid-
den to press off bearings, making efforts on rollers or separator. Do not admit falling of bearings;
- before assembly wash out bearings in benzine, wipe with clean soft napkin and dry them. Cover rollers
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and separator with lubricant ЛИТОЛ-24. Bearing chambers of end brackets and bearing covers, and also oil
tubes carefully should be washed out with benzine and blown with compressed air;
- ports of feeding of lubrication, sealing grooves and bearings to fill completely with lubricant ЛИТОЛ-24,
and fill chambers of boards and covers on 50 % of their volume. Expenditure of lubrication on unit of bearing
40 - 2,5 kg, on unit of bearing 30 - 2,5 kg;
- at mounting of bearing covers combine its oil-drain chases with bores in end brackets;
- before wiring internal bearing rings heat them in lubricated bath up to 100 0С. Contingence of rings
about walls and bottom of metal bath at heat is not supposed;
- at wiring do not admit sidesways and strong impacts on rings of bearings;
- test conformity of bearings to nameplate data of engine. Pay attention to absence of visible faults of
bearings (quality of separator), absence of ectogenic turnings on in lubricant;
- in case of detection of specified imperfections, and also cracks and shells in details, bearings should
be replaced.
Disassembly, clearing, visual inspection and assembly of brush device:

- disconnect nosepieces of outputs of sweepers from brackets 18, and brackets from brackets 22. De-
lete with clean napkin, moistened in benzine, dust, mud, traces of lubrication from surfaces of brackets and
brush-holders;
- test condition of sweepers. At presence of chopped off scratches with depth more than 1 mm, and also
before reaching protuberance of strap 47 on sweeper of ledge of brush-holder 48 replace sweepers on all
brush-holders on new. Brushes brand is specified in certificate or Operation manual on concrete electric motor;
- test condition of brackets 22. Surface of brackets should be clean, should not have chopped off depth
more than 2 mm, cracks, burnings. Traces of burnings and cracks on case of brackets are inadmissible;
- test sizes of windows of brush-holders under sweepers. Test condition of cases of brush-holders. On
cases there should not be cracks and traces of burnings from transfers of arc and circular fire. On surfaces of
windows there should not be cracks, nicks-and-burrses. Pressure gears should not be separated any way from
brush-holders at their deduction from fixing. Disassembly of brush-holder should be carried out only in case of
need of its repair;
- connect brackets 18 with brackets 22, and nosepieces of brush-holders to brackets 18. Install spacing
between brush-holders and working surface of collector from 2 up to 3,5 mm.
Clearing and visual inspection of armature:

- clear armature of dust, mud and traces of lubrication, blow with dry compressed air;
- test insulance of winding of armature, if necessary produce drying of insulation. Drying of windings
should be produced according to instruction «Drying of large electric machines of alternating and direct-
current», included in package of operation documentss of traction electric motor. If after drying insulance of
winding is not rebuilt, replace armature;
- examine collector. Its working surface after normal operation in maintenance should have brilliant pol-
ished surface of brown tincture (polish liquid) without scratches, marks, torquering of copper in spacing be-
tween plates and burnings. In all cases of fault of working surface of collector and at depth of chases in insulat-
ing spacers between plates of collector less than 0,5 mm restore working surface of collector (see Operation
manual ОБС.460.893 РЭ);
- working surface of collector should be wiped with soft napkin moistened in engineering spirit or ben-
zine. Nicks-and-burrses from torquering should be deleted by rigid nonmetallic sweeper. If assembly of engine
is impeded, wrap up working surface of collector in strong paper or board;
- put armature on special rack for storage or jamb with felt or rubber gasket;
- measure firmness of fit of inner rings of bearings to face surfaces of rings 31. Local spacing should be
not more than 0,05 mm in zone and no more than 50 mm in diameter;
- examine insulation of taper collector 23. It should be equal, glossy, without strong dust, without burns,
scratches and surface tears.
Assembly of engine
Before assembly clear of dust and mud all details and units of engine. Delete nicks and rust on mounting
surfaces.
Assembly of engine should be performed only after heat of magnetic system to temperature from 70 up
to 100 °С, in connection with execution of installation of end brackets with tightness.
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Assembly of engine is to be carried out as follows:

- install brackets with brush-holders 18 on brackets 22, connect connecting leads to brackets according
to connecting circuit (see figure 6.15);
- install magnetic system vertically with brush device downwards on special jamb;
- start armature in magnetic system, install bolts 9 (see figure 6.14), fastening working board 8 in tapped
holes of frame. Set armature into position, having turned bolts. Install bolts 9, fastening end bracket on side of
collector;
- install thermistor in bearing cover 3;
- adjust distance between surface of collector and cases of brush-holders from 2 up to 3,5 mm;
- at reduction of brush-holder and sweeper into position roll of spring is installed on sweeper. At mount-
ing into position it is necessary to shift pressure of fingers by pressure gear downwards and to make sure, that
protuberance of strap 47 goes into special flutes of case of brush-holder 48. it is necessary to dissolve current
carrying stranded wires of sweepers and not to suppose conveyances of working stroke of spring snug.
The normal operation of brush-collector unit is ensured at level of outrun of collector in heated condition
no more than 0,04 mm.
Outrun of collector no more than 0,06 mm, if it does not result in aggravation of commutation of engine,
is admitted in operation.
Violation of normal condition results in emersion of cracks in springs. Integrity of springs should be
checked every 6 months of operation. Pressure of spring - not less than 3,2 kg on sweeper. At presence of
cracks in springs, it is necessary to replace pressure gears by new, identical ones.
The traction electric motor of ДК – 722Е
Disassembly of engine
- install engine vertically with collector up, on jamb defending rear end of shaft and providing support of
electric motor on rear end bracket 22 (see figure 6.7);
- unscrew bolts 13 fastening end bracket 11 to frame 14. Insert these bolts into squeezing bores of
board and, uniformly twirling them, to squeeze board. Turn out squeezing bolts;
- cautiously, preserving against impacts take out armature shaft 1 together with board, drawing through
outputs through rubber inserts. Put armature on special rack for storage or jamb with felt or rubber gasket, ar-
mature should not be rested on end bracket;
- for disassembly of bearing mount assemblies unscrew nuts 6, bolts 23 and remove covers 5 and 25.
If on collector there are burrs, outcome of separate plates, under sweepers 9 or outrun of surface more
than on 0,08 mm collector should be notched and grinded. Before propoint armature should be heated in fur-
0
nace to temperature 120 - 140 С and collector bolts should be tightened.
The outrun of collector in heated condition should not exceed 0,04 mm while in operation. Variance be-
tween outrun in cold and heated condition - no more than 0,02 mm. Minimum diameter of collector at wear or
turning - 327 mm.
In traction electric motor sweepers of brand ЭГ-84 by cross-section 2х12,5х32 mm are applied. Allow-
able wear of sweepers on altitude - 25 mm.
The force of pressure of finger to sweeper should make 28 - 32 N. Testing of force is made by dyna-
mometer ДПУ-0-2. Adjusting of force of pressure of finger on sweeper is carried out by adjusting screw.
Damaged sections of insulation of windings insulate with glass-calico ribbon, and cover with insulation
enamel ПКЭ-19 and dry.
Inspection of insulance concerning case of electric motor and between windings is made by megaohm
meter on 1000 V serially for every circuit having separate outputs, at electric joint of all other circuits with case.
After measurement of insulance of every circuit unload its electric joint with grounded case.
Insulance of windings of electric motor concerning its case and between windings should be not less
than 7,0 MOm in cold condition, 1,0 MOm in heated condition (after trial on heating up in control condition).
Maximum deviation of resistance of all windings of electric motor in cold condition should be + 6 %.
If resistance between winding and case is less than above-stated dry electric motor with hot air with
temperature of 100 - 120 0С or current flow 270 - 310 A. At drying by current every two minute turn armature
on some angle. Manholes of collector chamber and output air-vent windows in rear end bracket should be
open.
At drying by current flow each hour measure temperature and insulance. First two-three hours tempera-
ture of windings should not be raised above 50 - 60 0С, and through 6 - 8 hours after beginning of drying – not
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higher than 70 0С.

In time of drying insulance of windings first drops, then starts to raise and, at last, is installed fixed or
raises a little. After setting of fixed resistance continue drying within two-three hours, and if change of resis-
tance is insignificant drying can be finished.
Assembly of engine
- wipe gudgeons of armature shaft 1 by cleaning cloth moistened in benzine;
- wash out bearings, labyrinth grooves and internal surfaces of end brackets;
- heat ball bearing 4 and inner ring of roller bearing 26 in motor oil to temperature 80 - 90 0С and keep it
during 10 - 15 minutes;
- install on armature shaft 1 internal cover 7, ball bearing 4 and slit barrel 3;
- install inner ring of roller bearing 26 on armature shaft;
- install outer ring of roller bearing 26 in end bracket 22 from drive end;
- put lubricant in bearing and cover 25. Type and amount of lubrication is specified in lubrication chart
and Operation manual. Grease mounting faces with lead oxide red. Tighten cover with bolts 23, having laid
washers;
- install inductor on jamb collector manholes downwards;
- wipe mounting faces of end bracket 22 by cleaning cloth moistened in benzine;
- install end bracket 22 and tighten bolts, having laid washers under it;
- install board 11 on armature shaft with ball bearing 4, preliminary having put lubricant in internal cover
7 and bearing 4;
- grease mounting surfaces of external cover 5 and board with 11 lead oxide red;
- put lubricant in cover 5 of bearing;
- install cover on board and tighten its nuts 6, having laid washers under it;
- install engine vertically with collector up on jamb providing support of electric motor on rear end
bracket 22;
- cautiously, preserving against impacts insert armature shaft 1 together with board 11, drawing through
lead-out wires through bores in board;
- turn bolts 13 fastening end bracket 11 to frame 14;
- connect waste of lead-out cable to brackets of brush-holders;
- install on collector 8 package of brush-holders 10;
- put sweepers 9 in brush-holder;
- install engine horizontally;
- install slit barrel 3 on armature shaft 1 on side of end bracket 22;
- through press-greaser apply 50 g of lubrication in each bearing mount assembly.
The traction electric motor ЭК-420А
Disassembly of electric motor

- install engine horizontally on lodgement;
- remove covers of collector manholes 1 (see figures 6.12), take out sweepers 4 of brush-holders 5,
wrap up collector with dense paper and tie with twine;
- disconnect wire connecting brush-holder with additional pole;
- disconnect wire connecting brush-holder with tire, transiting through coil of additional pole to output Я1;
- unscrew bolts 7 fastening front end bracket 6 to frame 8, and, unscrewing them in squeezing bores
squeeze board from frame;
- install fastening device on end of shaft 13 and fix it;
- cautiously, preserving against impacts take out armature 11 together with end bracket 6 of frame;
- put armature on wood saddle linings or rack storage without support on board;
- if necessary disassembly of bearing mount assemblies is made in front bearing mount assembly by un-
screwing nuts 3 and removing cover 2, and in rear bearing mount assembly – unscrewing bolts 10 and removing
cover 12.
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Assembly of engine
- wipe gudgeons of armature shaft 13 with cleaning cloth moistened in benzine;
- wash out bearings, labyrinth grooves and internal surfaces of end brackets;
- heat ball bearing and inner ring of roller bearing in motor oil to temperature 80 - 90 0С and keep it dur-
ing 10 - 15 minutes;
- install on armature shaft 13 internal cover, ball bearing and barrel;
- install inner ring of roller bearing on armature shaft 13;
- install outer ring of roller bearing in end bracket 9 from drive;
- put lubricant in roller bearing and cover 12. Type and amount of lubrication is specified in lubrication
chart and Operation manual. Tighten cover by bolts 10;
- wipe mounting faces of end bracket 9 by cleaning cloth moistened in benzine;
- install end bracket 9 and tighten bolts, having laid washers under it;
- install board 6 on armature shaft with ball bearing, preliminary having put lubricant in internal cover and
bearing;
- To put lubricant in external cover 2 of bearing;
- install cover on board and tighten its nuts 3, having laid washers under it;
- install fastening device on end of shaft 13 and fix it;
- cautiously, preserving against impacts insert armature shaft 13 together with board 6;
- turn bolts 7 fastening end bracket 6 to frame 8;
- connect wire connecting brush-holder with tire, transiting through coil of additional pole to output Я1;
- connect wire connecting brush-holder with additional pole;
- install sweepers 4 in brush-holders 5, install covers of collector manholes 1.
The requirements to assembled electric motors

After assembly electric motors should meet following requirements:
- working surface of collector should be without pollution combustive-lubricating and paintwork materials,
without burrs, agnails and other mechanical damages. Facets on crimps of collector bars should be by all
working part of collector, grooves between collector bars should be depth 0,5 - 1,5 mm and without pollution,
binding on cuff of collector should be without mechanical damages;
- sweepers should be preliminary smoothed, local spalling of crimps at contact area of sweeper of its
cross-section should be not more than 10 %, pressure gears of brush-holders should be lowered on sweepers;
- identification mark and arrangement of wires should match to wiring scheme of joints of electric motor;
- armature should be twirled manually without jam, in bearings there should not be knocks at extreme
positions of armature;
- in electric motor there should not be ectogenic subjects.
After assembly install electric motor on test-bed and apply no-load tests during 30 - 40 minutes at rotary
speed 500 - 600 rpm with purpose of validation of assembly and wear-in of sweepers on collector. Bearings
should work without knocks with uniform noise, and contact area of abrading of sweepers to collector after
running-in should be not less than 75 % of its cross-section. After validation of assembly and wear-in of
sweepers on collector blow internal surfaces of electric motor with dry compressed air.
After maintenance produce trials of electric motor. Test methods, sequence of execution of operations
and technical requirements should match GOST 2582-81.
At trials of electric motor it is necessary to be guided by following rules:

- resistance of windings to direct current in practically cold condition should not differ from values, shown
in certificate of electric motor more, than on 10 %;
- trials on heightened rotary speed should be carried out at rotary speed exceeding on 25 % greatest rotary
speed, within two minutes at idle running of heated electric motor;
- trial of electric strength of spring coil insulation of windings should be carried out at heightened voltage
on 50 % over nominal within 5 minutes;
- outrun of collector on heated electric motor should be no more than 0,04 mm, and variance between
outrun in cold and hot condition should be no more than 0,02 mm;
- insulance of all windings concerning case of electric motor and between windings in heated condition
should be not less than 1,0 MOm;
- trial of electric strength of insulation of windings concerning case of electric motor and between windings
should be carried out within one minute with test voltage Uисп of frequency of 50 Hz
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Uисп. = 2U + 1000, V
- inspection of commutation, rotary speed and reversing should be carried out only at replacement of
poles or armatures, pay attention to presence of necessary gaskets in straps of brush-holders intended for
mounting of neutral.
At trial of electric motor there should not be circular fire and mechanical damages. Collector and brush-
holders after trial should be suitable to further operation without clearing and any reparation.
After trials electric motor should meet following requirements:

- collector should have smooth from bright up to dark brown color working surface without traces of flash-
ing off from transfers of electric arc, without burnings, filter sludging of copper and pollution;
- contact area of wear-in of sweeper to collector should be not less than 75 % of its cross-section and
should not have double smooth surface;
- sweepers should not have one-sided development of edges, traces of burning, fault and traces of ex-
cessive heating of current carrying wires;
- collector should not have traces of violation of welding of waste of sections in risers;
- bindings should not have cracks, stratifications and burrs;
- insulation of windings should not have traces of mechanical or electric faults;
- bolted joints should be tightened and should not have slackenings.
After execution of all maintenance operations:

- install covers of access hatches;
- cover surfaces of electric motor with enamel ПФ-115 or MЛ-12.
In case of sending electric motor on storage perform its rust-preventive treatment.
6.3.2 Repair of electric apparatuses

Possible failures, maintenance operation, repair and adjustment of apparatuses of traction electric drive
are specified in operation manual (ДЖТИ.655133.029 ИЭ) and instructions on adjustment (75131-2100030И)
of traction electric drive for dump trucks with payload capacity of 120-130 t.
6.3.2.1 Repair of running control unit

While in operation of running control unit can appear such failures, as wear or burning of contact pieces,
slackening of fastening of fixed contacts or contact joints.
Replacement of contact pieces and retorque of fastenings can be produced without removal of control
unit from dump truck. For this purpose unscrew screws 10 (see figure 6.28), fastening side 8 and lower 12
covers and remove them. Disconnect wires from contact bolts 9, roll lock nut and nut of their fastening and re-
move contact bolts.
For dismounting control unit from dump truck disconnect wires from terminal block and pull-rod from bar
13, unscrew four bolts of fastening of control unit to grounding of cabin and remove it.
Disassembly of control unit is to be carried out as follows:

- unscrew screws 10 fastening side 8 and lower 12 covers and remove them together with gaskets;
- disconnect wires from contact bolts 9;
- unscrew bolts 23 and remove lath 3 in assembly with cam elements 1;
- unscrew bolts of 2 fastening cam elements to lath and remove them;
- if necessary unscrew lock nut and nut of fastening of contact bolts 9 and remove them;
- disconnect contact bridge 11 from bar of cam element;
- unscrew bolt 7 and remove bar 13 from shaft 21. Take out tab from keyway of shaft;
- unscrew bolts of fastening of covers 15 and 20 and remove them;
- extract drum of control unit from case;
- press bearings 19 from shaft;
- unfasten and unscrew nut and remove from shaft lock washer 14, ring 16, cams 17 and insulating
washers 18.
Assembly and mounting of running control unit should be carried out observing following requirements:
- at assembly of drum locating holes of cams 17 and keyway of shaft place in one plane, and identifica-
tion mark of cams should be directed aside keyway;
- before mounting of cam drum in case of cavity of ball-bearings 20 fill lubricant Литол-24;
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- install spacing between contact pieces in open condition conveyance of lath 3 together with brackets
22 in longitudinal bores of case;
- overlapping rollers of cam elements 1 with cams is made by offset of lath 3 in axial direction concern-
ing bracket 22;
- test spacing between contact pieces of cam elements which should be 2 - 3 mm at neutral (vertical)
position of bar 13. Clearance adjustment is ensured with editing of cross-section of cam.
6.3.2.2 Repair of brake control unit

Characteristic failures, order of removal from dump truck, disassembly, assembly and requirements at
repair of brake control unit are same as for running control unit.
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Electro-motor-wheel
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7 ELECTRO-MOTOR-WHEEL
7.1 General information
Electro-motor –wheel is fastened to casing of back axle and switches on traction motor 2 (figures 7.1 or
7.2), reducer 8, back wheel hub 4, brake gears of service 3 and parking 1 brake systems and induction sensor
of speed limit.
Brake gears of electro-motor –wheels of trucks BELAZ -7514-10/75145 (payload capacity 120 t) – block,
service brake gears are fitted on the body of motor-wheel reducer, parking ones – on the end bracket of trac-
tion motor (from the side of collector), brake gears of electro-motor wheels of trucks BELAZ -75131/75132
(payload capacity 130 t) – disk, service and parking brake gears are fitted on end bracket or frame of traction
motor.
Reducer of motor wheel – double-row, differential, with spurs, is mounted in the hub of rear wheel. Reducer of
the trucks BELAZ -7514-10/75145 is differ from reducer of trucks BELAZ-75131/75132 by gear ratio, dimensions of
parts and their embodiment.
Technical state of reducer is defined in the operation process:

– by external examination;
– orally (operation noisiness);
– by heat rate.
Under external examination on oil leakage it ‘s possible to discover wear or damage of collar, as well as
precipitation of pores and cracks in body, body or hub. Random breakdowns or parts strengthening weakening
can be orally discovered. By heat disturbance of bearing adjustment or oil level change at the reducer can be
discovered.
7.2 Repair of electro-motor wheels
7.2.1 Removal of electro-motor wheel from the truck
Removal of electro-motor wheel from the truck is realized in the following way:
– with the help of special hydraulic elevator or hoisting crane put up the necessary axle side (previously
having made measures, excluding spontaneous truck movement getaway) and install the rest under the back
axle housing ;
– unfasten and remove from the wheel (see section «Running gear»);
– turn the reducer center in order to the cork of drain hole 5 (see figures 7.1 or 7.2) will be down, screw off
it and pour out the oil;
– cut off the hose of high pressure from the cylinder of service brake system(for electro-motor wheels of
trucks BELAZ -7514-10/75145), hoses of high pressure from the cylinders of service and parking brake sys-
tems (for electro-motor wheels of trucks BELAZ-75131/75132);
– cut off leading-outs of electric engine from power cables and unfasten them ;
– disconnect the plug of cylinder rod extender of parking brake system (for electro-motor wheels of
trucks BELAZ -7514-10/75145), having taken off the finger;
– cut off cable assembly from the sensor of speed limit;
– cut off hoses for lubrication of electric engine bearings (if necessary) (for electro-motor wheels of
trucks BELAZ -7514-10/75145);
– take off elastic socket for supply of cooling air to the traction motor (for trucks BELAZ-75131/75132);
– unscrew bolts 7 and take off cap 11 of the reducer and packing ring. Remove retaining ring 10 and so-
lar gear 9 of the first row from the torsion shaft 12, remove torsion shaft;
– unscrew bolts and nuts of electro-motor wheels fastening to the back axle housing;
– fasten reducer of motor-wheel (for trucks BELAZ-7514-10/75145) by adoption (figure 7.3), install the
rest (figure7.4) to the loader (for trucks BELAZ-75131/75132)and by means of bolts, screwing into squeezing
holes of reducer body, disconnect electro-motor wheel from the housing of back axle. Suspension (figure 7.5)
is intended for fastening and transportation of motor-wheels (for trucks BELAZ-7514-10/75145);
– fasten traction motor by ring-bolts or adoption (figure 7.6) (for trucks BELAZ-75131/75132) and un-
screw bolts 15 ( see figures 7.1 or 7.2) of traction motor 2 fastening to the reducer 8 body,
– cut off by means of bolts, screwing into the squeezing holes of traction motor, traction motor from re-
ducer and take aside;
– unscrew bolts of torsion shaft 13 flange fastening to the flange of traction motor 14 and remove it;
– unscrew bolt of traction motor flange fastening and remove flange 14.
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Figure 7.1 –Electro-motor wheel of the truck BELAZ -7514-10/75145:

1 –parking brake mechanism; 2 –traction motor; 3 –service brake system; 4 –hub of back wheel; 5 –plug of drain hole; 6 –plug of
filling hole; 7, 15 –bolts; 8 –reducer; 9 –sun gear of first row; 10 –locking ring; 11 - cap; 12 –torsion shaft; 13 –flange of torsion shaft;
14 – flange of traction motor
Figure 7.2 – Electro-motor wheel of the truck BELAZ -75131/75132:

1 –parking brake mechanism; 2 –traction motor; 3 –service brake system; 4 –back wheel hub; 5 –plug of drainage hole; 6 –plug of
filling hole; 7, 15 – bolts; 8 –reducer; 9 –sun gear of first row; 10 –locking ring; 11 – cap; 12 –torsion shaft; 13 – flange of torsion shaft;
14 – flange of traction motor
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Electro-motor-wheel
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Figure 7.3 –Suspension 7808-7263 for fastening of motor-wheel reducer of the truck BELAZ-7514-10/75145:
1 – reducer of motor-wheel; 2 – mooring
Figure7.4 –Support 360-007 for removal and mounting of electro-motor wheel of the trucks BELAZ-75131/75132:
1 –cross-beam; 2 – lengthwise beam; 3 – chain; 4 – rear rest; 5 –front rest; 6 – hook; 7 – rest; 8 –inner beam; 9 – roller
7-3
Electro-motor-wheel
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Figure7.5 –Suspension 7808-7061 for fastening and transportation of motor-wheel of trucks BELAZ-7514-10/75145:
1 – lug; 2 – thimble; 3 – rope; 4 – ring; 5 – cramp; 6 – finger; 7 – electric motor-wheel
Figure7.6 – Adoption 360-001 for removal and mounting of traction motor

of electro-motor wheel of trucks BELAZ-75131/75132:
1 – reducer of motor wheel; 2 – finger; 3 – bracket; 4 – loader L-34 or 4045; 5 – traction motor; 6 – support 360-007; 7 – cross-bar
7-4
Electro-motor-wheel
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7.2.2 Dismantling of reducer

Realize dismantling of reducer in the following way:
– unwrench bolts and nuts 43 (figures 7.7 or 7.8), take out ring 44, squeeze collar 45;
– put the body of motor-wheel reducer to the vertical position and hub up;
– unwrench drain cork 13, unwrench bolts 12 and by means of bolts , screwing into the squeezing holes,
take off driving cap 14 as assembly with first row and solar gear of second row 23, adaptation 360-008
(рисунок 7.9) is intended for removal and mounting of cage of first row without removal of electro-motor wheel
and tires from the truck;
– remove packing ring 35 from the driving cap;
– dissplint and unwrench bolts 21 and remove 2 tightening plates 22 (semirings) of solar gear of second
row 23;
– unscrew bolts 32, and by means of bolts, screwing into the squeezing holes, take off cap of the first
row 16 cage;
– remove packing ring 31 from the cage cap;
– extract the cage as assembly with satellites and bearings;
– press from the cage 17 bearings 19;
– dismantle cage, having disspinted and unwrenched fastening bolts 29 of tightening plates of satellites
axes and having removed plates 27, having squeezed axes 26 and removed satellites 24;
Figure7.7 – Reducer of motor-wheel of truck BELAZ-7514/75145:

1 – reducer body; 2 – undercollar ring; 3 – clamp; 4 – spacer ring; 5, 12, 21, 29, 32, 36, 43,47 – bolts; 6 – collar; 7 – hub; 8, 19, 25,
38 – bearings; 9 – crown gear of second row; 10 – stop collar; 11 – regulating bolt; 13 - drain plug; 14 – drive cap; 15 – crown gear of first
row; 16 – cap of first row cage; 17 – first row cage; 18 – control plug; 20 – reducer cap; 22, 27, 37 – locking plates; 23 – sun gear of sec-
ond row; 24 – satellite of first row; 26 – axe of first row satellite; 28, 31, 35 – packing rings; 30, 39 – locking rings; 33 – stop bolt;
34 –lubricator; 40 – crown gear of second row; 41 – satellite of second row; 42 – axe of second row satellite; 44 – ring; 45 – collar;
46 – axe of brake shoe; 47 – brake drum
7-5
Electro-motor-wheel
7513-3902080 RM
– squeeze bearings 25 from satellites;

– take out of satellite the locking ring 30;
– cut off crown gear 15 with drive cap 14 and take off gear;
– dissplint and unwrench bolts 11 of stop collar 10 fastening and take off ring;
– fasten and take off hub 7 from the reducer 1;
– take off internal ring of external bearing 8 from the body of reducer 1;
– for dismantling of motor-wheel hub of truck BELAZ-7514-10/75145 unwrench bolts and remove brake
drum 47;
– unscrew bolts 5 of clamp fastening, remove clamps 3, extract spacer ring 4 and squeeze big glands 6;
Figure 7.8 – Reducer of the motor-wheel of the truck BELAZ-75131/75132:

1 – reducer body; 2 – undercollar ring; 3 – clamp; 4 – spacer ring; 5, 12, 21, 29, 32, 36, 47 – bolts; 6 – collar; 7 – hub; 8, 19, 25,
38 – bearings; 9 – crown gear of second row; 10 – hrust collar; 11 – adjusting bolt; 13 – drain plug; 14 – drive cap; 15 – crown gear of first
row; 16 – cap of first row cage; 17 – first row cage; 18 – control plug; 20 – reducer cap; 22, 27, 37 – locking plates; 23 – sun gear of sec-
ond row 24 – satellite of first row; 26 – axe of first row satellite; 28, 31, 35 – packing rings; 30, 39 – retaining rings; 33 – spacing washer;
34 – lubricator; 40 – crown gear of second row; 41 – satellite of second row; 42 – axe of second row satellite; 43 – nut; 44 – ring; 45 – col-
lar; 46 – packing
7-6
Electro-motor-wheel
7513-3902080 RM
–squeeze from hub 7 the external ring – at first of external bearing 8, making effort to the crown gear
9,and then – internal bearing;
– unlock and unwrench bolts 36 of fastening of tightening plates of second row satellite axes, take off
tightening plates 37 and squeeze satellite axes 42;
– take out satellites 41, squeeze from them bearings 38, extract tightening plates 39;
–squeeze inner ring of the internal bearing 8;
–in case of need to remove undercollar ring 2 (for trucks BELAZ-7514-10/75145), cut off from the body
and remove undercollar ring 2, having unwrenched bolts 47 through vent holes in the body (for reducer of the
truck BELAZ -75131/75132).
Figure 7.9 –Adaption 360-008 for removal and mounting of the

first row casing( adaption is used as attached implements to
the loader L-34):
1 – bracket; 2 – finger; 3 – insert; 4 – cross-bar; 5 – cage of
first row; 6 – loader L-34
7.2.3 Checking of the technical state of parts of motor-wheel reducer

Nominal and maximum dimensions of the main parts of motor-wheel reducers are shown at the tables
7.1 and 7.2.
Table 7.1 – Nominal and maximum dimensions of the main parts of motor-wheel reducer
of the truck BELAZ-7514-10/75145
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
75191-2405210-01/211-01
Right (left) reducer body:
Diameter of landing journals for taper − 0 ,024
roller bearing 710 709,8
− 0 ,074
Steel 40Л
Hole diameter for satellite axes
+ 0 ,087
100 100,15
7-7
Electro-motor-wheel
7513-3902080 RM
Continuation of the table 7.1
Dimensions, mm
Material Hardness
nominal maximum
7512-2405264 Steel 20Х2Н4А

−0,30 Tooth face
First row satellite 142,48 141,8 Substitute:
−0,38 58 – 62 HRCэ
Length of common normal 18ХГН2МФБ
7512-2405284-10
Crown gear of the first row
Tooth size +1, 4
(by rollers ∅15,037±0,002)
810,9 812,8 Spline and tooth faces
+1,2 Steel 38Х2МЮА
>550HV5
Spline size
−1,5
(by rollers ∅9±0,002) 918,26 915,5
−1,7
7512-2405300
Casing of the first row
Diameter of the holes for satellite +0,022
axes 100 100,07 Steel 40Л Spline face >45HRCэ
−0,013
Spline size +0,55

181,6 182,7
(by rollers ∅9±0,002) + 0,17
75132-2405332
Axe of the first row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
75132-2405334
Drive cap of the first row
Spline size +0.26
(by rollers∅9±0,002) 891,6 892,8 Steel 40Л
+ 0.09
Diameter of holes for bearing +0,063

440 440,12
75132-2405342
+0,063
Casing cap 440 440,12 Steel 40Л
Diameter of holes for bearing
7519-2405372
Solar gear of the second row −0,165
Length of the common tooth normal
81,74 81,00
Steel 20Х2Н4А
Tooth and spline faces
−0,245
Substitute: 58 - 62 HRCэ
−0,75 18ХГН2МФБ
Spline size (по роликам ∅9±0,002) 207,83 206,00
−0,85
7519-2405434 Steel 20Х2Н4А
−0,19 Tooth and spline faces
Satellite of the second row 111,969 111,40 Substitute:
−0,31 58 - 62 HRCэ
Length of the common normal 18ХГН2МФБ
75191-2405492
Axe of the second row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
7-8
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Material Hardness
nominal maximum
7519-2405496
Crown gear of the second row
Tooth size +1,4
(by rollers ∅18±0,002) 809,984 812,00 Steel 38Х2МЮА
+1,1 >550HV5
Spline size −1,5

948,26 945,5
(by rollers ∅9±0,002) −1,7
7512-2405522
Solar gear of the first row
−0,165
Length of the common tooth normal 57,018 56,10 Steel 20Х2Н4А
−0,285 Substitute:
58 - 62 HRCэ
18ХГН2МФБ
Spline size +0,063
67,143 68,2
(by rollers ∅6,212±0,002)
7512-2405526
Torsion shaft −0,10 Steel
86,3 85,2 375 - 444 НВ
Spline size −0,21 45ХН2МФА
(by rollers ∅6,212±0,002)
75191-2405532
Flange of torsion shaft
Spline size +0,063 Spline face and faces
(by rollers ∅6,212±0,002) 67,143 68,2 Steel 20Х for collar
54 - 60 HRCэ
Wear of surface under the working 0.3 mm of side
edges of collars
75191-3104114-20
Undercollar ring Face for collar>52
0.5 mm of side Steel 45
Wear of surface under the working HRCэ
edges of collars
7512-3104015
Motor-wheel hub +0,26
922,2 923,5 Steel 40Л
Spline size + 0,09
(by rollers ∅9±0,002)
Table 7.2 – Nominal and maximum dimensions of the main parts of motor-wheel reducer
of the truck BELAZ -75131/75132
Dimensions, mm
Material Hardness
nominal maximum
75132-2405210-01
Reducer body:
Diameter of landing journals for taper −0,024
roller bearings 710 709,8 Steel 40Л
−0,074
+0,087
Hole diameter for satellite axes 100 100,15
7-9
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Material Hardness
nominal maximum
75132-2405264 Steel 20Х2Н4А

−0,30 Tooth face
Satellite of the first row 142,277 141,6 Substitute:
−0,38 58 - 62 HRCэ
75132-2405284
Crown gear of the first row
Tooth size +1, 4
(by rollers ∅15,037±0,002)
804,04 805,9 Steel 38Х2МЮА
+1,2 >550HV5
−1,5
Spline size 918,26 915,5
−1,7
75132-2405300
Casing of the first row
Hole diameter for satellite axes +0,022
Spline size
100 100,07 Steel 40Л Spline face>45HRCэ
−0,013
+0,55
181,6 182,7
+ 0,17
75132-2405332
Axe of the first row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
75132-2405334
Drive cap of the first row
Spline size +0,26
891,6 892,8 Steel 40Л
+0,09
+0,063
Diameter of the hole for bearing 440 440,12
75132-2405342
+0,063
Casing cap 440 440,12 Steel 40Л
Diameter of the hole for bearing
7519-2405372
Solar gear of the second row
−0,165 Steel 20Х2Н4А
Length of the general tooth normal 81,74 81,00 Tooth and spline faces
−0,245 Substitute: 58 - 62 HRCэ
18ХГН2МФБ
Spline size −0,75
207,83 206,00
(by rollers∅9±0,002) −0,85
7519-2405434 Steel 20Х2Н4А
Satellite of second row 111,969 111,40 Substitute:
−0,31 58 - 62 HRCэ
75191-2405492
Axe of the second row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
7-10
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Material Hardness
nominal maximum
7519-2405496
Crown gear of the second row
Tooth size +1,4
809,984 812,00 Steel 38Х2МЮА
+1,1 >550HV5
−1,5
Spline size 948,26 945,5
−1,7
75132-2405522
Solar gear of the first row −0,165
57,312 56,40 Steel 20Х2Н4А
Substitute:
58 - 62 HRCэ
+0,180 18ХГН2МФБ
Spline size 86 87,2
+ 0,073
(by rollers ∅6,5±0,002)
75132-2405526
Torsion shaft −0,10 Steel
106,42 105,3 375 - 444 НВ
Spline size −0,20 45ХН2МФА
(by rollers ∅6,5±0,002)
7520-2405532
Flange of the torsion shaft
Spline size +0,180 Spline face and faces
(by rollers ∅6,212±0,002)
86 87,2 Steel 20Х for collar
+ 0,073
54 - 60 HRCэ
Wear of surface under the working 0.3 mm on
edges of collars side
75191-3104114-20
Undercollar ring 0.5 mm on Face for collar>52
Steel 45
Wear of surface under the working side HRCэ
edges of collars
75132-3104015
Motor-wheel hub +0,26
922,2 923,5 Steel 40Л
Spline size + 0,09
(by rollers∅9±0,002)
7.2.4 Assemblage of motor-wheel

Assemblage of motor-wheel should be realized in conditions excluding ingress of dust, chips, dirt to the
parts. Before assemblage scrutinize bearings, diametrical surfaces and faces on the body, hub and stop ring.
Nicks, scratches and other defects on rings, cages and solids of revolution of bearings are not permitted. Un-
der finding of prominent nicks on faces of parts, conjugated to bearings, clean flush with the main surface.
Under assemblage it’s required to use standard or special instrument. Under mounting of parts and units
it’s permitted to use hammers and drifts from nonferrous metal and alloys. Insertion of bearings is recom-
mended to realize on hydraulic presses with the help of special arbors or with help of mechanical adaptations.
Realize assemblage of reducer of motor-wheel in the following way:
–install reducer body 1 (see figures 7.7 or 7.8), of the motor wheel to the horizontal site by flange for fas-
tening and snub from rotation;
– install to the body the mechanisms of service brake system (for electro-motor wheels of trucks BELAZ
-7514-10/75145), if they were under disassemblage (see section « Braking systems»);
–fasten and install to the body undercollar ring 2 and fasten it with bolts 47 (for electro-motor wheels of
trucks BELAZ -75131/75132);
–fasten (figure 7.10) and install to the body undercollar ring (wheels of truck BELAZ-7514-10/75145);
7-11
Electro-motor-wheel
7513-3902080 RM
Figure 7.10 –Method of undercollar seal fastening before

installation
– fasten (figure7.11) internal bearing ring;
Figure 7.11 – Method of fastening of bearing internal ring
– install on the body of reducer the internal bearing ring and squeeze up to the stop (figure7.12). The
probe of 0,03mm thickness should not pass between thrust end of internal bearing ring and body. In case of
0
bearing mounting with heating the heat temperature should not exceed 120 С;
Figure 7.12 –Mounting of inner bearing ring

to the body of reducer
7-12
Electro-motor-wheel
7513-3902080 RM
– assemble satellites of the second row(figure 7.13), have mounted into the satellite 1 locking ring 2 and
having squeezed bearings 3 up to the stop into the ring, previously having lubricated by oil the conjugated
faces of satellite;
Figure 7.13 –Satellite of the second row as assembly:

1 – satellite; 2 – stop ring; 3 – bearing
– install satellites into the body of the reducer 1 (see figures 7.7 or 7.8), squeeze the satellite axes 42,
previously having lubricated by lubricating grease conjugated holes of the body and bearings, mount tightening
plates 37 of satellite axes and fasten them to the body by bolts 36, having stopped bolts 3 (figure7.14) by pin
wire 2.
Figure 7.14 –Stopping of satellite axe of the second row:

1 – satellite axe; 2 – pin-wire; 3 – bolt; 4 – locking plate
Satellites should be free rotated on the bearings. Slipping of the

inner bearing rings on the axes is not permited. Motor–wheel with
mounted satellites of the second row is shown on the figure 7.15;
Figure 7.15 – Motor-wheel with installed satellites

of the second row
– squeeze into the wheel hub 7 (see figures 7.7 or 7.8) the external ring of the inner bearing 8, collar 6,
previously having lubricated by lubricating grease the conjugated faces of hub. Mount spacer ring 4 and fasten
clamping 3 by bolts 5 to the hub, mount and fasten by bolts the brake drum 47 (for electro-motor wheels of
trucks BELAZ -7514-10/75145), mount the crown gear 40 and squeeze the external ring of external bearing 8,
previously having lubricated by lubricating grease the conjugated faces of hub. The probe of 0.03 mm thickness
shouldn’t pass between thrust ends of external bearing rings and hub. The cavity between collars should be
7-13
Electro-motor-wheel
7513-3902080 RM
filled by lubricating grease Литол-24;

– bolts 11 and 33 (24 regulated and 12 stop ones for reducer of electro-motor wheel of truck BELAZ -
7514-10/75145), 11 (24 regulated ones for trucks BELAZ -75131/75132) should be free turned by hand into
the threaded holes of body 1 and stop collar 10 respectively;
– fasten and mount hub onto the body of reducer along the internal hub bearing, at that don’t damage
rubber glands of the hub packing and unite teething of the crown gear of second row and satellites of second
row. Before hub installation lubricate the operational edges of collars by lubricant Литол-24. Rotate hub for-
ward- back on the bearing for support of rollers abutment to the operational board of bearing;
– mount internal ring of outer bearing 8 and stop ring 10. Mount oil catcher (for trucks BELAZ-7514-
10/75145). Snug (not tightening) up bolts 11 (24pieces).
Realize regulating of hub tapered bearings in the following way:
– check the momentum of hub rotation through the second row. It should be not more 500 N.m (on the
technological gear of the second row not more 135 N.m. Fix the value of such momentum;
– rotating hub through the second row,
tighten by turn per 2 diametrically located 8
bolts 3 (figure7.16) by torque 20 N.m. Repeat
bolt tightening in the same way up to setting of
torque 20 N.m in all 8 bolts. Repeat bolt tight-
ening in the same way up to setting of torque
40 N.m in all 8 bolts 3. Tightening of regulated
bolts is shown on figure 7.17.
Figure7.16 – Location of stop collar bolts:

1, 3 – regulating bolts; 2 – thrust bolt (only for re-
ducer of motor wheel of truck BELAZ-7514-10/75145, on
the reducer of motor wheel of truck BELAZ-75131/75132
are not mounted)
Figure7.17 – Tightening of adjusting bolts
7-14
Electro-motor-wheel
7513-3902080 RM
Check by probe the gap between roller faces and bearing board 4 (figure7.18). If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 near located rollers, at which gap exceed 0,4
mm), pass to the carrying out of the next point. Otherwise repeat bolt tightening in the same order up to estab-
lishment of torque 60 Н.м in all 8 bolts.
Figure 7.18 –Checking up of clearances :

1 –reducer body; 2 – regulating bolt; 3 –thrust collar; 4 –bearing;
А – placement of probe ; Б - gap
Check by probe the gap between faces of rollers and operation board of bearing. If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in which gap exceeds
0,4 mm), pass to the performance of the next point. Otherwise repeat the bolt tightening in the same order up
to the establishment of torque 80 N.m on 8 bolts.
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in whiches gap ex-
ceeds 0,4 mm), pass to the performance of the next point. Otherwise repeat the bolt tightening in the same or-
der up to the establishment of torque 100 N.m on 8 bolts .
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in whiches gap ex-
ceeds 0,4 mm), pass to the performance of the next point . Otherwise disassemble and realize parts detection.
Realize the adjustment of hub tapered bearings of motor wheel reducers of truck BELAZ-7514-10/75145
further in the following way:
– wrench the rest adjusting bolts by torque 20 N.m. Release bolts 3 (see figure7.16) and tighten them by
torque 20 N.m.
– wrench stop bolts 2 (12 pieces) against stop. Tighten by turns all diametrical stop bolts by torque
600 – 640 N.m. Repeat bolt tightening in the same order up to establishment of torque 600 – 640 N.m on all
bolts;
– tighten regulating bolts 1 and 3 (24pieces) by turns per 2 diametrical ones by torque 400 – 440 N.m;
– check by the probe the gap between roller faces and operaion bearing board. For 70% of rollers the
gap shouldn’t exceed 0,4 mm. Here there shouldn’t be more than 3 closely located rollers in whiches the gap
exceeds 0,5 мм (see figure7.18);
– check the hub torque through the second row. It can be encreased in comparison with earlier measured
torque (not more 500 N.m) not more than on 400 N.m (on the technological gear of second row as compared
with earlier measured torque (not more135N.m) not more than on 108 N.m;
– stop bolts by pin-wire (see figure7.16);
– if necessary under performance of adjustment the change of inner bearing ring is permitted.
Attention: there were changes at the design of motor-wheel reducers of trucks BELAZ-7514-10/75145,
produced from 2003 : the stop bolts 2 were canceled, and for regulating of hub bearings the adjusting washers
are installed under adjusting bolts (design is similar to the reducer of motor-wheels of trucks BELAZ -
75131/75132). Realize the regulating of tapered bearings of hubs of motor wheels reducers of truck BELAZ-
7514-10/75145 with above changes analogously to the considered further regulating of tapered bearings of
hubs of motor wheels reducers of truck BELAZ -75131/75132.
7-15
Electro-motor-wheel
7513-3902080 RM
Realize the adjustment of tapered bearings of motor-wheel reducer hub of BELAZ-75131/75132 further
in the following way:
– check up hub operating torque through the second row. It can be encreased in comparison with earlier
measured torque (not more 500 N.m) not more than in 400 N.m (on technological gear of the second row in
comparison with earlier measured torque (not more135 N.m) not more than in 108 N.m;
– in four equilocated places against bolts 3 (see figure7.16) measure gap Б (see figure7.18), Б1, Б2, Б3,
Б4 with accuracy to +0,02 mm;
– grind spacing washers 33 (24pieces) (see figures7.8) in size С=(((Б1+Б2+Б3+Б4):4)+0,2) with accu-
racy 0,015;
– unwrench 8 adjusting bolts 3 (see figure7.16);
– wrench adjusting bolts 1 and 3 (24 pieces) putting onto it per spacing washer out of ground kit in order
to spacing washers will be in gap Б (see figure 7.18);
– tighten diametrical adjusting bolts by turn by torque 400 – 440 N.m;
– cotter bolts in pairs by pin wire;
–if necessary under adjustment the replacement of inner bearing ring is permitted.
Realize assemblage of the first reducer row of electro-motor wheel in the following way:
– install into the satellite of first row 3 (figure 7.19) retaining ring 2;
Figure 7.19 –Satellite of the first row:

1 – bearing; 2 –stop ring; 3 – satellite
– insert into the satellite the bearings 1 against stop into the retaining ring, previously having lubricated
by oil the conjugated satellite faces;
– put satellites into the carrier 17 (see figures 7.7 or 7.8) of the first row, insert axles26, previously hav-
ing lubricated by lubricating grease the conjugated faces of body and bearings, mount and fix by bolts the lock-
ing plates 4 (figure 7.20), stop bolts 3 by pin -wire 2;
Figure7.20 – Stopping of the satellite axe of the first row:

1 – satellite axe; 2 –pin-wire; 3 –bolt; 4 –locking plate
– built up onto the cage 17 (see figures 7.7 or 7.8) the bearings 19, here apply force only to the internal
bearing rings (under application of force to the external rings of bearings the surfaces and solids of revolution
are damaged);
– mount into the drive cap14 the crown gear of the first row 15, the cage of first row with satellites, hav-
ing united teething of the first row crown gear and of first row satellites, the cap of first row cage 16 with
packing ring 31, previously having lubricated the ring by lubricating grease, and tightening by bolts 32
assemble the first row of reducer;
– mount the crown gear of second row 23, fasten two locking plates 2 (semirings) (figure7.21) by bolts 1
to the cage of first row and stop bolts by pin wire 3;
7-16
Electro-motor-wheel
7513-3902080 RM
– fasten the first row to the hub 7 (see figures7.7 or 7.8) by bolts 12, having mounted packing ring 35,
previously having lubricated the ring by lubricating grease (be careful under introduction of solar gear of the
second row 23 into the satellites of the second row 41);
– wrench into the hub threaded holes the return tubes. Put the return tubes on joint sealant
«Унигерм 9»;
Figure 7.21 –Stopping of the solar gear of the second row:

1 – bolt; 2 – locking plates; 3 – pin-wire
For mechanization of adjustment of second row tapered bearing of motor wheel reducer of truck
BELAZ-7514-10/75145 and hub turning under measurement of gap between brake drum and linings of motor
wheel reducer brake the stand 281-30 (figure7.22) is intended.
The stand consists of the following main parts: frame 7, actuator 4, ground 3 and control console fixed
on the supports 2 on site 1 at the electrical cabinet.
Frame 7 is intended for mounting and fixation on it of adjustable unit and placement of actuator inside
the frame. Base plate, in which 8 fingers are mounted for fixation of adjustable unit body, is fixed to the lower
part of frame.
Actuator 4 is intended for crank through torsion shafts 6 and sun gears 5 of reducer second row under
tapered bearings regulating and for reducer hub crank under measurement of gap between brake drum and
linings. Actuator consists of worm-and-wheel reducer and electric motor. Spline clutch for mounting of change
torsion shafts is fixed on outlet reducer end.
For gap adjustment in tapered bearings and under gap measurement between brake drum and linings –
install the second reducer row to the stand base plate, fix unit against turning along cage holes, install change
torsion shaft 6 introducing into engagement with clutch of actuator. Install to the shaft the sun gear 5 introduc-
ing into engagement with satellites of second row. Turning the hub through satellites, tune gap at the tapered
bearings, as mentioned above. After gap regulating at the tapered bearings, turning the hub measure the gap
between brake drum and linings and if necessary tune.
Figure 7.22 – Stand 281-30 for adjustment of tapered bearings:

1 – electrical cabinet; 2 – rests; 3 – ground; 4 – actuator; 5 – sun gear; 6 – torsion shaft; 7 – frame
7-17
Electro-motor-wheel
7513-3902080 RM
Under measurement of the gap between brake drum and linings under fully assembled reducer of the
motor wheel it’s necessary to install reducer onto stand, remove cap 11 (see figure7.1) and install the change
crown gear of first row. Turning the hub measure the gap between brake drum and linings and if necessary
tune.
For regulating of gap of tapered bearings of motor wheel reducer of truck BELAZ-75131/75132 the stand
ЧРЦ 1.00, which is similar to stand 281-30 described above, is intended.
Realize assemblage of electro-motor wheel in the following way:
– fasten the reducer of motor-wheel by device (see figures 7.3 or 7.5) and install it onto the support (fig-
ures7.4);
– install into body 1 the collar 45 (see figures7.7 or 7.8), previously having lubricated by lubricating
grease the conjugated body face, wrench into the body studs (see figures 7.8) (for the reducer of motor-wheel
of truck BELAZ-75131/75132), mount guard ring 44 (see figures 7.7 or 7.8), wrench nuts or bolts 43;
– mount flange 14 (see figures 7.1 or7.2) onto the shaft of traction motor and fasten it by bolt with elastic
washers (tighten by torque 260 – 320 N. m). Put bolts on sealant «Унигерм 9»;
– fasten by bolts to the flange of traction motor the flange of torsion shaft 13 (tighten by torque 270 –
315 N.m);
– fill up labyrinth grooves of packing 46 (see figures 7.8) by lubricant Литол-24 and lubricate the opera-
tion edges of collar 45 (see figures 7.7 or 7.8);
– fasten traction motor by ring bolts (for the electro-motor wheel of the truck BELAZ -7514-10/75145), by
adaptation (figure 7.6) (for electro-motor wheel of the truck BELAZ-75131/75132) and install it into reducer
body, having tightened by bolts 15 (see figures 7.1 or7.2) (tighten by torque 800 – 1000 N.m). Before installa-
tion lubricate the landing face of electric engine by lubricant Литол-24;
– mount on to torsion shaft 12 the inner retaining ring (2 rings for electro-motor wheel of the truck BE-
LAZ-7514-10/75145);
– mount torsion shaft into the spline cavity of flange 13 up to stop;
– mount onto torsion shaft the crown gear 9 of the first row and outer retainer ring 10;
– mount cap 11with packing ring, previously having lubricated the ring by lubricating grease, and fasten
it by bolts 7;
– mount into the cap 4 (figure 7.23) the rest 2 up to the stop in to the torsion shaft 7. Measure gap be-
tween faces of cap and rest. Collect the kit of shims 1 in width for amount of clearance plus (1 – 2) mm and
mount it between cap 4 faces and rest 2 faces. Fix the rest in cap by bolts;
Figure 7.23 – Torsion shaft clearance adjustment:

1 –regulating washer; 2 – stop; 3 – stop ring; 4 – cap; 5 –crown gear of first row;
6 – ball stop; 7 – torsion shaft;
А – gap
– fasten electro-motor wheel of the truck BELAZ-7514-10/75145 by adoption (see figure 7.3), on the
support for truck BELAZ-75131/75132 by loader and bring it to the back axle housing, unite the holes by turn of
motor-wheel and fasten the motor-wheel to the back axle housing, having tightened bolts by torque 1300 –
1500 N.m for the truck BELAZ -7514-10/75145 и 500 – 550 N.m for truck BELAZ -75131/75132;
– join to the gauge of speed limitation the hoses for lubrication of traction motor bearings, leadings-out of
traction motors to the power cables. Join hoses of high pressure to the cylinders of brake system, connect cyl-
inder rod extender clevis of parking brake system with regulating lever (for the truck BELAZ-7514-10/75145).
Mount and fix by clamps the elastic nipple for supply of cooling air to the traction motor (for the truck BELAZ -
75131/75132).
7-18
Electro-motor-wheel
7513-3902080 RM
7.2.5 Running-in of the motor-wheel reducer

Running – in of the motor wheel reducer is realized with the aim of the quality control of assemblage and
break-in of its main units and parts .
Realize running-in of reducer of motor- wheel in the following way:
– install reducer 1 (figure7.24) as assembly to the running-in stand;
– after the installation carry out 3 switchings on of the service brake (for the truck BELAZ -7514-
10/75145) by pressure of the operation fluid (hydraulic oil АМГ-1 ГОСТ6794-75, temperature 40 – 70 0С, pres-
sure(12 + 1,5) МPa) – at this time the adjustment of the device of automatic gap regulation is carried out. Here
during not less than 5 minutes carry out the check up of the internal pipelines and cylinders of service brake
(leaks of operation fluid are not permitted).
After unbraking between lining and brake drum the gap should be not less 0,05 mm. The local rubs of
lining and drum, not leading to the drum heat over 70 0С during the running in, are permitted;
– pour the industrial oil И-20А ГОСТ20799-88 to the reducer till the level of check plug;
– perform running-in in 2 modes under the table 7.3.
Figure 7.24 – Adoption 282-6-1 for running-in

1 – reducer; 2 – traction motor ДК-722; 3 – support; 4 – casing; 5 – hose; 6 – tachogenerator
Table 7.3 –Running-in modes

Running mode 1 2
-1
Rotation speed of electric engine shaft, min 800 + 70 1500 + 70
Running time, not less, min 25 20
7-19
Electro-motor-wheel
7513-3902080 RM
During the running-in on each of above modes of electric engine operation define the waste of idling
which should not exceed loss, indicated on the diagram of idling waste (figure7.25).
Figure7.25 – Diagram of idle losses
During the running-in watch the rise of unwanted sounds and knocks. After the running-in control the
heat of brake on the external face of drum, the heat of reducer on the face of external cap at the zone of loca-
tion of check and filter plugs. The heat shouldn’t exceed 70 0С. Under occurrence of elevated heat tempera-
ture, idle loss, leakages, unwanted sounds and knocks at the reducer of motor-wheel you need to clarify and
eliminate the reasons of malfunctions, after that to perform running-in once more. Noise level shouldn’t exceed
95 dB on the distance (1000 + 100) mm under the general noise level not more 85 dB;
After the running-in pour the oil out of reducer.
7-20
Running gear
7513-3902080 RM
8 RUNNING GEAR
8.1 Suspension
8.1.1 General data
Suspension of dump trucks BELAZ-7514-10 and BELAZ-75145.
Front suspension is independent, from each side of dump truck pneumohydraulic cylinder 4 (figure
8.1.1), pivot 5, swivel member 8 with hub of front wheel 7 and bracket of pivot 6 are installed.
Figure 8.1.1 - Front suspension of dump trucks BELAZ-7514-10 and BELAZ-75145:

1, 22 - greasers; 2, 12, 14, 16 - nuts; 3 – upper bracket of suspension cylinder; 4 - pneumohydraulic cylinder of suspension;
5 - pivot; 6 - bracket of pivot; 7 - hub of front wheel; 8 - swivel member; 9 – lower mud shield; 10 - barrel; 11, 33, 34 - bolts; 13, 17 - studs;
15 - expanding barrel; 18 - lever of steering trapezoid; 19, 32 - pins; 20 – barrel of pivot; 21 - safety valve; 23 - supporting ring; 24 - cuff;
25 - wiper ring; 26 - scratcher; 27 - boot; 28 - lower bracket of suspension cylinder; 29 - buffer; 30 - apron with mud shields; 31 - tube of
lubrication supply; 35 - disk; 36 - trunnion ball of suspension cylinder
8-1
Running gear
7513-3902080 RM
The pneumohydraulic cylinder is fastened with self-locking nuts 2 to upper 3 and to lower brackets 28.
Lower bracket is fastened with bolts 33 to upper butt of pivot.
The pivot 5 is rigidly connected to swivel member 8 and can displace together with wheel in bracket of
pivot 6 in axial and angular directions. Bracket of pivot is fixed on frame by means of barrels 10 and bolts 11
with nuts 12.
As plain bearings of pivot metal-plastic barrels 20 inserted in boring of bracket of pivot are used. From
conveyance in axial direction barrels are secured by pimples. Barrels from both sides of eyelets of bracket of
pivot 6 are sealed with cuffs 24 which are protected from damage by wiper rings 25 and scratchers 26.
The buffer 29 restricts conveyance of pivot at maximum stroke of release and softens impacts.
Rear suspension is dependent and consists of two pneumohydraulic cylinders 3 (figure 8.1.2), trans-
versal rod of suspension 4, central lever 2 of rear axle and eyelet 6 with hinge.
The loads operating on wheels of rear axle, are transmitted to frame through cylinders of suspension,
transversal rod and central hinge. Cylinders of suspension react only vertical loads, rod reacts only transversal
loads, and central hinge reacts vertical, transversal and longitudinal loads.
Pneumohydraulic suspension cylinders are fastened to brackets on frame and crankcase of rear axle by
self-locking nuts 32.
The transversal rod 4 is fixed to brackets on frame and crankcase of rear axle with help hinged bearings
23 that are fixed on fingers of rod 26 through distance barrel 29, pinch plates 21 and bolts 20 and 28.
The eyelet 6 of central hinge is fixed to central lever with help of bolts 16 and nuts 17, and is also
hingedly fixed to bracket of frame by finger 9.
Figure 8.1.2 – Rear suspension of dump trucks BELAZ-7514-10 and BELAZ-75145:

1 - protective boot; 2 - central lever; 3 - pneumohydraulic cylinder of suspension; 4 - rod of suspension; 5 - lock plate; 6 - eyelet
with grounding; 7 - cover; 8, 11, 13, 16, 20, 35 - bolts; 9 - finger; 10, 17, 32 - nuts; 12, 36 - splints; 14, 23 – hinged bearing; 15 - stuffing
box of central hinge; 18, 27, 31 - greasers; 19 - stuffing box of rod; 21 - pinch plate; 22 - conic barrel; 24 - ring; 25 - barrel; 26 - finger of
rod; 28 - special bolt; 29 - distance barrel; 30 - sealing ring; 33 - disk; 34 - boot.
8-2
Running gear
7513-3902080 RM
Suspension of dump trucks BELAZ-75131 and BELAZ-75132.

The front suspension is dependent and consists of two pneumohydraulic cylinders 3 (figure 8.1.3), eye-
lets 28 with hinge, lever of front axle and transversal rod 2.
The loads operating on wheels of front axle are transmitted to frame through suspension cylinders,
transversal rod and an eyelet with hinge. Cylinders of suspension react only vertical loads, rod reacts only
transversal loads, and central hinge reacts vertical, transversal and longitudinal loads.
The suspension cylinder is fastened to upper 33 and to lower 21 brackets by self-locking nuts 19. Upper
bracket is fastened to frame by bolts and is welded on it. Lower bracket is fastened to upper butt of swivel
member by bolts. Transversal rod 2 is hingedly connected to cross bar of frame and beam of front axle by
means of taper fingers 7. Eyelet 28 is fixed to bar of front axle with help of bolts 29, and is also hingedly fixed
to bracket of frame by finger 25.
Figure 8.1.3 - Front suspension of dump trucks BELAZ-75131 and BELAZ-75132:

1, 15 - greasers; 2 - rod; 3 - pneumohydraulic suspension cylinder; 4, 12, 20, 23, 29, 31, 36 - bolts; 5, 13, 30 - disks; 6 - barrel;
7, 25 - fingers; 8, 24 - stuffing boxes; 9 - locking ring; 10, 26 - hinged bearing; 11, 27 - covers; 14 - adjusting washer; 16 - buffer; 17 - liner;
18 - ring; 19 - nut; 21 - lower bracket of suspension cylinder; 22 - trunnion ball of suspension cylinder; 28 - eyelet with grounding; 32 - tube
of lubrication of trunnion ball; 33 - upper bracket of suspension cylinder; 34 - boot; 35 – locking; 37 - splint
8-3
Running gear
7513-3902080 RM
The rear suspension is dependent and consists of two pneumohydraulic cylinders 2 and 4 (figure
8.1.4), transversal rod of suspension 3, lever of rear axle and eyelet 7 with central hinge.
The loads operating on wheels of rear axle are transmitted to frame through suspension cylinders,
transversal rod and central hinge. Cylinders of suspension react only vertical loads, rod reacts only transversal
loads, and central hinge reacts vertical, transversal and longitudinal loads.
Pneumohydraulic suspension cylinders are fastened to brackets on frame and crankcase of rear axle
with self-locking nuts 29.
The transversal rod of suspension 3 is fixed to brackets on frame and crankcase of rear axle with the
help of hinged bearings 23 timbered on fingers of rod 20 through distance barrels 17, pinch plates 25 and bolts
18 and 26.
The eyelet 7 of central hinge is installed on barrels 11 and fixed to central lever with the help of bolts 15
and nuts 14 and is also hingedly fixed to bracket of frame by finger 9.
Figure 8.1.4 - Rear suspension of dump trucks BELAZ-75131 and BELAZ-75132:

1 - mud shields; 2 - left pneumohydraulic suspension cylinder; 3 - rod of suspension; 4 - right pneumohydraulic suspension cylin-
der; 5 – locking plate; 6, 15, 26, 32 - bolts; 7 - eyelet with grounding; 8 - cover; 9 - finger; 10, 14, 29 - nuts; 11, 21, 24 - barrels; 12,
23 – hinged bearings; 13 - stuffing box of central hinge; 16 - sealing ring; 17 - distance barrel; 18 - special bolt; 19 - greaser; 20 - finger of
rod; 22 - ring; 25 - pinch plate; 27 - stuffing box of rod; 28 - disk; 30 - boot; 31 - trunnion ball of suspension cylinder
8-4
Running gear
7513-3902080 RM
The suspension cylinder (figure 8.1.5) represents piston-type air spring in combination with hydraulic
shock absorber. Working element in cylinder is engineering gaseous nitrogen. In suspension cylinder damping
fluid ЛУКОЙЛ - АЖ is applied as working fluid.
Front and rear suspension cylinders of dump trucks BELAZ-7514-10, BELAZ-75145, BELAZ-75131 and
BELAZ-75132 are analogous in construction and differ only in sizes of parts, configuration of chase on rod of
absorber and amount of filled oil and gas pressure level.
The suspension cylinder consists of tube of basic cylinder 13 and rod 34 with piston and partition of ab-
sorber welded on it. Lower cover 25, which fastens housing 11 to butt of rod, is fastened to lower part of rod, and
to upper part of tube of major cylinder upper cover 38 is fastened by bolts. In upper and lower cover trunnion balls
40, timbered by covers 39, are installed. Between upper 38 and lower 25 covers and cover 39 adjusting gaskets
24 are installed.
Between spherical surfaces of covers and trunnion balls liners 2 of metal-polymeric ribbon are installed.
Trunnion balls are greased through push-type lubricating fitting.
Two compression valves 33 and valve of release 29 are located on partition of absorber. In body of re-
lease valve rod of absorber 36 displaces The rod comprises two long slots of variable section executing func-
tion of throttle of variable resistance of valve of release of absorber. Rod of absorber is also the drive gear for
pump 28.
The housing 11 forms cavity И in which working fluid is filled up to level of check plug 15. Working fluid
is intended for refilling of cavity Л and K and for lubrication of housing sealing. Leakproofness of movable joint
of tube of major cylinder 13 and housing 11 is ensured with sealing ring 53 and safety ring 54. Protective boot
9, timbered between ring 30 and sealant 31, serves for protection of external surface of cylinder from dust and
mud.
Leakproofness of fixed joints is ensured with rubber sealing rings of round cross-section. For prevention of
working fluid escape from suspension cylinder movable joint “rod – tube” of major cylinder is sealed with fluoro-
plastic cuff 57, which working crimps are unclenched by rubber spacing ring 56. Cuff is installed with tightness that
is regulated by set of adjusting gaskets 61 and supported by spring 60. Sealing of junction “tube of major cylinder –
piston” is ensured with fluoroplastic washers 52 on piston of rod 34.
Pressure-relief valve 10 serves for protection of housing 11 from overcharges, at pressure boost in its
cavity due to decrease of volume at squeeze of cylinder and because of possible escape of working fluid
through cuff and other joints. In order to set cylinder back in operation condition it is to be filled by nitrogen
through priming valve 3.
For maintenance of fixed level of working fluid in cavity Л ram-type pump 28 is installed in boring of
lower cover 25 and timbered by flange 19 with bolts 26 and washers.
External fault symptom of suspension cylinders is change of their altitude relatively to normal running
order.
At abnormal operation of suspension cylinders (roll of dump truck, strong leak of oil) test their service-
ability by defining size C (see figure 8.1.1) for cylinders of front suspension of dump trucks BELAZ-7514-10,
BELAZ-75145, size Н1 (see figure 8.1.5) for cylinders of front suspension of dump trucks BELAZ-75131 and
BELAZ-75132 and size Н for cylinders of rear suspension. These sizes are defined by special (characteristic)
ruler (figure 8.1.6) on which two scales are marked: charge and working. Points on scales indicate level of gas
pressure in cylinder of given size at correct charging of cylinders. Besides, zones of admissible scatter of size
at operation of cylinders are marked on working scale of ruler.
The charge scale located on ruler at right side is intended for monitoring charged cylinder or when gas
pressure in cylinder is absent completely. Working scale located on ruler at left serves for inspection charging of
suspension cylinders in operation.
For performing check of dimensions install unloaded dump truck on equal horizontal platform. At cor-
rectly charged front suspension cylinder of dump trucks BELAZ-7514-10, BELAZ-75145 upper crimp of swivel
member 8 (see figure 8.1.1) should be placed against zone of admissible scatter of size of cylinder. At per-
forming measurement butt of ruler should rest against lower butt of bracket. Front suspension cylinder of dump
trucks BELAZ-75131 and BELAZ-75132 is considered normally charged if center of check plug 15 (see figure
8.1.5) is placed against zone of admissible scatter of size of cylinder.
8-5
Running gear
7513-3902080 RM
Figure 8.1.5 - Pneumohydraulic suspension cylinder:

1 - pin; 2 - collar step; 3 - priming valve; 4, 5, 23, 26 - bolts; 6, 17, 18, 20, 55 - rings; 7, 19 - flanges; 8 – support washer; 9 - protec-
tive boot; 10 - safety valve; 11 - housing; 12 - guiding of rod with axle box; 13 - tube of major cylinder; 14 - pinch nut; 15 - check plug;
16 - filter; 21 - safety valve; 22, 53 - sealing rings; 24, 61 - adjusting layer pads; 25 - lower cover; 27 – locking screw; 28 - pump; 29 - body
of release valve; 30 - ring; 31 - sealant; 32 - bead; 33 - body of compression valve; 34 - rod; 35 - plug of compression valve; 36 - rod of
absorber; 37 – sensor valve; 38 - upper cover; 39 - cover; 40 - trunnion ball; 41, 46, 62 - sealing gaskets; 42 - cover; 43, 49 - rods; 44,
51 - nuts; 45, 48 - bodies; 47 - sealing taper; 50, 60 - springs; 52 - washers; 54 - safety ring; 56 - spacing ring; 57 - cuff of rod; 58 - ring of
cuff; 59 - pressure ring;
Н1, Н2 - dimensions; И, К, Л – cavities
8-6
Running gear
7513-3902080 RM
Figure 8.1.6 - Characteristic ruler:

а) of dump trucks BELAZ-7514-10, BELAZ-75145:
1 - size for completely compressed cylinder; 2 - working scale of pressures
in cylinder; 3 - nominal size of cylinder on loaded dump truck; 4 – pressure, corre-
sponding to nominal size of cylinder; 5 - zone of admissible scatter of cylinder size;
6 - nominal size of cylinder on unloaded dump truck before dissolution of nitrogen;
7 - charging scale of pressures in cylinder; 8 - size of completely unclenched cylin-
der; 9 - size of rear cylinder filled with oil
b) of dump trucks BELAZ-75131, BELAZ-75132:

1 - size for completely compressed cylinder; 2 - working scale of pressures
in cylinder; 3 - nominal size of cylinder on loaded dump truck; 4 - size tolerance of
cylinder on equipped dump truck; 5 - pressure corresponding to nominal size of cyl-
inder of equipped dump truck; 6 - zone of maximum deviation of cylinder size of
equipped dump truck in operation; 7 - charging scale of pressures in cylinder; 8 -
size of completely unclenched cylinder; 9 - size of rear cylinder filled with oil
The rear suspension cylinder is considered normally charged

if butt of housing 11 is against zone of admissible scatter of size of
working scale of ruler. At measuring of size Н ruler is interposed
under protective boot 9 against stop into ring 30 so that it is not dis-
placed upwards from its seat.
Whereas sizes of all suspension cylinders are intercon-
nected among themselves, change of size of one (out-of-order) cyl-
inder calls resizing in other cylinders. Out-of-order cylinder, as rule,
is the one with the least size. Measure in addition gas pressure in
out-of-order cylinder by means of work tool (figure 8.1.7) and, if it is
below normal (on working scale of characteristic ruler) on more
than 0.3 МPа for front and 0.2 МPа for rear cylinders, it is neces-
sary to perform preventive recharge.
The pump of cylinder 28 (see figure 8.1.5) ensures the de-
fined level of working fluid at its escape from cavity Л.
If oil level in housing is higher than check plug, there is no
need to merge it, as during operation pump will pump it inside the
cylinder. If there is enough oil in housing of cylinder and height of
cylinder diminishes, it is necessary to remove it from dump truck
and to eliminate failure.
Sharp decrease of cylinder height testifies the emersion of
significant escapes of working fluid through joints, and recharge of
cylinder with gas on dump truck without elimination of failure is in-
effective.
Remove out-of-order cylinder from dump truck, disassemble
it observing safety precautions and eliminate failure.
8-7
Running gear
7513-3902080 RM
Figure 8.1.7 – Work tool for measuring pressure in cylinders:

1 - manometer; 2, 9 - sealing gaskets; 3, 8 - adapter connectors; 4 - hose; 5 - nut; 6 - needle; 7 – sealing ring
8.1.2 Suspension cylinders troubleshooting

Suspension cylinders troubleshooting is specified in table 8.1.1
Table 8.1.1 — Suspension cylinders troubleshooting
Trouble and its symptom Possible reason Remedy
Pressure in all cylinders does not corre- Incorrect charging Adjust charging:
spond to pressure on characteristic ruler – test oil level and gas pressure in all cylinders according to
Operation manual;
– charge cylinders with oil and gas on characteristic ruler
In one cylinder according to characteristic Incorrect charging of cyl- Adjust charging of cylinder according to Operation manual
ruler pressure differs from required level inder
most of all
One or several cylinders constantly do not Nonhermetic priming Check condition of copper gasket under valve. If it is solid or
hold sizes "H" or "Н1" (there are no leak- valve damaged on planes replace it and charge cylinder with gas
age of oil)
After charging cylinder abruptly runs down Cuff is worn out. Non- Remove and disassemble cylinder observing safety precau-
and oil escapes through pressure-relief hermetic pump tions, test condition of cuff and pump. Replace worn out and
valve or safety ring damaged parts
On release strokes knocks in cylinder are Fluoroplastic wasers on Remove and disassemble the cylinder. Replace washers on
heard piston rod are worn out piston of rod
8.1.3 Safety precautions at removal, repair and mounting of suspension cylinders on dump truck
At disassembly and assembly of suspension cylinders be careful, as gas in them is under high pressure.
At filling and charging of cylinders, at repair, disassembly and assembly, boost charge on dump truck «Rules
for Construction and Safe Operation of bulbs working under pressure» should be strictly observed.
At removal of suspension cylinders from dump truck and their repair observe the following rules:
- before removal of cylinder from dump truck release gas through priming valve. For release of gas re-
move cap from priming valve and turn special sleeve on valve before opening it. After release of gas unscrew
special sleeve a little so that priming valve is closed, and then turn special sleeve on valve in three minutes
again. Operation on opening and close of priming valve with an interval in three minutes is to be carried out not
less than three times as nitrogen dissolved in oil evaporates fast, and right after unscrewing special sleeve the
pressure in cylinder is recreated;
8-8
Running gear
7513-3902080 RM
- starting disassembly of cylinder be convinced of absence of gas pressure in it. It is forbidden to disas-
semble cylinder (wrench fastening bolts of upper and lower covers, wrench priming valve, wrench pinch nut) if the
cylinder is under pressure;
- housing plug or safety valve are to be unscrewed only after release of gas from housing, that is per-
formed lifting the rod with sealing taper above valve body;
- it is forbidden to remove lower cover of cylinder and housing at presence of working fluid in cavities of
cylinder and housing. Oil from housing should be merged through bores for plug or for safety valve, and from
cylinder – through bore under priming valve;
- storage and transportation of charged cylinders is to be performed in vertical position only in order to
prevent gas leaks through mobile rod seal. Aberration of cylinder from vertical position should not be more
than on 300;
- before connection of reducer to new bulb at gas charging of cylinder be convinced that on bulb with
compressed gas inscription "NITROGEN" of yellow color and ring marking strip of brown color is present;
ATTENTION: IT IS FORBIDDEN TO PERFORM CHARGING OF SUSPENSION CYLINDERS WITH OXYGEN! IT
CAN CAUSE EXPLOSION!
- install bulb with gas to the prescribed place equipped with devices for fixing of bulb. At change of bulb -
fix it;
- unscrew valves and connecting nuts only with corresponding wrenches, trying not to hit them;
- gas to suspension cylinders is to be supplied smoothly through reducer;
- observe common safety precautions on working place.
8.1.4 Removal of suspension cylinders from dump truck

Before removal of front and rear suspension cylinders from dump truck release gas through priming
valve of cylinder observing rules specified in subsection 8.1.3. Install thrust blocks under front and rear wheels.
Removal of front suspension cylinder is to be carried out in the following sequence:
- turn front wheels in extreme position;
- unscrew bolts 33 (see figure 8.1.1) of lower bracket 28 of suspension cylinder fastening to pivot 5 (for
dump trucks BELAZ-7514-10, BELAZ-75145), bolts 20 (see figure 8.1.3) of lower bracket 21 of suspension cyl-
inder fastening to swivel member (for dump trucks BELAZ-75131, BELAZ-75132);
- hang out frame of dump truck, having installed jack in its front part, up to exit of lower bracket of sus-
pension cylinder with tube of lubrication supply from pivot or swivel member;
- install special jambs under spars of frame instead of jacks;
- install gripper of device for removal and mounting of suspension cylinders (figure 8.1.8), having in-
stalled jaws 13 and 14 on tube of major cylinder under butt of upper cover of suspension cylinder 4, safely
press jaws by means of nut 11 with handle 12 to tube of cylinder;
- unscrew nut 2 (see figure 8.1.1) of suspension cylinder fastening to upper bracket (for dump trucks
BELAZ-7514-10, BELAZ-75145), unscrew bolts 20 of bracket 33 fastening to bracket of frame (for dump trucks
BELAZ-75131, BELAZ-75132);
- remove cylinder;
- unscrew nuts on trunnion balls of upper and lower brackets fastening and remove brackets from sus-
pension cylinders;
- install suspension cylinders in special container in vertical position.
Removal of rear suspension cylinder is to be carried out in the following sequence:
- unscrew nut 32 (see figure 8.1.2 for dump trucks BELAZ-7514-10, BELAZ-75145), nut 29 (see figure
8.1.4 for dump trucks BELAZ-75131, BELAZ-75132) of lower trunnion ball of suspension cylinder fastening to
bracket of rear axle;
- hang out frame of dump truck, having installed jack in its rear part, up to exit of tail of trunnion ball of
cylinder from bore of lower bracket of suspension cylinder;
- install gripper of device for removal and mountings of suspension cylinders (see figure 8.1.8), having
installed jaws 13 and 14 at tube of major cylinder under butt of upper cover of suspension cylinder 4 and press
jaws safely by means of nut 11 with handle 12 to tube of cylinder;
8-9
Running gear
7513-3902080 RM
Figure 8.1.8 – Device 360-014 for removal and mounting of suspension cylinder (used as attached implements to loader):
а) - removal and mounting of rear suspension cylinder; b) - removal and mounting of front suspension cylinder;
1 - fork of loader; 2 - cross bar; 3 - bracket of support; 4 - suspension cylinder; 5 - bracket; 6 - shaft; 7 - trunnion ball; 8 - transver-
sal bracket; 9 - longitudinal bracket; 10 - finger; 11 - nut; 12 - handle; 13, 14 - jaws
- unscrew nut of upper trunnion ball of suspension cylinder fastening;

- remove cylinder;
- install suspension cylinder in special container in vertical position.
Front and rear suspension cylinders removed from dump truck with the
help of special device can be carried on section of disassembly and assembly
of cylinders with the help of fastening device (figure 8.1.9).
For transportation it is necessary to screw nut of device 3 on thread tail
of trunnion ball of suspension cylinder.
Figure 8.1.9 – Device 7808-6675 for transportation of cylinders of front suspension

(thread on nut М48х2); device 7808-7026 for transportation of cylinders
of rear suspension (thread on nut М56х2):
1, 2 - rings; 3 - nut; 4 - suspension cylinder
8-10
Running gear
7513-3902080 RM
8.1.5 Disassembly of suspension cylinders

Stand (figure 8.1.10) is intended for mechanization of processes of disassembly and assembly of sus-
pension cylinders. Capture 7 is intended for fixing of work-piece on stand and for turning movement up to re-
quired position. Fixing of cylinder is carried out with help of folding clinch and swing bolt with nut. Clamper 2,
powered by hand lever 6, is intended for locking cylinder in required position. Twirl of capture together with
work-piece timbered in it is carried out with the help of worm reducer 4 by hand lever 3.
Before disassembly remove from cylinder sealant 31 (see figure 8.1.5), protective boot 31 and ring 30.
Disassembly is to be performed as follows:
- install completely stretched suspension cylinder in device and fix it in vertical position (it is possible to un-
clench cylinder by pressure of nitrogen with consequent discharge);
- by means of special sleeve open priming valve in order to be convinced that there is no gas in cylinder,
by lifting rod with sealing taper of pressure-relief valve release gas from housing;
- unscrew bolts 23 and remove covers 39 of trunnion balls;
- remove trunnion balls 40 and liners 2 from upper 38 and lower 25 covers;
- unscrew bolts 4, remove upper cover 38 with rod 36 of absorber, incline cylinder and drain oil;
- from upper cover 38 turn out priming valve 3, sensor valve 37 and having unscrewed bolts 5 of flange
7 remove rod 36 of absorber;
- unscrew plugs 15 on housing 11 and drain oil from cavity И;
- turn cylinder so that its lower cover is up, unscrew bolts 4 and remove lower cover 25;
- take out pump 28 from lower cover, having unscrewed bolts 26 of flange 19;
- remove housing 11 from tube of major cylinder 13 and turn out pressure-relief valve 10;
- install and fix suspension cylinder in horizontal position and pull out rod 34 through upper part of cylin-
der;
- turn out from case of compression valves 33 plugs 35, unlock cases of compression valves, turn out
cases and take out from them beads 32, remove basic washer 8, case 29 of release valve of absorber;
- remove washers 52 from piston of rod 34;
- turn out pinch nut 14 of tube of major cylinder 13 and remove package of parts of sealing: ring of cuff
58, cuff 57 with spacing ring 56, pressure ring 59, adjusting gaskets 61, spring 60 and guiding rod 12 with axle
box.
Disassemble pump if it is necessary.
Figure 8.1.10 – Stand ЭСБ 10 for disassembly and assembly of cylinders of pneumohydraulic suspension:
1 - grounding; 2 - clamper; 3 - hand lever of drive gear; 4 - worm reducer; 5 - bearing mount assembly; 6 - hand lever of clamper;
7 - capture
8-11
Running gear
7513-3902080 RM
Disassembly of pump is to be performed as follows:

- fix pump in device for external surface of case 5 (figure 8.1.11),
having provided its reliable fastening;
- unscrew nut 18;
- remove washer 16 of pump;
- squeeze package of parts 1, 6, 7, 10, 11, 12, 13, 14 through upper
part of case 5 of pump;
- remove from plunger 6 axle box 1;
- remove plunger 6 as an assembly with back-pressure valve 15;
- remove glass 7 from barrel 10;
- take out bead 11 and saddle 12 from barrel.
Figure 8.1.11 – Pump:

1 - axle box; 2, 3, 4, 8, 9 – sealing rings; 5 - case; 6 - plunger; 7 - glass; 10 - barrel;
11 - bead; 12 - saddle; 13 - washer; 14, 17, 19 - protective washers; 15 - back-pressure
valve; 16 - washer of pump; 18 - nut;
I, II, III - hollows
8.1.6 Disassembly of central hinges of front and rear suspension

While in operation fingers and hinged bearings of central hinge expose to wear. Repair is carried out by
substitution of worn out and damaged parts.
Disassembly of central hinge of front suspension of dump trucks BELAZ-75131, BELAZ-75132 is to be
performed as follows:
- install jambs under spars of frame in front part of bumper;
- install thrust blocks under wheels of front axle and rear axle of dump truck;
- release gas from cylinders of front suspension through priming valve, observing rules specified in sub-
section 8.1.3;
- install jamb under central bar of beam of front axle in its front part for exclusion of falling out of bar after
squeezing of finger;
- remove protective boot from central hinge;
- unscrew bolts 31 (see figure 8.1.3) of disk 30 fastening and remove disk;
- unscrew bolts 36 of lock plate fastening 35 and remove plate;
- install device as it is shown in figure 8.1.12 (on side of four tapped holes at butt of finger 2, preliminary
having unscrewed one series of bolts of eyelet 1 fastening to bar of front axle), and, having supplied pressure
in actuator 5 with the help of manual pump НСР–400МА or hydraulic station, squeeze finger 2.
IT IS FORBIDDEN TO STAND OPPOSITE TO FINGER THAT IS BEING SQUEEZED.
Figure 8.1.12 – Device 360-017 for squeezing of

central hinge finger of front suspension on
dump trucks BELAZ-75131, BELAZ-75132:
1 - eyelet; 2 - finger; 3 - insert; 4 - bracket; 5 – hydraulic cylin-
der; 6 - thrust block; 7 - spar of frame
8-12
Running gear
7513-3902080 RM
- disconnect device from lever;

- lower lever of front axle downwards (in order to provide convenient disassembly) on jamb;
- unscrew bolts 29 and remove eyelet 28 from truck;
- unsplint and turn out bolts 23 from both sides of eyelet;
- remove covers 27 with stuffing boxes 24;
- squeeze hinged bearing 26 from eyelet 28.
Disassembly of central hinge of rear suspension on dump trucks BELAZ-75131, BELAZ-75132 is to be
- install thrust blocks under wheels of front axle and rear axle of dump truck;
- release gas from cylinders of rear suspension through priming valve, observing rules specified in sub-
section 8.1.3;
- install jambs on edges of fourth cross bar of frame;
- install jamb in its front part under central bar of rear axle;
- remove mud shield 1 (see figure 8.1.4) from central hinge;
- unsplint and turn out locking bolts of nut 10 and unscrew nut;
- unscrew bolts 32 of locking plate 5 fastening and remove plate;
- install jamb in region of flange under lever in order to exclude falling of lever after release of finger;
- install device (preliminary having unscrewed one series of bolts of eyelet 7 fastening to lever of rear
axle) as it is shown in figure 8.1.13 (on part of thread М110х3), and supplying pressure in hydraulic cylinder 3
squeeze finger 9 with the help of manual pump НСР–400МА or hydraulic station.
IT IS FORBIDDEN TO STAND OPPOSITE TO FINGER THAT IS BEING SQUEEZED.
- disconnect device from lever;
- lower lever of rear axle downwards (in order to provide convenient disassembly) on jamb;
- unscrew nuts 14 (see figure 8.1.4) and remove bolts 15 and eyelet 7 from dump truck;
- turn out bolts 6 from both sides of eyelet;
- remove covers 8 with stuffing boxes 13;
- squeeze hinged bearing 12 from eyelet 7.
Disassembly of central hinge of rear suspension on dump trucks BELAZ-7514-10, BELAZ-75145 is to be
performed analogously to disassembly of central hinge of rear suspension on dump trucks BELAZ-75131, BE-
LAZ-75132 described above.
Figure 8.1.13 - Device 360-018 for squeezing of central

hinge finger of rear suspension on dump trucks BE-
LAZ-75131, BELAZ-75132:
1 - spar of frame; 2 - thrust block; 3 – hydraulic cyl-
inder; 4 - bracket; 5 - bolt; 6 - nut; 7 - eyelet; 8 - finger;
9 - insert
8.1.7 Disassembly of pivot unit of front suspension on dump trucks BELAZ-7514-10, BELAZ-75145
While in operation pivot, pivot barrels and pivot sealing are exposed to wear out. In case of wear of
chromic coverage of pivot or exit of lubrication through sealing at gun-greasing of pivot joint it is necessary to
replace worn-out parts.
Removal and disassembly pivot joint of front suspension on dump trucks BELAZ-7514-10, BELAZ-
75145 is to be performed as follows:
- install thrust blocks under wheels of rear axle of dump truck;
- release gas from cylinder of front suspension through priming valve, observing rules specified in sub-
section 8.1.3;
- unscrew bolts 33 (see figure 8.1.1) of lower bracket 28 of suspension cylinder fastening to pivot 5;
- close priming valve on suspension cylinder;
- hang out frame of dump truck, with help of crane (jacks) in its front part until free hanging of lower part
of cylinder of front suspension;
8-13
Running gear
7513-3902080 RM

- remove front wheel from hub (see «Wheels and tires» section);
- disconnect cylinder of turning movement and pull-rod of steering trapezoid from lever of steering trape-
zoid 18 (see “Steering” section);
- disconnect hose of service brake system;
- fasten hub 7 by device;
- unscrew nuts 12 of bolts 11 of pivot bracket 6 fastening to frame, remove pivot unit and install it on
jamb;
- disconnect lever of steering trapezoid 18 from swivel member having unscrewed nuts 14, 16 and ex-
tract expanding barrels 15;
- turn out stud from pivot tail;
- install pivot unit on stand and squeeze pivot from swivel member.
Disassembly of pivot is to be performed as follows:
- fix beam 9 of stand (figure 8.1.14 b) on hub 1 of wheel;
- install and fix pivot unit as assembly on frame 6 of jamb;
- insert washer 2 into threaded hole of pivot tail, tighten bolt 3;
- install mobile bracket 4 in right position, having fixed its with bolts;
- squeeze pivot tail from eyelet of tappet with the help of hydraulic device 5;
- install bracket 4 in left position;
- remove hub as assembly from frame of jamb;
- install wheel hub 1 (figure 8.1.14 а) with swivel member on support brackets of stand table 11 for final
squeezing of pivot;
- lock mobile table and support swinging arms with screws to secure them from moving;
- connect worm reducer 4 and swivel member of wheel hub with the help of turnbuckle 3;
- tighten connective head 9 in tapped hole of pivot tail 12;
- switch on electromotor, bring power-transmission screw 6 against stop in connective head, lock screw
in connective head and squeeze pivot 12;
- from eyelets of bracket 6 (see figure 8.1.1) extract barrels of pivot 20 and sealing: scratcher 26, wiper
ring 25, cuff 24 with support ring 23 and replace them;
- replace pivot if there are sections with wear out of chromic coverage on its surface. If there are no such
0
sections unroll pivot on 180 . In order to perform this rearrange pin 19 in second bore at lower butt of pivot. If
pin can not be extracted cut it off.
8.1.8 Removal and disassembly of transversal rods of front and rear suspension
While in operation fingers and hinged bearings of transversal rod are exposed to wear out. Repair is car-
ried out by substitution of worn out and damaged parts.
Removal and disassembly of transversal rod of front suspension on dump trucks BELAZ-75131, BELAZ-
- unscrew fastening bolts 12 (see figure 8.1.3) of hinged bearing 10 on one side of rod 2;
- remove cover 11;
- remove rod together with bearing 10 from finger 7 with the help of puller device;
- perform analogous operations on other side of rod;
- extract stuffing boxes 8 of rod;
- remove locking rings 9;
- squeeze hinged bearings 10 from rod with the help of arbor.
Removal and disassembly of transversal rod of rear suspension on dump trucks BELAZ-75131, BELAZ-
- unscrew bolts 18 and 26 (see figure 8.1.4) and remove pinch plates 25;
- extract distance barrel 17;
- beat out finger 20, applying force from the side of taper barrel 24;
- extract liberated end of transversal rod from bracket;
- remove sealing rings 16 from barrels 21 and 24;
- perform analogous operations on other side of rod;
- extract stuffing boxes 27 of rod;
– remove locking rings 22;
– squeeze hinged bearings 23 from rod with the help of arbor.
Removal and disassembly of transversal rod of rear suspension on dump trucks BELAZ-7514-10, BE-
8-14
Running gear
7513-3902080 RM
LAZ-75145 is to be performed analogous to procedures mentioned above for dump trucks BELAZ-75131, BE-
LAZ-75132.
Figure 8.1.14 - Stand ЭСБ 3 for assembly-disassembly of pivot:

а) - stand ЭСБ 3:
1 - wheel hub with swivel member; 2 - support bracket; 3 - turnbuckle; 4 - reducer; 5 - support bracket; 6 - power-transmission
screw; 7 - electromotor with tightening device; 8 - frame; 9 - connective head; 10 – mechanism for lifting and lowering of table; 11 - mobile
table; 12 - pivot; 13 – bracket of pivot;
b) - jamb ЭП 11 (comes in package with the stand):
1 - wheel hub with swivel member; 2 - washer; 3 - bolt; 4 - mobile bracket: 5 - hydraulic device; 6 - frame; 7 - pivot; 8 - bracket of
pivot; 9 - beam
8-15
Running gear
7513-3902080 RM
8.1.9 Check-up of technical condition of suspension parts

After disassembly check up technical condition of working surfaces of suspension parts by external ex-
amination and sampling of their critical parameters. Besides, tube of major cylinder, rod, cuff, guiding of rod
and piston should not have corrosion, burrs and other mechanical damages on their working surfaces.
Most frequent imperfections of cuffs are shown in figure 8.1.15.
Figure 8.1.15 - Most frequent imperfections of sealing cuffs of rod:

1 - sealing crimps are uniformly worn out; 2 - local wear of crimps or ribbing as result of operation on adualterated oil or at insuffi-
cient purity of sealing surfaces; 3 - emergency collapse of cuffs because of excessive deformation of sealing rings (high tightness)
After disassembly of suspension cylinders all general mechanical rubber work-pieces and cuffs are sub-
ject to obligatory substitution.
Rated and maximum permissible dimensions of suspension parts on dump trucks BELAZ-75131, BE-
LAZ-75132 are specified in table 8.1.2, and on dump trucks BELAZ-7514-10, BELAZ-75145 – in table 8.1.3.
Table 8.1.2 — Rated and maximum permissible dimensions of major suspension parts on dump
trucks BELAZ–75131, BELAZ–75132
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
549А – 2907036
Tube of major cylinder:
Inner diameter +0,09
260 +0,21
260 241 – 285 НВ
Outer diameter Steel 45 ТВЧ h 1 – 4 mm
(coverage Хтв.30) НRС 53 min
290 There should not
− 0,13 be places with
wear of chromic
coverage
549Б – 2907126-01
549Б – 2907127-01
Upper and lower covers: Steel 45 167 – 217 НВ
Diameter of sphere 124,1 There should not
− 0,07 be faults
8-16
Running gear
7513-3902080 RM
Continuation of table 8.1.2
Dimensions, mm
trolled parameters
rated permissible
549Б – 2907056-11
Rod:
−0,100
Outer diameter 220 219,7 – 219,8 Steel 45 ТВЧ h 1,5 – 3,0 mm
− 0,172
Outer diameter on rolled up bronze on −0,100

piston 250 249,7 – 249,8 Strip
− 0,172 ДПРНТ3,0
НД Бр.ОФ
6,5-0,15
549А – 2907076 Strip
Guiding of rod with axle box: ДПРНТ3,0
+0,072 +0,185 НД Бр.ОФ
Inner diameter on bronze 220 220
6,5-0,15
549Б – 2907178
Body of contraction valve of shock-
+0, 2 Steel 35 229 – 285 НВ
absorber: 8 7
Diameter of inner hole
549Б – 2907186
Plug of compression valve: ТВЧ h 2,0 – 3,0 mm
Steel 35
Condition of butt from the side of di- There should not be chips and cracks 42 – 49 НRCэ
ameter 10
7513 – 2907327 241 – 285 НВ
Rod: Steel 45 ТВЧ h1 mm
Condition of surface on diameter 25 There should not be burrs and faults НRCэ50
549А – 2907330 There should not be faults of working sur-
Plunger of pump faces (on diameters 16, 20 and 30 mm). Steel 45
Back-pressure valve should be hermetic
549Б – 2907427 There should not be places with wear of Ribbon of

Collar step plastic stratum brand «С»
2,05х130
549Б – 2907428
241 – 285 НВ
Cover: There should not be burrs and faults Steel 45 ТВЧ h 1,5 - 3 mm
Condition of spherical surface НRC51
549Б – 2907447 Rotundity should 241 – 285 НВ

Trunnion ball: +0,054 not fall outside limits Steel 40Х ТВЧ h2 mm
Diameter of sphere
120 of 0,1 mm НRCэ51
7519 – 2907036
Tube of major cylinder:
+0,13 +0,21
Inner diameter 280 280 241 – 285 НВ
Steel 45 ТВЧ h1,5 mm
There should not be НRCэ53
Outer diameter
(coverage Хтв.30) 330 places with wear of
− 0,14 chromic coverage
7519 – 2907076 Strip
Guiding of rod with axle box: ДПРНТ3,0
+0,115 +0,29
Inner diameter on bronze 250 250 НД Бр.ОФ
6,5-0,15
8-17
Running gear
7513-3902080 RM
Dimensions, mm
trolled parameters
rated permissible
7519 – 2907056-11
Rod:
Outer diameter −0,100
250 249,7 – 249,8 Steel 45 ТВЧ h1,5 mm
− 0,172 НRC53
Outer diameter on rolled up bronze on −0,11 Strip

280 279,6 – 279,7
piston − 0,24 ДПРНТ3,0
НД Бр.ОФ
6,5-0,15
7519 – 2907126-02
7519 – 2907127-01
Upper and lower covers: Steel 45 167 – 217 НВ
Diameter of sphere 154,1 There should not
− 0,1 be faults
7513 – 2917327
241 – 285 НВ
Rod: There should not be burrs and faults Steel 45 ТВЧ h1 mm
Condition of surface on diameter 25 НRCэ50
7519 – 2907427
Ribbon of
Collar step There should not be places with wear of plastic
brand «С»
stratum
2,05х130
7519 – 2907428 241 – 285 НВ

Cover: Azotize
There should not be burrs and faults Steel 40Х
h0,3 mm
Condition of spherical surface
НV2400
7519 – 2907500 Rotundity should 241 – 285 НВ
Trunnion ball: +0,08 not fall outside lim- Steel 40Х ТВЧ h 2 - 7 mm
Diameter of sphere
150 its of 0,1 mm НRCэ50
7513 – 2909016-10
Normalization
Rod of suspension: +0,063 Steel 35 ТВЧ h 3 - 5 mm
Inner diameter under bearing
130 130
− 0,04 НRCэ42
7513 – 2909078
Finger: Carbonize
−0,036
Diameter under bearing 90 89,85 – 89,90 Steel h 1,6 – 2,0 mm
− 0,090 20ХН3А 58 – 64 НRCэ
Cores НRCэ32
Conic surface (1:10) There should not
be faults
7513 – 2909118
Barrel:
−0,085 There should not
Outer diameter (up to cutting) 132
− 0,148 be faults Steel 45 241 – 285 НВ

be faults
8-18
Running gear
7513-3902080 RM
Dimensions, mm
trolled parameters
rated permissible
75131 – 2909188
Tall barrel (length of barrel 84-0,54):
Outer diameter +0,125 There should not
241 – 285 НВ
148 be faults
+ 0,100
Inner diameter +0,087 Steel 45 ТВЧ h 2 - 5 mm

118 +0,14 НRCэ50
118
There should not ТВЧ h 2 - 5 mm

Butt of barrel (on diameter 135-1) be working-out of НRCэ50
more than 0,5 mm
7513 – 2909188
Tall barrel (length of barrel 107-0,54):
+0,125 There should not
Outer diameter 148 241 – 285 НВ
+ 0,100 be faults

118 +0,14 НRCэ50
118
There should not ТВЧ h 2 - 5 mm

Butt of barrel (on diameter 135-1) be working-out of НRCэ50
more than 0,5 mm
7519 – 2919187
Low barrel:
Outer diameter +0,125 There should not 241 – 285 НВ
150 be faults
+ 0,100 Steel 45
Inner diameter +0,16 ТВЧ h 2 - 5 mm

134 +0,25 НRCэ50
134
75131 – 2919230
Normalization
Eyelet with grounding: −0,014 215 – 215,02 Steel 35 ТВЧ h 1,5 – 5,0 mm
Inner diameter
215 35 – 50 НRCэ
− 0,060
7513 – 2909230
Normalization
Eyelet with grounding: Steel 35 ТВЧ h 1,5 – 5,0 mm
180 180,01 – 180,03
Inner diameter − 0,04 35 – 50 НRCэ
75131 – 2919016:
Normalization
Rod of suspension: +0,030 +0,072
200 Steel 35 ТВЧ h3 mm
Inner diameter under bearing (length − 0,016
200 НRCэ42
of rod on shafts is 1050 mm)
7513 – 2919016
Normalization
Rod of suspension: +0,063 Steel 35 ТВЧ h3 mm
Inner diameter under bearing
180 180
− 0,04 НRCэ42
7513 – 2909426
Finger (length of finger - 312 mm):
First outer diameter −0,145 241 – 285 НВ
134 134
− 0,245 − 0, 4
−0,036 −0,120 Steel 40Х ТВЧ h3 mm

Second outer diameter 120 120 47 – 53 НRCэ
− 0,090 − 0,207
Хтв.12 (on three di-
−0,120 ameters)
Third outer diameter 118 118
− 0,207 − 0,35
8-19
Running gear
7513-3902080 RM
Dimensions, mm
trolled parameters
rated permissible
75131 – 2909426
134 134
− 0,245 − 0, 4
−0,036 −0,120 Steel 40Х ТВЧ h3 mm

− 0,090 − 0,207
−0,120 ameters)
− 0,207 − 0,35
7521 – 2919078
Finger of rod: Carbonize
−0,043
Outer diameter 130 129,85 – 129,9 Steel h 1,4 – 1,8 mm
− 0,083 20ХН3А 59 – 63 НRCэ
Core НRCэ32
be faults
75211 – 2909078
Finger of rod: Carbonize
−0,05
Diameter under bearing 120 119,78 – 119,8 Steel h 1,6 – 2,0 mm
− 0,14 20ХН3А 59 – 63 НRCэ
Core НRCэ32
be faults
7513 – 2919186
Tall barrel:
Outer diameter +0,125 There should not 241 – 285 НВ
150 be faults
+ 0,100

118 +0,14 НRCэ50
118
There should not be ТВЧ h 2 - 5 mm

Butt of barrel (on diameter 135-1) working-out of more НRCэ50
than 0,5 mm
7513 – 2919187
Low barrel:
241 – 285 НВ
150 be faults
+ 0,100 Steel 45
Inner diameter +0,16 ТВЧ h 2 - 5 mm

134 +0,25 НRCэ50
134
75132 – 2919230
Eyelet with grounding: ТВЧ h 1,5 – 5,0 mm
−0,014 Steel 35
215 215 – 215,02 40 – 50 НRCэ
Inner diameter − 0,060
7513 – 2919426-10
134 134
− 0,245 − 0, 4
−0,036 −0,120 Steel 40Х ТВЧ h 3 - 5 mm

− 0,090 − 0,207
−0,120 ameters)
− 0,207 − 0,35
8-20
Running gear
7513-3902080 RM
Table 8.1.3 — Rated and maximum permissible dimensions of major suspension parts on dump
trucks BELAZ–7514-10, BELAZ–75145
Dimensions, mm
trolled parameters
rated permissible
7519 – 3001018-01
Pivot of swivel member: There should not be ТВЧ h 3 - 5 mm
−0,056 Steel 45
Outer diameter 260 places with wear of 47 – 53 НRCэ
−0,186
(coverage Хтв.60) chromic coverage
7519 – 3001016-11 There should not be places with wear of Ribbon of brand
Barrel of pivot plastic stratum «С» 2,56х100
7519 – 3001060
Bracket of pivot:
+0,13 Steel 40Л 146 – 229 НВ
Inner diameter 265,25 265,5
7521 – 2919016-01:
Normalization
Rod of suspension: +0,030 +0,072
200 Steel 35 ТВЧ h3 mm
Inner diameter − 0,016
200 НRCэ42
(length of rod on shafts is 1220 mm)
75211 – 2909426
134 134
− 0,245 − 0, 4
−0,036 −0,120 Steel 40Х ТВЧ h3 mm

− 0,090 − 0,207
−0,120 ameters)
− 0,207 − 0,35
7519 – 2919230-10
Normalization
Eyelet with grounding: −0,014 Steel 35 ТВЧ h 1,5 – 3,0 mm
215 215 – 215,02
Inner diameter − 0,060 40 – 50 НRCэ
7519 – 2919186
Tall barrel:
Outer diameter 150 241 – 285 НВ
+ 0,100 be faults

118 +0,14 НRCэ50
118
There should not be ТВЧ h 2 - 5 mm

Butt of barrel (on diameter 135-1) working-out of more НRCэ50
than 0,5 mm
7521 – 2919154
Barrel:
150 be faults
+ 0,08 Steel 40Х 241 – 285 НВ
Inner diameter +0,1 +0,25

132 132
7521 – 2919155
Conic barrel:
Outer diameter 150
+ 0,08 be faults Steel 40Х 241 – 285 НВ

be faults
8-21
Running gear
7513-3902080 RM
Dimensions, mm
trolled parameters
rated permissible
7521 – 2919158
Distance barrel:
−0,085 There should not
Outer diameter (up to cutting) 132
− 0,148 be faults Steel 45 241 – 285 НВ

be faults
8.1.10 Assembly of suspension cylinders

Assembly of suspension cylinders should be performed in conditions providing protection of unit from hit
of dust, abrasive corpuscles, water and mud. On parts there should not be agnails and rust, and on working
surfaces and facets there should not be nicks, scratches and other faults.
Before assembly all ports and remote places of parts should be cleared of swaft and mud, blown with
compressed air. After that parts should be washed out in diesel fuel or white spirit and dried up.
At assembly, transportation, mounting and disassembly, and also at other operations with suspension
cylinders it is forbidden to transmit force to housing 11 (see figure 8.1.5) in order to prevent damage in view of
its thin-walledness.
Assembly of suspension cylinders is executed with observance of following rules:
- at assembly all thread and rubbed surfaces of parts should be greased with working fluid;
- rubber sealing rings of round cross-section, fluoroplastic cuff 57, fluoroplastic protective
washers 52 should be washed out in working fluid before mounting in cylinder (or pump);
- at mounting rubber sealing rings make sure that rings are not twisted in grooves and are not
undercuted.
Cylinders of front and rear suspension of dump truck are analogous in construction and differ only in
sizes and configuration of chase of variable section on rod of absorber, amount of filled oil and level of gas
pressure. In order not to mix rods of absorbers at repair of cylinders identification mark is plotted on their lower
butt on factory-manufacturer.
At lower butt of rod of absorber of front suspension cylinders of dump truck BELAZ-7514-10, BELAZ-
75145 digit "3", and rear - digit "4" is stamped. On rods of absorbers of front suspension cylinders of dump
truck BELAZ-75131, BELAZ-75132 digit "15", and rear - digit "16" is stamped.
Probably during operation of cylinder digits of identification mark will be “chocked" so that it is impossible to
define them. Than it is possible to distinguish rods only on configuration of chases of variable section (figures 8.1.16
and 8.1.17).
Assembly of upper cover is to be performed as follows:
- install in propoint of upper cover 38 (see figure 8.1.5) rod 36;
- put on rod flange 7 and fix it by bolts 5 with washers (tightening torques of threaded connections of
suspension cylinders are specified in table 8.1.5);
- install sealing ring 6 in groove of upper cover.
Before starting assembly of lower cover it is necessary to perform assembly of pump 28.
Assembly of pump is to be performed as follows:
- fix case 5 (figure 8.1.11) pump for outer diameter in device, having provided its reliable fastening;
- install on barrel 10 sealing rings 8, 9 and protective washers 14;
- insert into barrel 10 saddle 12 with sealing ring, bead 11 and glass 7;
- insert into case 5 washer 13, barrel 10 in assembly with saddle, bead and glass;
- install on plunger 6 sealing ring 4 and protective washers 17;
- insert plunger 6 in assembly with back-pressure valve 15 into barrel 10;
- install on axle box 1 sealing rings 2, 3 and protective washers 19;
- put on axle box 1 plunger 6 and insert it into case 5;
- put washer 16 on case 5 of pump;
- turn nut 18 on case 5 of pump.
8-22
Running gear
7513-3902080 RM
Figure 8.1.16 - Rod of absorber of suspension cylinder of dump truck BELAZ-7514-10, BELAZ-75145:
1 - cylinder rod of front suspension; 2 - cylinder rod of rear suspension
Figure 8.1.17 - Rod of absorber of suspension cylinder of dump truck BELAZ-75131, BELAZ-75132:
1 - cylinder rod of front suspension; 2 - cylinder rod of rear suspension
8-23
Running gear
7513-3902080 RM
Assembly of lower cover is to be performed as follows:

- in ring bore of lower cover 25 (see figure 8.1.5) install ring 20;
- put on flange 19 on pump and fix it by bolts 26 with washers;
- install pump 28 in inner chamber of cover;
- insert filters 16 and sealing rings 18.
Assembly of rod is to be performed as follows:
- install valve of release 29 of absorber in bore of rod 34;
- install support washer 8;
- screw cases of compression valves 33 in tapped holes;
- install bead 32 in inner chamber of each valve of contraction of shock-absorber and stamp it;
- turn plugs of compression valves 35, preliminary having installed sealing gasket under butt of plug
heads;
- unbend edges of support washer 8 on edges of compression valve body 33;
- install two washers 52 in external groove of piston of rod.
Assembly of major cylinder is to be performed in the following sequence:
- fix in stand (see figure 8.1.10) tube 1 (figure 8.1.18) of major cylinder;
- insert into tube of major cylinder guiding 2 of rod with axle box and package of sealing parts: thrust ring
9, pressing ring 5 with spring 4, adjusting gaskets 3 (the greatest amount - 4 pieces), spacing ring 8 with cuff of
rod 7, ring of cuff 10;
- screw pinch nut 6.
Tightness of cuff is adjusted through amount of adjusting gaskets 3. In case of incorrect size delete or add ad-
justing gasket.
Figure 8.1.18 - Scheme of tightness adjustment for cuff of

rod:
1 - tube of major cylinder; 2 - guiding rod with axle
box in assembly; 3 – adjusting gasket; 4 - spring; 5 - pressing
ring; 6 - pinch nut; 7 - cuff of rod; 8 - spacing ring; 9 - thrust
ring; 10 - ring of cuff; 11 - sealing ring
Measurements of tightness are to be performed at completely compressed package of sealing. Ring of

cuff 10 through adjusting gaskets should be pressed to guiding of rod 2.
Measurement of tightness are to be performed by means of measuring device with measuring force from
7 up to 9 N, eliminating strain and fault of working crimps.
Sizes of cuffs of cylinders front and rear suspension at installed tightness in limits from 2,0 up to 2,3 mm
after tightening of pinch nut are shown in table 8.1.4.
8-24
Running gear
7513-3902080 RM
Table 8.1.4 - Sizes of cuffs of suspension cylinders after tightening of pinch nut
Place of Recommended size, Recommended Torque of pinch nut,
Name
measuring mm tightness, mm N.m
Cuff of rod of the front
217,7 — 218,0
cylinder
Inner diameter 2,0 — 2,3 9000 — 10000
Cuff of rod of the rear
247,7 — 248,0
cylinder
Sampling of tightness of cuffs (inner diameter) is to be executed by measuring tool eliminating strain and
fault of working crimps of cuffs. For sampling tightness of cuffs it is recommended to use special caliper which
jaws have big length and width as contrasted to usual calipers (figure 8.1.19).
Figure 8.1.19 - Caliper for sampling tightness of cuff of suspension cylinder
Such caliper is easy to make using usual caliper having soldered to it specially produced jaws, as it is
shown in figure. Jaws are to be soldered with copper-zinc solder. After that perform test of caliper on exacti-
tude of measurement as prescribed by instruction on inspection of probing devices.
After adjusting tightness of cuff (deriving of required inner diameter size) unscrew pinch nut 6 (see figure
8.1.18), take out ring 10 cuff. Put sealing ring 11 on ring of cuff and insert it into tube of major cylinder 1.
Special device (figure 8.1.20) is designed for mechanization of process of tightness adjustment of cuff of
cylinder sealing package. Device consists of adjustment stand (280-55-6), hydraulic equipment and electrical
equipment.
The adjustment stand consists of bed 3, hydraulic cylinder 2 and squeezing mechanism 1. Hydraulic
equipment consists of pump 4, hydraulic distributor 5 and hydraulic reservoir 6.
For adjusting tightness install package of sealing in guidings of squeezing mechanism 1, set upper rod 7
into working position and contract package of sealing. Measure inner diameter of cuff and change amount of
adjusting gaskets at misfit of size.
8-25
Running gear
7513-3902080 RM
Figure 8.1.20 - Device 280-62 for adjusting tightness of cuff:

1 – squeezing mechanism; 2 - hydraulic cylinder; 3 - bed; 4 - pump; 5 - hydrodistributor; 6 - hydraulic reservoir; 7 - upper rod
After mounting sealing package in tube of major cylinder turn pinch nut 6 (preliminary having greased
thread with lubricant Литол-24) not turning approx 1,5 revolutions till compression of package of sealing parts
(against stop);
- install rod 34 (see figure 8.1.5) in assembly with valves in tube of major cylinder 13 so that butt of pis-
ton was on distance of 25 mm from butt of tube of major cylinder of front suspension and on distance of 55 mm
up to butt of tube of major cylinder of rear suspension;
- tighten pinch nut 14 with torque (see table 8.1.5);
- ihrough tapped holes in pinch nut prick-punch ring of cuff 58, having made deepening with angle taper
0
of 90 and depth of not less than 1,5 mm;
- in tapped holes of pinch nut install and turn locking screws 27;
- prick-punch locking screws in two points aside from slot on screw.
The further assembly of suspension cylinders is to be performed as follows:
- put ring 30 in assembly with rod 34 on tube of major cylinder 13;
- install sealing ring 53, safety ring 54 and ring 17 in housing 11;
- put housing 11 on rod 34;
- install assembled lower cover 25 in rod 34 and fix it by bolts 4 with washers;
- unscrew plugs 35 of compression valves and fill oil in cavities of cylinder up to level of upper butt of
piston of rod (filling of cylinder is to be performed in vertical position);
- tighten plugs of compression valves;
- install assembled upper cover 38 in tube of major cylinder and fix it by bolts 4 with washers;
- refuel cylinder with oil through bores under priming valves up to level of bores;
- screw priming valve 3 and valve of sensor 37, having installed sealing gaskets 46under them;
- screw safety valves 21 in upper 38 and lower 25 covers;
- install insert 2 of trunnion balls 40 in upper and lower cover, having greased spherical surface of insert
with lubricant Литол-24;
- install adjusting gaskets 24 on upper and lower covers;
- insert trunnion balls into upper and lower covers, preliminary having greased spherical surface with lu-
bricant Литол-24;
- install sealing rings 22 in covers 39;
- fix by bolts covers 39 to upper 38 and to lower 25 covers so that trunnion balls 40 had no longitudinal
backlash and were twirled in any direction with torque of no more than 60 N.m for front cylinder and torque of
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no more than 75 N.n for rear cylinder, regulate it be gaskets 24;

- press pins 1 in trunnion balls, having observed max size of 13 mm.
Tightening torque of threaded connections at assembly of suspension cylinders should match to values
specified in table 8.1.5.
Table 8.1.5 — Tightening torque of threaded connections at assembly of suspension cylinders
Name of part Designation Tightening torque, N.m
Pinch nut (М270х4) 549А-2907087 9000 — 10000

Pinch nut (М300х4) 7519-2907087 9000 — 10000
Priming valve (М16х1,5) 540-2917360-01 110 — 140
Bolts of flange of absorber rod fastening
(М10) 201495 25 — 32
Bolts of upper and lower covers and
covers of trunnion balls fastening
(М12х1,25) 340279 70 — 90
(М14х1,5) 340348 110 — 140
(М16х1,5) 340446 160 —200
Plug of compression valve of absorber
(М20х1,5) 549Б-2907186 100 — 140
Case of compression valve of absorber
(М32х2) 549Б-2907178 100 — 140
Captive nut of pump (М48х1,5) 549А-2907259 100 — 140
Bolts of pump washer fastening (М10) 201495 22 — 32
Locking screws (М12) 341590 16 — 22
Болты крепления шайбы насоса (М8) 201454 11 — 17
Charging cylinder with gas is to be performed as follows:

- connect reducer of device to bulb with nitrogen through adapter connector 2 (figure 8.1.21);
- screw adapter connector 17 of devices on priming valve of suspension cylinder;
- open valve on bulb with nitrogen. Check gas pressure in bulb on manometer 3;
- tightening regulating screw 12 of reducer create gas pressure in cylinder prior to beginning of release;
- close valve on bulb and release gas from ports and hose of device by sleeve 8;
- turn needle 15 prior to beginning of priming valve opening. Beginning of priming valve opening is de-
fined on moment of aberration of arrow on manometer 10. Perform wrenching of needle cautiously in order not
to damage valve spring;
- open valve on bulb and by screw 12 of reducer release cylinder up to such size that pressure on ma-
nometer 10 coincides with level of pressure indicated on characteristic ruler (see figure 8.1.6) or it agrees with
table 8.1.6;
- turn out needle 15 (see figure 8.1.21), close valve on bulb, disconnect device from priming valve, test
leakproofness of valve and place of its mounting, close valve cover;
Table 8.1.6 – Gas pressure in cavity of completely released cylinder
Dump truck designation Suspension cylinder Cylinder designation Gas pressure, МPа
front 7519-2907020-10 2,47+0,016

BELAZ–7514-10, BELAZ–75145
Rear 7519-2917020 0,86+0,025
Front 7513-2907020-20 2,8+0,016

BELAZ–75131, BELAZ–75132
rear 7513-2917020-20/021-20 1,06+0,016
- fill oil in cavity of housing up to level of plug 15 thread (see figure 8.1.5). Cylinder should be in vertical
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position;
- turn plugs 15 and pressure-relief valve 10, preliminary having installed sealing gaskets;
- remove suspension cylinder from device for assembly;
- install protective boot 9 and put sealant 31.
IN ORDER TO AVOIDE GAS LEAKS THROUGH MOBILE ROD SEAL STORAGE AND TRANSPORTATION OF
CHARGED SUSPENSION CYLINDERS IS TO BE PERFORMED IN VERTICAL POSITION, ABERRATION FROM VER-
TICAL POSITION SHOULD NOT EXCEED 300.
Figure 8.1.21 - Device 531-3924370-10 for charging suspension cylinders:

1, 9, 11, 18 - sealing gaskets; 2, 6, 17 - adapter connectors; 3, 5 - manometers; 4 - reducer; 7 - valve; 8 - sleeve for release of gas;
10 - manometer for monitoring gas pressure in suspension cylinder; 12 - regulating screw of reducer; 13 - hose; 14 - nut; 15 - needle;
16 - sealing ring
8.1.11 Mounting of suspension cylinders on dump truck

Mounting of suspension cylinders on dump truck is to be executed in the following sequence:
- deliver suspension cylinders from section of assembly to place of their mounting to dump truck by
means of special device (see figure 8.1.9);
- install suspension cylinder in gripper of device (see figure 8.1.8) and lock them safely;
- before mounting of suspension cylinders tails of trunnion balls and torquering threaded connections are
to be greased with lubricant Литол-24.
Mounting of cylinders of front suspension of dump trucks BELAZ-7514-10, BELAZ-75145:
- install on lower trunnion ball 36 (see figure 8.1.1) disk 35, lower bracket 28 of suspension cylinder with
buffer 29 and fix them with nut 2 with torque 1600 - 2000 N.m;
- install and fix tube of lubrication supply 31in tail of lower trunnion ball;
- install disk 35 on upper trunnion ball;
- install suspension cylinder by means of device by upper trunnion ball in bore of upper bracket of sus-
pension cylinder and fix it by means of nut 2;
- screw greaser 1 in tail of upper trunnion ball;
- fix lower bracket 28 of suspension cylinder to pivot 5 by bolts 33 with washers by torque 700-900 N.m;
- fix boots 27 on upper and lower trunnion balls.
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Mounting of front suspension cylinders on dump trucks BELAZ-75131, BELAZ-75132:

- install disk 13 on lower and upper trunnion balls 22 (see figure 8.1.3), on lower - lower bracket 21 of
suspension cylinder, on upper - bracket of suspension cylinder 33 and fix them by nuts with 19 torque of 1600 -
2000 N.m, after torquering tighten nut on angle 600 (one edge);
- install and fix tubes of lubrication supply 32 of trunnion balls in tails of trunnion balls;
- install and fix upper bracket of suspension cylinder 33 by bolts 20 with washers with torque of 910 - 1020 N.m
to bracket of frame, and lower bracket of suspension cylinder 21 to swivel member. Before tightening of bolts 20 of
lower bracket of suspension cylinder 21 fastening to swivel member adjust by means of adjusting washers 14 spac-
ing between butts of bracket of suspension cylinder 21 and ring 18. Spacing should not be more than 0,5 mm. Work-
ing surface of part 17 is to be greased with lubricant Литол-24;
Mounting of rear suspension cylinders of dump trucks BELAZ-7514-10, BELAZ-75145:
- install disk 33 on lower and upper trunnion balls (see figure 8.1.2);
- install suspension cylinder by means of device by upper trunnion ball in bore of bracket of frame and fix
it by means of nut 32 with torque of 2700 - 3150 N.m;
- install tail of lower trunnion ball in bore of bracket of rear axle and fix it by means of nut 32;
- screw greasers 31 in tails of upper and lower trunnion balls;
Mounting of rear suspension cylinders of dump trucks BELAZ-75131, BELAZ-75132:
- install disk 28 on lower and upper trunnion balls 31 (see figure 8.1.4);
- install suspension cylinder by means of device by upper trunnion ball in bore of bracket of frame and fix
it by means of nut 29 with torque of 1800 - 2000 N.m;
- install tail of lower trunnion ball in bore of bracket of rear axle and fix it by means of nut 29;
- screw greaser 19 in tails of upper and lower trunnion balls;
AFTER MOUNTING SUSPENSION CYLINDERS ON ALL DUMP TRUCKS TRUNNION BALLS ARE TO BE
GREASED WITH LUBRICANT ЛИТОЛ-24 THROUGH GREASERS TILL EMERSION OF LUBRICATION FROM
SAFETY VALVES.
8.1.12 Assembly of central hinges of front and rear suspension

Install thrust blocks under wheels of front axle and rear axle.
Assembly of central hinge of rear suspension of dump trucks BELAZ-7514-10, BELAZ-75145 is to be
- press stuffing boxes 15 in covers 7 (see figure 8.1.2);
- install cover with stuffing box in eyelet with grounding 6 and fix by bolts 8 with torque of 360 - 440 N.m;
- press hinged bearing 14 against stop in cover. Before mounting hinged bearing is to be greased with
blend of 90 % of lubrication Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75. Outer ring of hinged
bearing is to be installed on sealer "УГ-9" TУ 6-01-1326-86;
The jointing plane of outer ring of hinged bearing should be installed on shaft, thus identification mark at
butts of both semi-rings should be on one hand of bearing, and semi-rings should be of one serial number. In-
0
ner ring of bearing after mounting in greased condition should be turned on angle of not less than 16 by hand
or under force (20 + 5) Н affixed on distance (200 + 50) mm from butt of inner ring;
- install cover 7 with stuffing box in eyelet with grounding 6 and fix it with bolts 8;
- lock bolts 8 from both sides of eyelet splint-wire 36;
- fix eyelet 6 in assembly with bearing to central lever by bolted joint with nut 17 torque of 1100 - 1400
N.m;
- install central lever 2 with eyelet 6 inside bracket of frame and, having combined bores in bearing and
bracket, press finger 9 against stop;
- install and fix by bolts 35 with washers lock plate 5. Spacing in junctions of lock plate is not permitted,
and can be eliminated by turning movement of finger 9. Bolt 35 tightening torque is 360 - 440 N.m;
- place and tighten with torque of 1800 - 2000 N.m split nut 10 (on factory-manufacturer torquering is
carried out by pneumobox wrench ИП 31-15 GOST 10210-83, Мкр maх 3150 N.m).
0
After torquering nut is to be tightened on angle of 60 (one edge). Torquering should be performed by
wrench with booster of torque that is sufficient for tightening or other equipment, observing safety precautions.
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INSUFFICIENT TORQUERING OF NUT RESULTS IN DAMAGE TO LOCKING WEDGE DEVICE, UNSCREWING

OF NUT AND IN ACCIDENT
The axial clearance in joint butt of finger 9, bearing and butt of barrel is not permitted;
- losk nut 10 from unscrewing with two bolts 11, splint them in turn with splint - wire 12;
- install protective boot 1.
Assembly of central hinge of front suspension of dump trucks BELAZ-75131, BELAZ-75132 is to be per-
formed as follows:
- install cover with stuffing box in eyelet with grounding 28 and fix it with bolts 23;
0 0
The jointing plane of outer ring of hinged bearing should be under an angle 90 + 5 to shaft Ж, thus
identification mark at butts of both semi-rings should be on one hand of bearing, and semi-ring should be of
one serial number. Inner ring of bearing after mounting should be turned on angle of not less than 150 by hand
without jams or under force (20 + 5) Н affixed on distance (200 + 50) mm from butt of inner ring;
- install cover 27 with stuffing box in eyelet with grounding 28 and fix it with bolts 23;
- lock bolts 23 from both sides of eyelet with splint-wire 37;
- fix eyelet 28 in assembly with bearing to central lever bolt 29 with torque of 910-1020 N.m;
- install central lever with eyelet 28 inside bracket of frame and, having combined bores in bearing and
it can be eliminated by turning movement of finger 25;
- install disk 30 and fix finger by bolts 31 with torque of 1100 – 1250 N.m with washers. Axial clearance in
joint butt of finger 25, bearing and butt of barrel is not permitted.
Assembly of central hinge of rear suspension of dump trucks BELAZ-75131, BELAZ-75132 is to be per-
formed as follows:
- install cover with stuffing box in eyelet with grounding 7 and fix it with bolts 6. Before assembly external
surfaces of bolts and bores mated to it are to be greased with two - three drops of sealer "Анатерм-8К" TУ - 6-
02-6-88;
The jointing plane of outer ring of hinged bearing should be installed on shaft И, thus identification mark
at butts of both semi-rings should be on one hand bearing, and semi-ring should be of one serial number.
0
The inner ring of bearing after mounting should be turned on angle not less than 15 under force (20 + 5)
Н, affixed on distance (200 + 50) mm from butt of inner ring;
- install cover 8 with stuffing box in eyelet with grounding 7 and fix it with bolts 6, having installed them
on sealer "Анатерм-8К";
- fix eyelet 7 in assembly with bearing to central lever bolted joint, nut 14 torque is 1200 - 1500 N.m;
- install central lever with eyelet 7 inside bracket of frame and, having combined bores in bearing and
and can be eliminated by turning movement of finger 9;
- place and tighten with torque of 1800 - 2000 N.m split nut 10 (on factory-manufacturer torquering is
carried out by pneumobox wrench ИП 31-15 GOST 10210-83, Мкр maх 3150 N.m).
After torquering nut is to be tightened on angle of 600 (one edge). Torquering should be performed by
wrench with booster of torque that is sufficient for tightening or other equipment, observing safety precautions.
INSUFFICIENT TORQUERING OF NUT RESULTS IN DAMAGE TO LOCKING WEDGE DEVICE, UNSCREWING

OF NUT AND IN ACCIDENT.
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- lock nut 10 from unscrewing by two bolts, Splint them in turn by splint-wire. Axial clearance in joint butt of
finger 9, bearing and butt of barrel is not permitted.
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ-24 TILL EMERSION OF LUBRICATION FROM UNDER STUFFING BOXES.
8.1.13 Assembly and mounting of transversal rods of front and rear suspension
Assembly and mounting of transversal rod of rear suspension of dump trucks BELAZ-7514-10, BELAZ-
- install locking ring 24 in head of rod 4 (see figure 8.1.2) and press hinged bearing 23 against stop in
locking ring.
The jointing plane of outer ring of hinged bearing should be installed under angle of 900 + 50 to direct-
axis of rod, thus identification mark at butts of both semi-rings should be on one hand of bearing, and semi-
rings should be of one serial number.
The inner ring of bearing after mounting in greased condition should be turned on full angle (against stop
in ring) by hand without jams or under force (20 + 5) Н, affixed on distance (100 + 50) mm from butt of inner
ring. Before mounting hinged bearings and finger of rod are to be greased with blend of 90 % of lubrication
Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75;
- install second locking ring, having fixed hinged bearing in head of rod;
- press stuffing boxes 19 in head of rod on one from each side of bearing and install sealing rings 30;
- carry out above mentioned operations on second head of rod;
- install head of transversal rod inside of brackets of frame and rear axle, having combined bores in rod
and bracket, install fingers 26;
- install plate pinch 21 on part of conic barrel 22 and fix by bolts with 20 torque of 360 - 440 N.m with
washers;
- install distance barrel 29, pinch plate 21 and fix them with bolts 20 and 28 with washers.
Assembly and mounting of transversal rod of front suspension of dump trucks BELAZ-75131, BELAZ-
locking ring.
0 0
At mounting of hinged bearings 10 jointing plane of outer ring should be installed under angle 90 + 5 to
direct-axis of rod 2, thus identification mark at butts of both semi-rings should be on one hand of bearing, and
semi-rings should be of one serial number.
The inner ring of bearing after mounting should be turned in outer ring on angle of 70 by hand without
jams or under load of no more than 20 Н, affixed on distance of100 mm from butt of inner ring;
- grease spherical surfaces of bearing with lubricant Литол-24 and put it in cavity of stuffing boxes 8;
- press stuffing boxes 8 in head of rod on one from each side of bearing;
- install fingers 7 in bores of inner ring of hinged bearings 10, and fingers from both sides of rod should
be unrolled on angle 1800 relative to each other;
- install covers 11 on butts of hinged bearings and fix them with bolts 12 with washers;
- install barrels 6 and disks 5 in bores of brackets of frame and front axle;
- install transversal rod 2 with fingers 7 in bores of brackets of frame and front axle and to tighten bolts 4
with torque of 2400 - 3000 N.m. Bolts 4 are to be installed on sealer "Анатерм-8К" TУ - 6-02-6-88.
Assembly and mounting of transversal rod of rear suspension of dump trucks BELAZ-75131, BELAZ-
locking ring.
The jointing plane of outer ring of hinged bearing should be installed under angle of 900 + 50 to shaft of
rod Ж, thus identification mark at butts of both semi-rings should be on one side of bearing, and semi-rings
should be of one serial number. Inner ring of bearing after mounting should be turned in outer ring on angle of
not less than 70 from force (10 + 5) Н, affixed on distance (100 + 50) mm from butt of inner ring.
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Before mounting of hinged bearing plane of plug of outer ring is to be greased with blend of 90 % of lu-
brication Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75, outer ring of hinged bearing is to be
greased with sealer "УГ-9" TУ 6-01-1326-86;
- press stuffing boxes 27 in head of rod on one from each side of bearing and install sealing rings 16;
- install head of transversal rod inside of brackets of frame and rear axle, having combined bores in rod
and bracket, install fingers 20;
- install pinch plate 25 on part of conic barrel 24 and tighten bolts 26 with washers;
- install distance barrel 17, pinch plate 25 and fix them with bolts 26 and 18 with washers. External sur-
faces of bolts and bores mated to them are to be greased with two - three drops of sealer "Анатерм-8К".
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ-24 TILL EMERSION OF LUBRICATION FROM UNDER STUFFING BOXES.
8.1.14 Assembly and mounting of pivot unit of front suspension on dump trucks BELAZ-7514-10,
BELAZ-75145
Assembly and mounting of pivot unit is to be performed as follows:
- install in eyelets of bracket 6 (see figure 8.1.1) barrels of pivot 20 and sealings: scratcher 26, wiper ring
25, cuff 24 with support ring 23.
Before mounting of bracket of pivot 6, barrels pivot 20, pivot 5 and sealings 23, 24, 25, 26 are to be
carefully cleared till full removal from their surface of dust, mud and preserving lubrication, and are to be dried
by wiping with soft paper or textile fabric napkins. Grease internal surface of bracket 6, swivel member 8, bar-
rels pivot with lubricant Литол-24;
- install and fix bracket 13 of pivot on mobile table 11 of stand (see figure 8.1.14 а);
- fix beam on wheel hub 1;
- install wheel hub with swivel member on support brackets 2;
- with the help of hoisting gear of table and screws perform centering of bores of swivel member and
bracket pivot shafts;
- lock mobile table and basic swinging arms with screws from moving;
- connect worm reducer 4 and swivel member with the help of turnbuckle 3;
- put pivot 12 on table of roll-table;
- perform centering of shaft of pivot regarding shafts of swivel member 1 and bracket of pivot 13. Lock
table of roll-table;
- turn connective head 9 in tapped hole of pivot tail;
- switch on electromotor, bring power-transmission screw 6 against stop in connective head, lock screw
in connective head and press pivot in bores of mated units;
- turn studs 13 and 17 in tapped holes of swivel member and pivot (see figure 8.1.1);
- install lever 18 of steering trapezoids on swivel member, fix it by nuts 14 with torque of 800-1000 N.m,
preliminary having installed expanding barrels 15;
- fix pivot 5 to lever of steering trapezoid 18 by nut 16 with torque of 1600 - 2000 N.m with washer;
- install pivot unit on dump truck, tighten nut 12 with torque of 1800 - 2000 N.m;
- connect to pivot lower bracket of suspension cylinder 28, having fixed bolts 33 with torque of 700 - 900
N.m with washers;
- connect with lever 18 of steering trapezoid the cylinder of turning movement and pull-rod of steering
trapezoid, hose of service brake system;
- install front wheel on hub;
- remove dump truck from jamb and charge suspension cylinder with gas according to characteristic ruler.
AFTER ASSEMBLY GREASE BARRELS OF PIVOT WITH LUBRICANT ЛИТОЛ-24 THROUGH GREASERS 22
TILL EMERSION OF LUBRICATION FROM PRESSURE-RELIEF VALVES 21.
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8.2 Front axle
8.2.1 Front axle of dump trucks BELAZ-75131 and BELAZ-75132
8.2.1.1 General information

Front axle is steerable, not driving. It consists of beam 6 (figure 8.2.1), right 4 and left wheels 9 with
brakes and swivel gear, joint among themselves with the help of cylindrical pivots 20.
Beam of front axle is welded structure of box-shaped cross-section with cast nosepieces welded on its
ends. Central lever of front suspension, which is hingedly connected to cross bar of frame, is welded on beam
with brackets of cylinders of turning movement.
The swivel member 7 (figure 8.2.2) is connected to beam 29 by pivot 20 (see figure 8.2.1.), which is fixed
in nosepiece of beam motionlessly with the help of locking member of pivot 16. Swivel member is turning on
pivot in four metal-plastic barrels 19 installed in upper and lower eyelets of tappet. Barrels are greased through
press-greasers 18 and are sealed by cuffs 27.
Six antifriction liners 11, installed on both sides of cover 13 (three from each side), execute role of plain
bearings. From turning liners are secured by thrust nibs that are included in bores in swivel member and cover.
Pivot rod 2 of steering trapezoid is fastened to lower eyelet of swivel member by means of studs 6 (see figure
8.2.2) and expanding taper barrels 4. Ring 18 (see figure 8.1.3) serves for limitation of upright conveyance of
beam of front axle with pivot. Adjusting washers 14 are intended for clearance adjustment between ring and
butt of bracket 21 of suspension cylinder.
The hub of front wheel 13 (see figure 8.2.2) with brake plate attached to it 8 is twirled on wrist pin of
swivel member 7 on two taper roller bearings 9 and 11. Sealing of bearings is carried out by cuff 25 and stuff-
ing box 21. In left wheel of front axle the drive gear of speedometer sensor 17 is installed, in right – adometer
33 can be installed on customer’s order.
Front axle is connected to frame by means of central hinge, transversal rod and suspension cylinders.
Some operations on repair of front axle, such as replacement of pivots and barrels, replacement of bear-
ings of hubs, pull-rod and bars of steering trapezoid, are executed directly on dump truck without removal of
front axle. Removal of front axle is needed only in cases if there is necessity of restoring bores in brackets of
cylinders of turning movement or repair of beam itself. In case of necessity in replacement of beam front axle is
removed from dump truck and disassembled on perts.
8.2.1.2 Removal of front axle from dump trucks BELAZ-75131 and BELAZ-75132
Front axle in assembly with hubs and brakes, pull-rod of steering trapezoid and cylinders of turning
movement are removed from dump truck in following sequence:
- apply parking brake and install thrust blocks under rear wheels;
- hang out front part of dump truck up to full disengagement of wheels from floor of platform, release gas
from cylinders of front suspension and install special jambs under frame behind front axle;
- remove wheels from hubs of dump truck front wheels (see «Wheels and tires» section). Before unfastening
of wheels release air from tires;
- disconnect sleeves of high pressure of steering from cylinders of turning movement, hoses of brakes,
lubrication lines of centralized automatic lubricating system. Before unhooking of sleeves and hoses remove
pressure of working fluid in hydraulic drive of braking systems;
- install special carriage-hoist under front axle and jack beam of front axle against stop in lower shelf;
- unscrew bolts 20 (see figure 8.3) of lower brackets 21 suspension cylinder fastening attached to swivel
members;
- unscrew bolt 4, disconnect transversal rod 2 of suspension from beam of front axle;
- lead out brackets of suspension cylinder up to exit of flanges from propoints of landing nests of swivel
members by smooth omitting of shaft on carriage-hoist;
- disassemble central hinge of front suspension and squeeze finger of central hinge (see section 8.1.6);
- make sure of reliable position of shaft on carriage-hoist and roll out front axle from under dump truck
installed on jambs;
- moor front axle with the help of fastening device and deliver shaft to section of repair (weight of front
axle is about 7760 kg).
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8.2.1.3 Disassembly of front axle of dump trucks BELAZ-75131 and BELAZ-75132

Disassembly of front axle is to be performed as follows:
- install front axle on special stand for disassembly and fix it;
- disconnect pipe ducts of braking system necessary for removal of brake cases 31 (see figure 8.2.2);
- unscrew, before releasing spring lock washer, upper bolt 34 of brake case 31 fastening to swivel mem-
ber 7, release, before releasing spring lock washer, lower bolt, completely turn out upper bolt and holding case
of brake (weight of case is about 100 kg), lower it against stop downwards, rotating it on lower bolt;
- remove case of brake with the help of load-lifting device, having turned out lower bolt 34;
- remove case of brake located on other side of swivel member in same sequence;
Figure 8.2.1 - Front axle of dump trucks BELAZ-75131 and BELAZ-75132:

1 - hose of high pressure; 2, 26 - triangles; 3, 5, 8, 10, 15 - tubes; 4 - right front wheel with brakes and swivel gear; 6 - beam of
front axle with lever; 7 - T-connector; 9 - left front wheel with brakes and swivel gear; 11, 24 - liners; 12, 23 - bolts; 13 - cover; 14 - safety
valve; 16 - locking member of pivot; 17 - plug; 18 - greaser; 19 – barrel of pivot; 20 - pivot; 21 - nut; 22 - clinch; 25 - connective valve;
27 - cuff
8-34
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Figure 8.2.2 – Swivel member with hub, brake and swivel gear of dump trucks BELAZ-75131 and BELAZ-75132:
1 - arrester; 2 - left rotary lever; 3 - barrel of pivot; 4 - expanding barrel; 5 - nut; 6, 22 - studs; 7 - left swivel member; 8 - brake
drisk; 9, 11 - bearings; 10 - arrester of volume; 12, 15, 19, 24, 34 - bolts; 13 - hub of front wheel; 14 - pinch ring; 16 - adjusting barrel;
17 - drive gear of speedometer sensor; 18 - sealing gasket; 20 - external cover of front hub; 21 - stuffing box; 23 - wheel; 25 - cuff; 26 - in-
ternal cover of front hub; 27 - choke; 28 - wiring harness of speedometer; 29 - beam of front axle; 30 - ring; 31 - case of brake; 32 - splint;
33 - adometer; 35 - washer; 36 - strap
8-35
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- unscrew bolts 12 and remove external cover 20 of hub of front wheel;

- unscrew bolts 19 and remove drive gear of speedometer sensor 17, having disconnected wiring har-
ness of speedometer 28 and sealing gaskets 18 (only for left wheel);
- unsplint and unscrew bolts 15 and remove pinch ring 14;
- extract stuffing box 21 out of boring of hub of front wheel 13;
- press hub in assembly with brake plate and inner rings of bearings with help of device (figure 8.2.3);
Figure 8.2.3 - Device 360-013 for removal and mounting of front hub on dump trucks BELAZ-75131 and BELAZ-75132:
1 - claw of loader; 2 - wheel hub; 3 - jamb; 4 - nut; 5 - hold-down tool; 6 - bolt; 7 - hand lever; 8, 10 - screws; 9 - insert;
11 - bracket; 12 - support
- disconnect and remove from front axle pull-rod of steering trapezoid and cylinders of turning movement
(see "Steering" chapter);
- unscrew nuts 5 (see figure 8.2.2) of pivot rods 2 of steering trapezoid fastening to swivel members;
- extract expanding barrels 4 and remove pivot rods;
- extract from upper eyelet of swivel members adjusting washers 14 (see figure 8.1.3), ring 18 with
buffer 16 and liners 17;
- unscrew bolts 12 (see figure 8.2.1) and remove cover 13 of pivot and liners 11;
- moor swivel member 7 with the help of load-lifting device (see figure 8.2.2) and hang it out;
- turn two eye bolts M14 in opposite tapped holes of pivot 20 (see figure 8.2.1) and moor pivot;
- turn out locking member 16 of pivot;
- squeeze pivot 20 by means of special device (figure 8.2.4). If squeezing of pivot is hampered due to
8-36
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origin of oxide film (corrosion) in joint “pivot-nosepiece of beam

of front axle” it is necessary to turn out plugs 9 and apply fluid
destroying oxide film through bores;
- remove swivel member in assembly and deliver it to sec-
tion of repair.
Figure 8.2.4 - Device 360-019 for squeezing of pivot on dump trucks

BELAZ-75131 and BELAZ-75132:
1 - power cylinder; 2 - insert; 3 - nut; 4 - barrel; 5 - swivel member;
6 - pivot; 7 - beam of front axle; 8 - bracket; 9 - plug
At disassembly of hub 13 (see figure 8.2.2) of front wheel apply device shown in figure 8.2.5 for squeez-
ing of outer ring of external bearing 11, apply device shown in figure 8.2.6 for squeezing of outer ring of inner
bearing 9 (see figure 8.2.2).
Figure 8.2.5 - Device 360-006 for squeezing of outer ring of external bearing (2007156А)
of hub of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - nut; 2 - screw; 3 - washer; 4 - beam; 5 - cover; 6 - stud; 7 - outer ring of bearing; 8 - hub
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Figure 8.2.6 - Device 360-009 for squeezing of outer ring of inner bearing (2007164А)
of hubs of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - hub; 2 - outer ring of bearing; 3 - remover; 4 - washer; 5, 7 - nuts; 6 - screw; 8 - insert; 9 - beam; 10 - stud; 11 - adapter
connector
At disassembly of swivel member 7 (see figure 8.2.2) for squeezing of inner ring of inner bearing 9 and
internal cover 26 of hub of front wheel apply device shown in figure 8.2.7.
Figure 8.2.7 - Device 360-005 for squeezing of inner ring of inner bearing (2007164А)
of hub of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - remover; 2 - cover; 3 - insert; 4 - wrench; 5 - inner ring of bearing; 6 - internal cover of front hub; 7 - hook; 8 - swivel member
8-38
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8.2.2 Swivel member with hub of dump trucks BELAZ-7514-10 and BELAZ-75145
8.2.2.1 General information

The hub of front wheel 25 (see figure 8.2.8) with attached to it bolts 51 of brake drum 9 is twirled on wrist
pin of swivel member 12 on two taper roller bearings 7 and 24. Sealing of bearings is carried out by stuffing
boxes 44 installed from both sides of hub. In left wheel drive gear of speedometer sensor 4 is installed.
The swivel member 12 is rigidly connected with pivot 14 and can displace together with wheel in bracket
of pivot 17 in axial direction and rotate around shaft of pivot. Bracket of pivot is fixed on frame by bolted joint.
Operations on repair, such as replacement of bearings of hubs and hub, are executed directly on dump
truck without removal of pivot unit of suspension.
Removal of pivot unit of suspension from dump truck, disassembly, repair, assembly and mounting on
dump truck is specified in chapter 8.1 "Suspension”.
8.2.2.2 Removal and disassembly of hub of front wheel
The hub of front wheel is removed from dump truck in following sequence:
- hang out frame of dump truck, with the help of crane (jacks) in its front part up to full disengagement of
wheels from floor of platform and install special jambs under spars of frame instead of jacks;
- remove wheel from hub 25 (see figure 8.2.8) of dump truck (see «Wheels and tires» section). Before unfas-
tening of wheels release air from tire;
- unscrew bolts 45 and remove external cover 3 of front wheel hub;
- unscrew bolts 6 and remove drive gear of speedometer sensor 4, having disconnected wiring harness
of speedometer 18 and sealing gaskets 5 (only for left wheel);
- unsplint and unscrew bolts 43 and remove pinch ring 1;
- extract stuffing box 44 out of boring of front wheel hub;
- moor hub with fastening or lifting device for simplification of squeezing and exclusion of falling of hub
after squeezing;
- fix device (figure 8.2.9) on hub 6 and press hub is assembly with brake drum and outer rings of bear-
ings;
- install hub on special jamb and fix hub in order to exclude of its falling;
- extract stuffing box 44 out of boring on other side of hub;
- unscrew bolts 51 (see figure 8.2.8) and disconnect brake drum 9 from hub (only if repair or replace-
ment of brake drum is necessary);
At disassembly of hub of front wheel apply device 360-006 shown in figure 8.2.5 for squeezing of outer
rings of bearings 7 and 24, and apply device (manufactured as 360-005, shown on figure 8.2.7) for squeezing
of inner ring of inner bearing 24.
8.2.3 Check-up of technical condition of front axle parts of dump trucks BELAZ–75131, BELAZ–
75132 and of swivel member with hub of dump trucks BELAZ–7514-10, BELAZ–75145
After disassembly test technical condition of working surfaces of parts by external examination and
measurement of their critical parameters.
Rated and maximum permissible sizes of parts of front axle of dump trucks BELAZ-75131 and BELAZ-
75132 are specified in table 8.2.1, rated and maximum permissible sizes of swivel member with hub of dump
trucks BELAZ-7514-10 and BELAZ-75145 are specified in table 8.2.2.
Besides, mounting of swivel members with cracks is not permitted. Pivots of swivel members of dump
trucks BELAZ-75131 and BELAZ-75132 are discarded also at presence of cracks, faults and wear of cylindri-
cal surface.
Hubs of front wheels are subject to discard or repair at presence of cracks, faults of thread under studs
of wheels and wear of mounting surfaces under bearings.
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8-40
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Figure 8.2.8 - Front wheel with brakes and swivel gear of dump trucks BELAZ-7514-10 and BELAZ-75145:
1 - pinch ring; 2 - adjusting barrel; 3 - external cover of front hub; 4 - drive gear of speedometer sensor; 5 - sealing gasket; 6, 31, 39, 43, 45, 51 - bolts;
7, 24 - bearings; 8, 23 - studs; 9 - drum brake; 10 - arrester of volume; 11 - internal cover of hub; 12 - swivel member; 13 – barrel of pivot; 14 - pivot; 15 -
greaser; 16 - safety valve; 17 - bracket; 18 - wiring harness of speedometer; 19 - stud of lever of rear suspension; 20, 22 - nuts; 21 - expanding barrel; 25 - hub
of front wheel; 26 - finger of spring; 27, 33, 36, 42 - splints; 28 - spring; 29 - pad with straps; 30 - wheel cylinder of front brake; 32 - protective boot; 34 - split
key; 35 - plunger; 37 - lever of steering trapezoid; 38 - washer; 40 - strap of shaft of pads; 41 - shaft; 44 - stuffing box; 46 - choke; 47 - scratcher; 48 – wiper
ring; 49 - cuff; 50 – support ring
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Figure 8.2.9 - Device 75131-3918350 for removal

and pressing hubs of front wheels:
1 - hand lever; 2 - screw; 3 - beam of remover; 4 - nut; 5 - disk; 6 - hub of front wheel
Table 8.2.1 — Rated and maximum permissible sizes of major parts of front axle
of dump trucks BELAZ–75131, BELAZ–75132
Dimensions, mm
trolled parameters
rated permissible
7513 – 3001005
Beam of front axle with lever +0,09 Steel 40 Л 156 – 229 НВ
Diameter of hole under pivot 210 210,2
7513 – 3001014
Swivel member
Diameter of wrist pin under bearings −0,017
280 279,88 Steel 45 241 – 285 НВ
−0,049
−0,018
320 319,88 Steel 40Л 156 – 229 НВ
−0,054
7513 – 3001016-10 There should not

Ribbon of
Barrel of pivot be places with
brand «С»
Thickness of barrel 2,60 + 0,05 wear of plastic
2,6х100
stratum up to metal
7513 – 3001019
241 – 285 НВ
Pivot −0,050 Steel 45 ТВЧ h 2 - 4 mm
Outer diameter 210 209,80 НRCэ47
−0,165
7513 – 3103015
Hub of front wheel
−0,045
Diameter of holes under bearings 420 420,00
−0,108 Steel 40Л 156 – 229 НВ
−0,045
480 480,00
−0,108
8-41
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Dimensions, mm
trolled parameters
rated permissible
7519 – 3103089-20
Pinch ring
Steel 40Л 156 – 229 НВ
Outer diameter under sealant 410 408,00
−1,55
7513 – 3103070-01
Inner cover of front hub ТВЧ h 1,5 - 4 mm
Steel 35
Outer diameter under sealant 480 479,75 НRCэ40
−0,125
Table 8.2.2 — Rated and maximum permissible sizes of major parts of front wheel
of dump trucks BELAZ–7514-10, BELAZ–75145
Dimensions, mm
trolled parameters
rated permissible
7519 – 3001013-30
Swivel member
−0,017 Steel 45 241 – 285 НВ
Diameter of neck of wrist pin under 280 279,88
inner and outer bearing −0,049
7519 – 3103015
Hub of front wheel
−0,045 Steel 40Л 156 – 229 НВ
Diameter of neck under bearing 420 420,00
−0,108
7519 – 3103089-20
Pinch Ring
Steel 40Л 156 – 229 НВ
Outer diameter under sealant 410 408,00
−1,55
7519 – 3103070-01
Inner cover of front hub ТВЧ h 1,5 - 4 mm
Steel 35
Outer diameter under sealant 480 479,75 НRCэ40
−0,125
8.2.4 Assembly and mounting of front axle of dump trucks BELAZ-75131 and BELAZ-75132
The parts of front axle delivered on assembly, should be cleared of mud, washed out and blown through
by compressed air.
Before assembly of barrel of pivot 19 (see figure 8.2.1), pivot 20, cover 13 and liner 11 are to be cleared
till full removal from their surface of dust, mud and preserving lubrication and are to be dried by wiping with soft
paper or textile fabric napkins.
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Assembly of front axle is to be executed on special stand. At wear out or mechanical damage of metal-
plastic stratum of pivot barrels extract them from eyelets of swivel member and install new.
Assembly of front axle.

For simplification of assembly of front wheel hub units and swivel member install half-assembled unit in
vertical position on special jamb.
Assembly of front axle is to be performed as follows:

- press internal cover 26 (see figure 8.2.2) of front wheel hub on wrist pin of swivel member 7 against
stop in butt of swivel member (the probe of 0,05 mm should not pass between butt of swivel member and butt
of cover);
- press inner ring of bearing 9 on wrist pin of swivel member against stop in butt of swivel member.
0
For simplification of assembly heat cover 26 and inner ring of bearing in oil to temperature 120 С. After
cooling up to ambient temperature make sure that ring of bearing is completely set on place;
- fill carefully lubricant Литол-24 in space between rollers of bearing 9, put lubricant in cavity of cover 26;
- press outer rings of bearings 9 and 11 in hub 13 against stop in butt (probe of 0,1 mm should not
pass).
For simplification of assembly, before mounting of outer rings of bearings in hub, put them in dry ice. Af-
ter press fitting and heat of rings to ambient temperature make sure, that they are completely set on place (the
probe of 0,1 mm should not pass between butt of hub and ring of bearing);
- press cuff 25 in boring of hub. Before assembly fill lubricant Литол-24 in inner chamber of cuff (be-
tween working crimps) on two - third of its volume;
- with the help of load-lifting device install hub 13 in assembly with brake disk 8 on wrist pin of swivel
member. Before mounting fill lubricant Литол-24 in cavity of arrester 10 of hub;
- install inner ring of external bearing 11 on wrist pin of swivel member, carefully having filled lubricant
Литол-24 in space between rollers of bearing, and by means of device (see figure 8.2.3) press bearing against
stop of rollers in outer ring of bearing;
- press stuffing box 21 (see figure 8.2.2) in boring hub, preliminary having impregnated it with oil МС-20;
- install pinch ring 14, preliminary having filled in cavity of ring lubricant Литол-24, combine bores and fix
ring with bolts 15 without tightening them;
- perform adjusting of roller taper bearings.
Adjusting of taper bearings is to be performed as follows:

- by turning hub (at three revolutions min) tighten six bolts 15 with torque of 100 - 140 N.m. Repeat op-
eration up to suitable twisting torque;
0
- unscrew bolts on 22 - 28 ;
- tighten adjusting barrels 16 with torque of 100 - 140 N.m;
- tighten twelve bolts 15 with torque of 100 - 140 N.m and splint by splints 32;
- install sealing gasket 18 on drive gear of speedometer sensor 17, combine bores, install and fix bolts
19 drive gear of speedometer sensor to fit ring 14, having connected wiring harness of speedometer 28 (only
for left wheel);
- install external cover 20 of front hub and fix it with bolt 12;
- install external cover of front hub with adometer 33 and fix it with bolts 12 (on customers’ demand for
right wheel only);
- install two cases 31 of brake on swivel member 7 and fix them with bolts 34 with torque of 1500 - 1800
N.m, having provided spacing of 1,5 mm min between butts of shafts of case straps and brake disk 8 with ad-
justing washers 35;
- install with the help of hoisting gear swivel member 7 in assembly with hub 13 and brake gear vertically
with shaft of bore under pivot and install it on jamb 3 (see figure 8.2.3);
- install barrel 19 of pivot in eyelets of swivel member (see figure 8.2.1) and press cuffs 27;
- turn two eye bolts in opposite tapped holes of pivot 20 and install pivot in bore of upper eyelet of swivel
member. Before mounting internal surfaces of pivot barrels, surface of pivot and eyelets of swivel member,
working crimps of cuffs are to be greased with thin stratum of lubrication Литол-24. Before assembly fill lubri-
cant Литол-24 in inner chamber of cuff 27 (between working crimps) on two - third of its volume;
- lead swivel member with pivot installed in it to beam of front axle 6 and combine bores of swivel mem-
ber with bore of beam;
- install arbor on pivot and press pivot till overlapping bores pivot and beams under locking member 16
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of pivot;
- turn locking member 16 against stop in combined bores of pivot and beams;
- on support surface in upper eyelet of swivel member install liners 11, cover 13 and fix them with bolts
12, preliminary having greased surface of liners with lubricant Литол-24;
- make sure that swivel member rotates on shaft of pivot to left and to right without jams. Use hoisting
device;
- install arrester 1 (see figure 8.2.2) with ring 30 in lower eyelet of swivel member;
- install pivot rod 2 of steering trapezoids and fix it by nuts 5 with torque of 800 - 1000 N.m to swivel
member, having installed expanding barrels 4 on studs 6 under nuts 5;
- connect and fix pipe ducts of braking system and lubricating system;
- install another swivel member on beam of front axle in the same sequence;
- install and fix pull-rod of steering trapezoid and cylinders of turning movement (see "Steering" section)
to pivot rod of swivel members and brackets of beam of front axle;
- after assembly grease barrels of pivots with lubricant Литол-24 through press-greasers 18 (see figure
8.2.1). Amount of lubrication is to be approx 0,2 - 0,3 kg in each eyelet of swivel member.
Mounting of front axle on dump truck.

Mounting of front axle on dump truck is to be performed as follows:
- moor front axle with the help of fastening device and deliver repaired shaft from section of assembly to
place of its mounting on dump truck;
- install front axle on carriage-hoist and, having made sure of its reliable fixing, drive it under dump truck
installed on jambs;
- install central lever of beam of front axle in eyelet inside of bracket of frame and press finger of central
hinge (for assembly of central hinge see "Suspension" chapter);
- by smooth lifting of front axle on carriage-hoist inject brackets of suspension cylinder up to input of
flanges into propoints of landing nests of swivel members;
- install lower bracket of suspension cylinder 21 and fix it to swivel member by bolts 20 (see figure 8.1.3)
with washers with torque of 910 - 1020 N.m. Before tightening of bolts 20 of lower bracket of suspension cylinder
21 fastening to swivel member adjust spacing between butts of bracket of suspension cylinder 21 and rings 18 by
means of adjusting washers 14. Spacing should not be more than 0,5 mm. Working surface of part 17 is to be
greased with lubricant Литол-24;
- connect transversal rod of front suspension to beam of front axle (for mounting of transversal rod see
"Suspension" chapter);
- roll out special carriage-hoist from under front axle;
- charge front suspension cylinders with gas;
- connect sleeves of high pressure of steering to cylinders of turning movement, hoses of brakes and lu-
brication lines of automatic lubricating system;
- install wheels on hubs of front wheels (see «Wheels and tires» section). After torquering of nuts pump
up tires with air up to required pressure;
After mounting front axle on dump truck adjust convergence of front wheels without removing dump
truck from jambs.
Adjusting of toe-in is to be executed in the following sequence:

- install front wheels in position corresponding to driving of dump truck on direct;
- measure size A (figure 8.2.10) between butts of board groundings of wheel rims at level of shafts of
front wheels in front of dump truck;
- turn wheels on half of revolution and measure size between specified points behind;
- toe-in is equal to difference of sizes Б - A and should be in limits of 5 - 10 mm. Adjusting is to be per-
formed by changing of length of pull-rod 3, having weakened bolts of terminal joints of transversal pull-rod
nosepieces. Difference of sizes B and Г should not exceed 5 mm. After adjusting of toe-in tighten nuts of ter-
minal joints of pull-rod nosepieces with torque of 110 - 140 N.m.
After mounting of front axle on dump truck and adjusting of toe-in remove dump truck from jambs, re-
move thrust blocks from under rear wheels.
8-44
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7513-3902080 RM
Figure 8.2.10 - Steering trapezoid:

1, 4 - cylinders of turning movement; 2 - pivot rod; 3 - transversal pull-rod; A, Б, В, Г - sizes
8.2.5 Assembly and mounting of hub of front wheel on dump trucks BELAZ-7514-10 and
BELAZ-75145
The parts delivered on assembly, should be cleared from mud, washed and blown by compressed air.
Assembly of front wheel hub.

Assembly of hub is to be performed as follows:
- press internal cover 11 (see figure 8.2.8) of front wheel hub on wrist pin of swivel member 12 against
stop in butt of swivel member (the probe of 0,05 mm should not pass between butt swivel member and butt
cover);
- press inner ring of bearing 24 on wrist pin of swivel member against stop in butt of swivel member.
0
For simplification of assembly heat cover and inner ring of bearing in oil up to temperature of 120 С. Af-
ter cooling to ambient temperature make sure that ring of bearing is completely set on place;
- fill lubricant Литол-24 in space between rollers of bearing and put lubricant in cavity of cover;
- press outer rings of bearings 7 and 24 in hub 25 against stop in butt (the probe of 0,1 mm should not
pass between them).
For simplification of assembly before mounting of outer rings of bearings in hub put them in dry ice. After
press fitting and heat of rings to ambient temperature make sure that they are completely set on place (the
probe of 0,1 mm should not pass between butt hub and ring of bearing);
- press stuffing boxes 44 from both sides in boring of hub, having impregnated them with oil МС-20;
- with the help of load-lifting device install hub 25 in assembly with brake drum 9 on wrist pin of swivel
8-45
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7513-3902080 RM
member. Before mounting fill lubricant Литол-24 in cavity of arrester of volume 10 of hub;
- install inner ring of external bearing 7 on wrist pin of swivel member, carefully having filled lubricant
Литол-24 in space between rollers of bearing, and by means of device (see figure 8.2.9) press hub of front
wheel against stop;
- install pinch ring 1, preliminary having filled lubricant Литол-24 in cavity of ring, combine bores and fix
ring with bolts 43 without torquing them;
- perform adjusting of roller taper bearings.
Adjusting of taper bearings is to be performed as follows:
- turning hub (at three revolutions min) tighten six bolts 43 with torque of 100 - 140 N.m. Repeat opera-
tion till suitable twisting torque;
- unscrew bolts on 22 - 280;
- tighten adjusting barrels 2 with torque of 100 - 140 N.m;
- tighten twelve bolts 43 with torque of 100 - 140 N.m and splint by splints 42;
- install sealing gasket 5 on drive gear of speedometer sensor 4, combine bores, install drive gear of
speedometer sensor and fix it with bolts 6 to pinch ring 1, having connected wiring harness of speedometer 18
(for left wheel only);
- install external cover 3 of front hub and fix it with bolts 45;
- install wheels on hubs of front wheels (see «Wheels and tires» section). After torquering of nuts pump
up tires with air up to required pressure;
After mounting of wheels on hubs, adjust toe-in of front wheels without removing dump truck from jambs.
Adjusting of toe-in is to be executed in the following sequence:

- install front wheels in position corresponding to driving of dump truck on direct;
- set wheels so that distance from rear point of brake drum at altitude of shaft of wheel up to plane of
support of bracket of pivot is on 3 - 6 mm more than from front point of brake drum, observing the size (80 + 5)
mm (between bracket pivot and lower eyelet of tappet). This size is established by charging of cylinders of
front suspension;
- adjust length of pull-rod 4 (see figure 8.2.11) and fix it to pivot rods 3. The difference of sizes A should
also be no more than 5 mm;
- put forward cylinder rod of turning movement in size B = (325 + 2) mm, adjust length of cylinder with
nosepiece 2 and fix it to lever of trapezoid. Tightening torque of nuts in terminal joints is to be 110 - 140 N.m. Af-
ter adjusting of toe-in, remove dump truck from jambs, remove thrust blocks from under rear wheels.
8.2.6 Adjusting of bearings of front wheel hubs during operation of dump trucks
Adjusting of bearings of front wheel hubs is to be performed as follows:

- hang out front of dump truck up to full disengagement of wheels from floor of platform and install spe-
cial jambs under spars of frame;
- remove external cover of front wheel hub;
- unsplint twelve bolts;
- unscrew bolts installed in bores of adjusting barrels on two - three revolutions;
- unscrew adjusting barrels on two - three revolutions;
- by rotating hub in both directions tighten six bolts, installed in bores without adjusting barrels in pinch
ring with torque of 100 - 140 N.m (figure 8.2.12);
0
- unscrew same bolts on 22 - 28 ;
- tighten adjusting barrels with torque of 100 - 140 N.m;
- tighten all twelve bolts with torque of 100 - 140 N.m (figure 8.2.13);
- splint all bolts in pairs (figure 8.2.14);
- install external cover of front wheel hub and fix it with bolts;
- remove dump truck from jambs, remove thrust blocks from under rear wheels.
8-46
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7513-3902080 RM
Figure 8.2.11 - Steering trapezoid:

1, 5 - cylinders of turning movement; 2 - nosepiece of cylinder; 3 - pivot rod; 4 - transversal pull-rod; A, Б, B - sizes
Figure 8.2.12 - Torquering of adjusting barrels
8-47
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7513-3902080 RM
Figure 8.2.13 - Final bolt tightening

of pinch ring
Figure 8.2.14 - Splinting of pinch

ring bolts
8-48
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7513-3902080 RM
8.3 Wheels and tires

Six non-disk wheels are installed on dump truck. The wheels of front axle are unary. The wheels of driv-
ing axle are dual. Wheels are fastened to the hub by means of clips and studs with nuts.
The wheel (figures 8.3.1 and 8.3.2) consists of rim, two bead, landing and key rings. Between rims of
dual rear wheels the spacing ring is installed.
Rim has a tapered internal surface for alignment and fastening of wheel to the hub. Key ring is of split
type. The rim and demountable landing ring have tapered shelves, on which tire beads are planted with tight-
ness.
Tires are tubeless. Sealing of rim with demountable landing ring is carried out by rubber sealing ring.
Figure 8.3.1 - Mounting of front wheel:

1 - valve; 2 - clip of wheel fastening; 3 - stud; 4 - nut of
wheel fastening; 5 - key rim ring; 6 - sealing ring; 7 - bead ring;
8 - tire; 9 - rim; 10 - landing ring
Figure 8.3.2 - Mounting of rear wheels:

1 - tire; 2 - rim; 3, 4 - valves; 5 - nut of wheel fastening; 6 - stud; 7 - clip of wheel fastening; 8 - landing ring; 9 - key rim ring;
10 - spacing ring; 11 - sealing ring; 12 - extension lead
8-49
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8.3.1 Removal of wheels from hubs

For removal of wheel, using jack or special hydraulic hoist, lift corresponding part of dump truck till
brake-off of wheels from surface of platform and install dump truck on jamb.
Before unscrewing nuts of wheel fastening in order to prevent accidents release air from tire. Before un-
fastening rear twin wheels air it is necessary to release air from both tires. At deaeration slide valve should be
unscrewed completely. If valve damaged, it is possible to release air from wheel by drilling several holes
(throughout in tire) with diameter of 4 - 5 mm in rim or side member of tire.
After complete deaeration make sure that there is no pressure in tire.
IT IS FORBIDDEN TO START UNFASTENING OF WHEEL, NOT HAVING CONVINCED IN ABSENCE OF AIR

PRESSURE IN TIRE!
It is necessary to observe the specified requirements at performing any works connected with necessity
of unfastening or removal of wheels.
At operation of dump truck in key part of wheel rim there can be cracks. If there is air in tire at releasing
of wheel fastening there can be sudden rupture of rim that can result in accidents.
For unfastening front wheel unscrew nuts 4 (see figure 8.3.1) from studs 3 and remove clips 2 of wheel
fastening.
For unfastening dual (rear) wheels unscrew nuts 5 (see figure 8.3.2) from studs 6 first at half of altitude
only and release clips 1. Having made sure that clips are released, unscrew nuts completely and remove clips. At
completely unscrewed nuts there can be blowout of clips, therefore it is forbidden to stand opposite clips of rear
wheels that are being removed.
At unscrewing and screwing nuts of rear wheels fastening it is necessary to apply special work tool (fig-
ure 8.3.3) for key support and to support wheel with fastening device. Before removal of internal wheel from
hub of rear axle remove spacing ring 10 (see figure 8.3.2).
At removal of wheels from hub it is necessary to preserve stud of wheels, valves and extension leads of
valves from damage.
Figure 8.3.3 – Work tool 360-012 for key support at unscrewing and screwing nuts of rear wheels fastening:
1 - key; 2 - holder; 3 - pin; 4 - washer; 5, 6 - bolts; 7 - disk; 8 - beam
8-50
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Wheeled manipulator (figure 8.3.4) is designed for mechanization of installation works on replacement of
wheels and for accomplishment of operations on canting, warehousing and transportation of large-sized
wheels.
Figure 8.3.4 - Wheeled manipulator BELAZ-6820
8.3.2 Disassembly and assembly of wheels

Dismantling and assembly of tires is to be carried out only on tire assembly stand (figure 8.3.5) providing
smooth and uniform application of loading on wheel parts, with application of work tools and devices. Opera-
tions of assembly and dismantling of tires on tire assembly stand are to be performed guided by certificate on
stand.
IT IS INADMISSIBLE TO BEAT OUT RIMS FROM TIRES WITH THE HELP OF SLEDGE HAMMER IN ORDER
TO PREVENT DEFORMATION OF WHEEL PARTS, AND EMERGENCE OF NICKS AND CRACKS.
DISMANTLING OF TIRE FROM RIM IS CARRIED OUT ON TIRE ASSEMBLY STAND AT ABSENCE OF AN AIR
PRESSURE IN TIRE.
Dismantling of tires is to be carried out in the following sequence:

- twirling hand lever 11 install brackets 9 on corresponding standard size of tire;
- install wheel on support platforms of brackets 9;
- install upper cross-piece 7 on bearing part 6 and lock it;
- switch on electromotor of pumping plant 10 and hauling down rod of power cylinder 1 press on landing
ring and press out tire till release of key and sealing rings;
- remove key and sealing rings;
- lift rod of power cylinder 1 in upper position, install thrust blocks of cross-piece 7 on diameter wheel
rims and lock them;
- hauling down rod of power cylinder 1 squeeze wheel rim from tire;
- lift rod of power cylinder in upper position;
- lift mobile plate 4 by cylinder 16 in upper position;
0
- install and fix on butt of wheel rim with an interval 60 six shoes corresponding to standard size of tire
being dismantled;
- pull down mobile plate 4 in lower position, thus tire hangs on shoes;
- install thrust blocks of upper cross-piece 7 on diameter of upper bead ring;
- pull down rod of power cylinder and squeeze landing ring from tire;
- lift rod of power cylinder in upper position and switch off electromotor of pumping plant;
- unlock and remove upper cross-piece 7;
- remove landing and upper bead rings;
- remove tire and lower bead ring;
- remove wheel rim from stand.
8-51
Running gear
7513-3902080 RM
Figure 8.3.5 – Tire assembly stand ЭСМ 5 for assembling and dismantling of tires:
1 - power cylinder; 2 - ground; 3 - protective casing; 4 - mobile plate; 5 - guiding plate; 6 - support of upper cross-piece; 7 - upper
cross-piece; 8 - jamb; 9 - bracket; 10 - pumping plant; 11 - hand lever; 12, 13, 14, 15 - pipe ducts; 16 - cylinder of mobile plate lifting;
17 – lower cross-piece
Before assembling check completeness of tire and wheel parts. Wheel and tire should be of prescribed
size only.
Only wheels with undisturbed coloring of all parts from internal and external sides are admitted for as-
sembling of tires. Application of wheel parts that are subjected to corrosion can result in their breakage during
operation that can cause accidents. Besides, application of unpainted wheel parts complicates not only as-
sembling, but also subsequent dismantling as tire adheres more strongly to unpainted surfaces of tire beads
than to the colored surfaces.
Before assembling test condition of tire by external examination. Inner hollow of it should be clean and
dry. Tire bead should not have leftovers of fin. Presence of moisture, mud and fin of rubber can become rea-
son of complicated or impossible air release from tire because of blockage of valve canal.
8-52
Running gear
7513-3902080 RM
Check carefully condition of rim elements, paying special attention on absence of cracks on flute for key
ring and sealing rings, on fluting planes of clamps of bead grounding and landing ring, on welded connections
of key part of rim and bead grounding to shell of rim. It is recommended to apply visual quality monitoring,
color, magnetic or ultrasonic flaw detection to reveal cracks. At visual control it is possible to take advantage of
magnifying glass.
It is forbidden to admit to assembling the rims and other wheel parts having such defects as cracks,
presence of rust and rolls of paint in places contacting with tire or other wheel parts, and also with infringement
of geometry (increased ovality of bead ring and rim, twisting of key ring, indents, agnails, etc.).
It is forbidden to use rims with bad condition of key flute and key rings with above mentioned defects as
at tire inflation there can be spontaneous dismantling.
Clear dirty sections of wheel, especially landing shelves of rim and places at valve bores of mud and
rust with metal brush, degrease and tint them. At collapse of more than 25 % of all coloring of wheel parts it is
necessary to perform full coloring, using soils and enamels intended for metal.
At assembling tire on rim it is necessary to observe caution in order to prevent damage of tire beads,
sealing ring and elements of rim providing leakproofness of joints. Re-use of sealing ring is not permitted. It is
forbidden to use bore fore valve for rim strapping.
For protection of slide valves from clogging and damage the valve should comprise cap.
IT IS FORBIDDEN TO:
- use sealing rings with defects;

- use bore for valve for rim strapping;
- carry out technological operations connected with heating of rim and its parts (welding, cutting,
etc.) when wheel is in assembly with tire.
Assembling of tires is carried out in the following sequence:

- switch on electromotor of pumping plant 10 and lift rod of power cylinder 1 in upper position;
- switch off electromotor of pumping plant;
- unlock and remove from support 6 of upper cross-piece 7;
- twirling hand lever 11 install brackets 9 on corresponding standard size of tire;
- install wheel rim on support platforms of brackets;
- put on lower bead ring on wheel rim;
- put on tire on wheel rim;
- install upper bead ring;
- install landing, sealing and key rings;
- install on support 6 of upper cross-piece 7 and lock it;
- install thrust blocks of cross-piece on diameter of landing ring and lock them;
- switch on electromotor of pumping plant 10 and depressing rod of power cylinder 1 press landing ring
into tire bead before releasing chases for sealing and key ring, after that put hand lever of power cylinder slide
valve in neutral position;
- install sealing and key rings in corresponding chases of rim. Grease new sealing ring with solution of
silicone oil or suds;
- lift rod of power cylinder in upper position, switch off electromotor of pumping plant;
- tire inflation with air is to be performed on tire assembly stand with screw-down mechanism fixed on
rod of power cylinder, providing safety of work.
The tire inflation by air is performed in the following order:

- preliminary pump up tire up to pressure of 0.08 – 0.10 МPа and test correctness of assembly of tire
with rim;
- pump up tire with air up to pressure in 1.2 – 1.25 times exceeding working pressure for providing
dense fit of tire bead to shelf of rim and sustain this pressure during 10 - 15 minutes;
- lower tire pressure to recommended working pressure level and test leakproofness, having filled studs
in flute of bead flanged edge. Leakproofness of joints “valve – rim” and “slide valve chamber – slide valve” is
also checked by suds;
- lower air pressure in tire up to 0.08 – 0.1 МPа;
- unfasten and remove upper cross-piece together with wheel from stand;
8-53
Running gear
7513-3902080 RM
- disconnect cross-piece from wheel and install it on stand.

Leakproofness of second bead is checked analogously, but wheel is stacked by key ring downwards.
Also test leakproofness of joint of valve with extension lead by soap emulsion.
Final estimation of leakproofness of wheel in assembly with tire is made by manometer on pressure de-
crease for 24 h. Pressure decrease is not permitted.
Lead-up of tire pressure up to normal level follows only after mounting wheel on hub. There should not
be people near to pumped tire. At mounting of extension leads it is necessary to test release of air from tire by
pressing slide valve of extension lead.
Transportation and storage of tires is to be performed in verticality. Assembled tires should be stored at
an air pressure in them of 0.08 – 0.10 МPа.
8.3.3 Mounting of wheels on hubs

For mounting of wheels fastening device or wheeled manipulator are to be used.
Wheel on front hub is to be installed in the following sequence:

- turn hub chase downwards and install wheel on hub having combined arrester of rim with chase of hub;
- install upper and lower, and then left and right clips and tighten nuts;
- install all other clips and tighten nuts. Tighten nuts oppositely for providing wheel wobble on side member
of tire case of no more than 10 mm;
- tighten nuts with torque of 800 - 900 N.m;
- pump up tire with air up to the required pressure. Screw cap on valve.
Rear wheels are to be installed on hub in the following sequence:
- put on hub installed by chase downwards internal wheel with extension lead of valve and spacing ring.
For alignment of internal wheel with tire on hub it is necessary to apply special work tool (figure 8.3.6). For pro-
viding concentric position of wheel in regard to hub it is recommended to fix it with lining chocks installed under
tire;
Figure 8.3.6 – Work tool 360-016 for alignment of internal wheel with tire on hub:
1, 4 - bolts; 2 - plate; 3 - chock; 5 - nut
8-54
Running gear
7513-3902080 RM
- install work tool on hub of rear wheel and tighten nuts 5 of wheel fastening in regular intervals;
- after mounting of internal wheel on taper of hub, tighten three bolts 1 for its fixing;
- remove work tool from hub of rear axle;
- install external wheel on hub;
- install clips and tighten nuts of wheel fastening gradually in 3 - 4 takings crosswise (serially oppositely).
Final tightening torque is 800 - 900 N.m. An admitted wheel wobble on side member of tire case should be no
more than 10 mm. Retightening of fastening nuts is to be performed after first running-in, and further after
every two - three running-ins up to stabilization of tightening torque of all nuts;
- unscrew bolts 1 from spacing ring;
- remove lining chocks from under internal wheel (if they have been installed);
- pump up tires with air up to operating pressure level and screw caps on valves.
On dump trucks valves such as БС and extension leads УГ17 of increased flow area are installed.
In order to speed-up tire inflation and deaeration through valve БС and extension lead УГ17 apply spe-
cial device (figure 8.3.7).
Figure 8.3.7 - Device 11-3118010 УН-17 for accelerated inflation of tires:

1 - locking ring; 2 - collet; 3 - fitting; 4 - rod; 5 - case; 6 - fly wheel; 7 – slide valve; 8 – cap-key; 9 - guiding nut; 10 - cap nut;
11 - adapter
8-55
Running gear
7513-3902080 RM
8-56
Steering
7513-3902080 RM
9 STEERING
The steering of dump trucks BELAZ-7514-10, BELAZ-75145 is of hydrovolumetric type with hydraulic
closed loop, consists of steering tube with hydraulic steer, release valve, valve of difference of pressures, hy-
drodistributor, two cylinders of turning movement executed as unit with tracking cavities, liquid damper, auto-
matic machine of unload of pump, pneumohydraulic accumulators, oil-tank, gear pumps, pivot rods, transver-
sal pull-rod and oil pipes.
Steering of dump trucks BELAZ-75131, BELAZ-75132 is of hydrovolumetric type with internal hydraulic
closed loop. It comprises hydraulic steer, jointed by propeller shaft with shaft of steering tube, booster of
stream, back-pressure valve, collector, two hydraulic cylinders of turning movement, axial-piston pump of vari-
able productivity, filters, three pneumohydraulic accumulators, oil-tank and oil pipes.
Repair of pneumohydraulic accumulators is shown in section "Braking systems".
9.2 Possible failures of steering
9.2.1 Basic failures of steering of dump trucks BELAZ-7514-10, BELAZ-75145, reasons and
methods of their elimination
For definition of possible reasons of failures of steering and methods of their elimination it is necessary
to be guided by table 9.1.
Table 9.1 – Basic failures of steering, reasons and methods of their elimination
Failure and its external

Probable reason Method of elimination
development
Pollution of hydraulic system, hit of solid corpuscles Pump over steer by turning movement of steerable
in hydraulic steer wheel. In case of need wash out or replace steer
Hit of solid corpuscles in spool-and-sleeve of hydro-
Large force to steerable Wash out hydrodistributor
distributor of steering
wheel
Heightened viscosity of working fluid at negative
Replace working fluid according to temperature
temperature of ambient air
Wear of pump НШ-10 Replace pump
Auto-oscillations of Tighten fingers or replace worn out hinges of
Heightened backlash in hinges of steering trapezoid
steered wheels steering trapezoid
At turning movement of Low level of working fluid in tank Bring level of working fluid in tank to norm
steerable wheel against
Pump has broken down Replace pump
stop system pressure is
not hoisted Hydromotor of steer is jammed Replace steer
Presence of air in system Remove air inflow
Pulsation of system
Presence of water in working fluid Replace fluid
pressure
Low level of working fluid in tank Bring level of working fluid to norm
Internal leakproofness of cylinder of turning move-
Replace sealing of cylinders
ment is damaged
The dump truck does Internal escapes in block of unloading-transfer Disassemble and wash out block of unloading-
not keep prescribed tra- valves transfer valves
jectory of driving
Springs of steer are broken Replace steer
Presence of air in system Remove air inflow
Defective or not charged pneumohydraulic accumu- Charge pneumohydraulic accumulators or replace
Often actuation of auto- lators them
matic machine of unload
of pump Escapes on back-pressure valve of automatic ma- Repair or replace automatic machine of unload of
chine of unload of pump pump
9-1
Steering
7513-3902080 RM
Continuation of table 9.1

Failure and its external de-
velopment
Heightened or underpres-
Automatic machine of unload of pump is abnor- Adjust or replace automatic machine of unload of
sure of oil in pneumohydrau-
mally adjusted or defective pump
lic accumulators
At slow twirl of steerable Wear of parts of steer Replace steer

wheel in one or both direc-
tions steered wheels are not
pivoted Internal escapes in block of unloading-transfer Disassemble and wash out block of unloading-
valves transfer valves
At trying to turn sweepingly, Insufficient oil supply Replace oil pumps

steering appears too slow Irregular resetting or failure of pressure-relief valves Adjustt pressure-relief valves or to replace dis-
and heavy in dispenser of steering penser
9.2.2 Basic failures of steering of dump trucks BELAZ-75131, BELAZ-75132, reasons and meth-
ods of their elimination
For definition of possible reasons of failures of steering and methods of their elimination it is necessary
to be guided by table 9.2.
Table 9.2 – Possible failures of steering, reason and methods of their elimination

development
The slow response of Steered shaft is overloaded Reduce axle load
steering on turning
movement of steerable Out-of-orderpressure-relief valve КП1.2 in hydraulic
Replace pressure-relief valve
wheel, weak reinforce- system of hoisting mechanism
ment or loss of rein-
forcement Pump of steering is defective Replace pump
Slow offset of dump Replace pull-rod and to test convergence of front

Pull-rod of steering trapezoid is damaged
truck on road to one side wheels
Presence of air in hydraulic system because of low
level of oil in tank, cavitations of pump, air inflow Find and remove failure
through sealings
Yawing of dump truck at Piston of hydraulic cylinder is slackened Repair hydraulic cylinder
in-line motion
Breakage of springs of neutral position in steer Replace springs of steer
Curving stock of hydraulic cylinder or fault of nozzle Replace out-of-order parts
Wear of parts of steer Replace steer
At slow twirl of steerable Wear of piston seals of hydraulic cylinder Replace sealing
wheel steered wheels
are not pivoted Wear of parts of steer Replace steer
Presence of air in hydraulic system owing to low

Remove failures, add oil in hydraulic reservoir up
level of oil, cavitation of pump, escape of oil through
to level
Unstablis steering sealings, etc.
Fastening of piston of hydraulic cylinder is slack-
Fix piston
ened
9-2
Steering
7513-3902080 RM

development
Wear of slots of drive axis of steer or propeller shaft Replace worn-out parts
The steerable wheel is
freely twirled without re- Low level of oil in tank Add oil
sponse of front wheels
Fault of hoses Replace hoses
Excessively big free
Wear of sealing of hydraulic cylinders Replace sealing of hydraulic cylinders
travel of front wheels
Jamming of steer Hit of corpuscles of mud in spool-and-sleeve Disassemble steer and to wash out parts
The vibration or sponta-
neous twirl of steerable Irregular connection of pipe ducts of steering Test correctness of connection of pipe ducts
wheel
Steered wheels are piv-
Pipe ducts abnormally connected to ports of hydrau-
oted aside, opposite to Correct connection of pipe ducts
lic cylinders
twirl of steerable wheel
Accumulation of air inside pump Pit air from pump
Breakage of power shaft of pump Replace shaft
Absence of pressure of oil
on exit of pump Significant escapes of working fluid in hydraulic sys-
Remove leakage
tem
Absence of oil on input of pump Restore oil level in tank
Valve of cut-off of pump is disadjusted Adjust valve
Low pressure of oil on
exit of pump Wear of pistons or cylinder block of pumping unit of
Replace worn-out parts or pump
pump
Excessively high pres-
sure of oil on exit of Valve of cut-off of pump is disadjusted Adjust valve
pump
Pipe ducts and hoses are not fixed Fix pipe ducts by clinches with rubber gaskets
Operation of hydraulic Insufficient level of working fluid in hydraulic tank Restore oil level
system is accompanied
by heightened noise Hit of air in hydraulic system Remove leakage of system
level Cold enough working fluid or its very tall viscosity Fill working fluid of required viscosity or preheat it
Hit of air in sucking hydroline Restore leakproofness of sucking hydroline
Hit of air in sucking hydroline Restore leakproofness of sucking hydroline
The working fluid foams
Insufficient level of working fluid in hydraulic tank Restore fluid level
Inconsistent or non- Hit of air in hydraulic system Remove leakage of system
uniform operation of
steering Insufficient level of working fluid in hydraulic tank Restore fluid level
pump works at pressure exceeding acceptable value Adjust valve of cut-off on required pressure
Insufficient level of working fluid in hydraulic tank Restore fluid level
Excessive heating of
hydraulic system Hit of air in sucking hydroline Restore leakproofness of sucking hydroline
Abnormally adjustes or out-of-order pressure-relief
Adjust or replace pressure-relief valve
valve in hydraulic system of hoisting mechanism
9-3
Steering
7513-3902080 RM

development
Leak on shaft of pump Fault of sealing Replace cuff
Disassemble slow or hard steering unit and re-
Slow or hard steering Jam of valve core of booster of stream
move jam of valve core
Heavy twirl of steerable Polluted throttle bore in valve core of hydrodistributor
Disassemble unit and clean throttle bore
wheel of sampling of direction of booster of stream
Polluted throttle bore in valve core of booster of
Disassemble unit and clean throttle bore
stream
Free rotation of steer- Leakage of shock-proof or inlet valves of booster of
Clean shock-proof and inlet valves
able wheel (without jam) stream
Excessively low pressure of wear of shock-proof
Adjust shock-proof valve
valve
9.3 Removal of units of steering from dump truck

Before removal of hydraulic device hydraulic unit, proximal to it surfaces, and also pipe ducts and arma-
ture should be cleared of mud and friablis colour.
Pit pressure prior to disconnect hydraulic lines.
After dismounting in order to prevent hit of mud in bores, waste of tubes and hoses should be enclosed
by chokes or sealed, for example by plastic packages.
9.3.1 Removal of units of steering of dump trucks BELAZ-7514-10, 75145
9.3.1.1 Removal of steer

Steer is to be removed from dump truck in following sequence:
- disconnect sleeves of high pressure from steer, preliminary having marked them;
- unscrew bolts of fastening of steer to steering tube and remove gear from dump truck.
9.3.1.2 Removal of column of steering

Column of steering from dump truck is to be removed in
following sequence:
- remove switches of turn indicators, light of headlights,
window wiper and window washer;
- unscrew bolts 2 fastening steering tube to floor of
cabin (figure 9.1);
- unscrew nuts 7 loose straps 6, fastening steering tube
to panel of gears;
- remove steering tube in assembly with steerable
wheel;
Figure 9.1 - Column of steering:

1 - steer; 2 - bolt; 3 - steering tube; 4 - bracket; 5 - layer pad; 6 - loose
strap; 7 - nut
9-4
Steering
7513-3902080 RM
9.3.1.3 Removal of hydraulic dispenser

The hydraulic dispenser is to be removed from dump truck in following sequence:
- disconnect, damp and mark each hydraulic line;
- supporting hydraulic dispenser, unscrew fastening nuts and remove it.
9.3.1.4 Removal of automatic machine of unload of pump

Automatic machine of unload of pump is to be removed from dump truck in following sequence:
- supporting automatic machine of unload of pump turn out fastening bolts and remove it.
9.3.1.5 Removal of liquid damper

The liquid damper is to be removed from dump truck in following sequence:
- supporting liquid damper turn out fastening bolts and remove it.
9.3.1.6 Removal of valve of difference of pressures

The valve of difference of pressures is to be removed from dump truck in following sequence:
- disconnect and damp hydraulic line;
- turn out from filter valve of difference of pressures.
9.3.1.7 Removal of filter

The filter is removed from dump truck in following sequence:
- disconnect sleeve of high pressure from filter;
- turn out from bracket and remove filter from dump truck.
9.3.1.8 Removal of release valve

- disconnect and damp hydraulic lines;
- unscrew fastening nut and remove release valve from dump truck.
9.3.1.9 Removal of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
The cylinder of turning movement is removed from dump truck in following sequence:
- disconnect sleeves of high pressure from cylinder of turning movement;
- unscrew nuts from conic fingers on brackets of bar of steering trapezoid and frame;
- moor cylinder of turning movement with help fastening device and hoisting gear;
- dismantle conic fingers from brackets of bar of steering trapezoid and frame and remove cylinder of
turning movement from dump truck.
Analogously second cylinder of turning movement is removed.
The pull-rod of steering trapezoid is removed from dump truck in following sequence:
- unscrew nuts of conic fingers of fastening of bent for to bars of steering trapezoid;
- dismantle conic fingers from bars of steering trapezoid and remove pull-rod from dump truck.
For removal of bars of steering trapezoid unscrew nuts of their fastening to swivel members. Then, ex-
tract conic barrels and remove bars of steering trapezoid.
9.3.2 Removal of units of steering of dump trucks BELAZ-75131, 75132
9.3.2.1 Removal of column of steering

Column of steering from dump truck is removed in following sequence:
- unscrew screws and remove plastic housings (figure 9.2);
- remove switches of turn indicators, light of headlights, window wiper and window washer;
- disconnect propeller shaft 2 of steering on part of shaft of steering tube;
- unscrew bolts fastening steering tube to lower panel of gears and fast-head wall of cabin;
- remove steering tube 3 with bracket in assembly with steerable wheel 4;
- remove cover of steerable wheel 4;
- unscrew nut of fastening of steerable wheel and remove wheel 4 from shaft of steering tube 3.
9-5
Steering
7513-3902080 RM
Figure 9.2 - Mechanical drive gear of

hydraulic steer:
1 - steer; 2 - propeller shaft; 3 - steering tube;
4 - steerable wheel; 5 - hand lever of resetting of steering
tube on discharge angle; 6 - hand lever of resetting of steer-
ing tube on altitude
9.3.2.2 Removal of steer

Steer is removed from dump truck in following sequence:
- disconnect propeller shaft 2 from shaft of steer 1;
- disconnect sleeves of high pressure from steer, preliminary having marked them;
- unscrew bolts of fastening of steer to bracket of floor of cabin and remove gear from dump truck to-
gether with flange.
9.3.2.3 Removal of booster of stream

The booster of stream is removed from dump truck in following sequence:
- supporting booster of stream turn out fastening bolts and remove it.
9.3.2.4 Removal of collector

Collector is removed from dump truck in following sequence:
- supporting collector turn out fastening bolts and remove it.
9.3.2.5 Removal of filter

The filter is removed from dump truck in following sequence:
- disconnect sleeves of high pressure from filter;
- unscrew fuse in heel of filter and merge oil;
- unscrew bolts of fastening of filter and remove filter from dump truck.
9.3.2.6 Removal of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
The cylinder of turning movement is removed from dump truck in following sequence:
- disconnect sleeves of high pressure from cylinder of turning movement;
- unscrew nuts from conic fingers on brackets of bar of steering trapezoid;
- moor cylinder of turning movement with help fastening device and hoisting gear;
- dismantle conic fingers from brackets of bar of steering trapezoid and beam of front axle and remove
cylinder of turning movement from dump truck.
9-6
Steering
7513-3902080 RM
The pull-rod of steering trapezoid is removed from dump truck in following sequence:
- unscrew bolts 7 and remove pinch plates 8 (see figure 9.25);
- remove distance sleeve 9;
- squeeze finger 4 from hinged spherical bearing 10;
For removal of bars of steering trapezoid unscrew nuts of their fastening to swivel members. Then, ex-
tract conic barrels and to remove bars of steering trapezoid.
9.4 Disassembly of units of steering
9.4.1 Disassembly of units of steering of BELAZ-7514-10, 75145
9.4.1.1 Disassembly of column of steering

Disassembly of steering tube is to be carried out as follows:
- remove cover 1 and unscrew nut 3 (figure 9.3);
- remove steerable wheel 2;
- unscrew screw 5 and remove barrel 4;
- weaken torquering of nut 11 of clamper, disconnect nozzle 6 and tube 8 on threaded connection and
remove them from shaft;
- remove from shaft combined radila-thrust bearings 7.
Figure 9.3 – Column of steer:

1 - cover; 2 - steerable wheel; 3 - nut; 4 - barrel; 5 - screw with washer; 6 - nozzle of column; 7 - combined radial-thrust bearing;
8 - tube of steering tube; 9 - shaft; 10 - bolt; 11 - nut
9.4.1.2 Disassembly of hydraulic steer

For disassembly of steer separate flange 2 (figure 9.4) as assembly with shaft 3 drive gears of steering
from hydraulic steer 1.
Disassembly of hydraulic steer is to be carried out as follows:
- unscrew bolts 3 and special bolt 21 with rolled head (figure 9.5);
- remove cover 4 and sealing ring 20;
- remove wreath 5 with spider 6 hydromotors of closed loop 1 and sealing ring;
- extract cardan 8 and remove distributor disk 7 and sealing ring;
- turn out thread barrel 19 and extract bead of back-pressure valve 17;
- extract from case 18 preset in verticality, barrel 9 as assembly with valve core 13, pin 10, springs 11
and restrictive ring 12, made insignificant force to shank of valve core 13. Large force, especially of shock
9-7
Steering
7513-3902080 RM
character, can cause fault of parts of distributive block;

- remove from valve core 13 (or extract from case 18) axial bearer 16;
- remove from valve core 13 restrictive ring 12 and delete from barrel 9 pin 10;
- extract from barrel 9 valve core 13 and springs 11;
- extract from case 18 sealing 15.
Figure 9.4 - Steer with flange:

1 - hydraulic steer; 2 - flange; 3 - drive axis of steer
Figure 9.5 - Hydraulic steer:

1 - hydromotor of closed loop; 2 - distributive block; 3 - bolt; 4 - cover; 5 - wreath; 6 - spider; 7 - distributor disk; 8 - cardan; 9 - bar-
rel; 10 - pin; 11 - leaf springs; 12 - restrictive ring; 13 - valve core; 14 - anther; 15 - combined sealing; 16 - axial bearer; 17 - back-pressure
valve; 18 - case; 19 - thread barrel; 20 - sealing ring; 21 - special bolt
9-8
Steering
7513-3902080 RM
9.4.1.3 Disassembly of hydraulic dispenser

Disassembly of hydraulic dispenser is to be carried out as follows:
- unscrew bolts 10 and remove from case 19 case 30 (figure 9.6);
- unscrew triangles 29 and turn out glasses 27 of case 30;
- unscrew fuse 7;
- unscrew bell jars 46, nuts 47 and unscrew from case 31 adjusting screws 42;
- extract from case of spring 41, nest of valves 40 and beads 43;
Figure 9.6 - Hydraulic dispenser:

1 - tire valve; 2, 36 - barrel; 3, 37 - valve core; 4 - choke; 5 - flange; 6, 10, 24, 33 - bolt; 7, 9, 11, 14 - plug; 8, 29, 34, 48 - triangle;
12, 17, 18, 21, 22, 23, 26, 28, 32, 36, 45 - sealing ring; 13 - washer; 15, 25 - cover; 16, 31, 38 - spring; 19, 30, 31 - case; 20 - point;
27 - glass; 35 - lock-nut; 39 - saddle; 40 - valve cage; 42 - adjusting screw; 43 - bead; 44 - leveling valve; 46 - bell jar; 47 - nut
9-9
Steering
7513-3902080 RM
- unscrew bolts 33 with locking washers and remove case 31;

- extract from case 31 saddle 39;
- unscrew bolts 24 with locking washers and remove cover 25;
- extract from case 30 of springs 38, valve cores 37 and leveling valves 44;
- if necessary squeeze barrels 36;
- unscrew lock-nut 35 from case 19 and remove triangles 8 and 48;
- unscrew points 20;
- unscrew bolts 6 and remove flanges 5;
- remove covers 15 and extract springs 16, washers 13;
- extract from barrel 2 valve core 3 and sealing rings 18;
- turn out from valve core 3 choke 4.
9.4.1.4 Disassembly of automatic machine of unload of pump

Disassembly of automatic machine of unload of pump is to be carried out as follows:
- unscrew bolts 26 and remove case of control package 16 (figure 9.7);
- unscrew bolts 10 and remove covers 12;
Figure 9.7 - Automatic machine of unload of pump:

1, 5, 7, 13, 20, 24, 30, 31, 36, 38, 44, 45, 48, 55 - sealing ring; 2, 15, 27, 41, 47 - spring; 3, 37 - glass; 4, 32 - bead; 6, 25 - valve
seat; 8, 51 - orifice plug; 9, 10, 2643, 52 - bolt; 11, 28, 39 - choke; 12, 42, 53 - cover; 14 - grid; 16, 35 - case; 17, 50 - barrel; 18 - plunger;
19 - adjusting collar; 21 - barrel; 22 - pusher; 23, 33 - split key; 29, 40 - adjusting bolt; 34 - guiding; 46 - piston; 49, 54 - valve;
- extract from case 16 choke 28, spring 27 and split key 23;
- extract from case 16 choke 11, spring 15, barrel 17 with grid 14, plunger 18, pusher 22, adjusting collar
9-10
Steering
7513-3902080 RM
19 and barrel 21;

- unscrew glass 37 and extract choke 39, spring 41, split key 33 with bead 32, guiding 34.
- unscrew bolts 43, 52 and remove covers 42, 53;
- from cover 53 take out piston 46;
- from case 35 extract springs 2, 47 glass 3, bead 4, valve seat 6, valve 49, valve seat 25 and, if neces-
sary, barrel 50;
9.4.1.5 Disassembly of liquid damper

Disassembly of liquid damper is to be carried out as follows:
- unscrew bell jars 7 and nuts 9 (figure 9.8);
- unscrew adjusting screws 8 and extract springs 5, nests of valves 4 and beads 3;
- clamp case 25 in jaws and unscrew bolts 16;
- cautiously remove covers 1;
- extract from covers of barrel 14 with pistons 27;
- extract from barrel pistons 27 as assembly;
- extract from case spring 23 and barrel 24;
- heat piston 27 and to unscrew from it thrust block10;
- extract from piston spring 26, bead 12, layer pad 11 and valve seat 13.
Analogously disassemble second piston.
Figure 9.8 - Liquid damper:

1 - cover; 2 - saddle of pressure-relief valve; 3, 12 - bead; 4 - valve cage; 5, 23, 26 - spring; 6, 11 - layer pad; 7 - bell jar; 8 - adjust-
ing screw; 9 - nut; 10 - thrust block; 13 - valve seat; 14 - barrel; 15, 21, 22 - sealing ring; 16 - bolt; 17, 20 - triangle; 18 - flange; 19 - tire
valve; 24 - barrel; 25 - case; 27 - piston;
I, II - cavities
9.4.1.6 Disassembly of filter

Disassembly of filter is to be carried out as follows:
- unscrew cover 6 (figure 9.9);
- unscrew rod 3 and extract from case 1 filter cartridge 4
as assembly;
- unscrew nut 2 and disassemble filter cartridge.
Figure 9.9 - Filter:

1 - case; 2 - nut; 3 - rod; 4 - filter cartridge; 5 - sealing ring; 6 - cover
9-11
Steering
7513-3902080 RM
9.4.1.7 Disassembly of valve of difference of pressures, release valve and back-pressure valve,
Disassembly of valve of difference of pressures is to be carried out as follows:
- unscrew transition nut 3 with washer 1 and ring 2 (figure 9.10);
- extract from case 5 guiding 4, spring 7 and valve 6.
Disassembly of release valve is to be carried out as follows:

- unscrew connective valve 8 (figure 9.11);
- unscrew transition nut 3 with washer 1 and ring 2;
- extract from case 5 guiding 4, spring 7 and valve 6.
Figure 9.10 - Valve of difference of pressures: Figure 9.11 - Release valve:

1 - washer; 2 - sealing ring; 3 - transi- 1 - washer; 2 - sealing ring; 3 - transition nut; 4 - guiding;
tion nut; 4 - guiding; 5 - case; 6 - valve; 5 - case; 6 - valve; 7 - spring; 8 - connective valve
7 - spring; I, II - ports
I, II - ports
Disassembly of back-pressure valve is to be carried out as follows:

- unscrew thrust block 1 (figure 9.12);
- from case 2 extract spring 3 and valve 4.
Figure 9.12 – Check valve:

1 – detent; 2 – case; 3 – spring; 4 – valve
9-12
Steering
7513-3902080 RM
9.4.1.8 Disassembly of hydraulic cylinder of turning movement

Disassembly of hydraulic cylinder of turning movement is to be carried out as follows:
- merge oil from cylinder of turning movement;
- unscrew bolts 2 fastening of tube 5 and remove tube (figure 9.13);
Figure 9.13 - Hydraulic cylinder of turning movement:

1, 4, 8, 10, 12, 14, 22, 30, 35, 38, 39 - sealing ring; 2, 18,
21, 28, 32, 33 - bolt; 3, 26 - nut; 5 - tube; 6 - piston; 7, 40 - curb; 9,
11 – press ring; 13 - flange; 15 - press cover; 16 - spherical bearing;
17 - thrust washer; 19 - greaser; 20 - cover; 23 - finger; 24,
29 - scratcher; 25 - protective washer; 27 - nozzle; tracking cylinder;
31 - case of tracking cylinder; 34 - cover; 36 - cylinder rod; 37 - cyl-
inder body
- unscrew bolts 33 fastening of cover 34 to cyl-

inder body;
- from cylinder body extract stock as assembly
with piston 6 and tracking cylinder 31;
- turn off nut 3 and remove from stock 36 piston
6;
- unscrew bolts 32 and remove cover 34;
- unscrew bolts 28, remove tracking cylinder 31,
flange 13 and press cover 15;
- unscrew nuts 26 terminal joints of nozzle 27
and remove nozzle from cylinder rod.
Disassemble bearing mount assembly on head
of cylinder rod of turning movement in following se-
quence:
- turn out greaser 19 of cover 20;
- unscrew bolts of fastening 21 of cover 20
hinged spherical bearing 16 remove cover and sealing
22;
- unlock bolts 18 fastening hinged spherical bear-
ing on conic finger 23;
- remove thrust washer 17;
- squeeze conic finger 23 from inner race hinged
spherical bearing;
- squeeze hinged spherical bearing 16.
Analogously disassemble bearing mount as-
sembly on head of cylinder body of turning movement.
9-13
Steering
7513-3902080 RM
9.4.1.9 Disassembly of pull-rod of steering trapezoid

Disassembly of pull-rod of steering trapezoid is to be carried out as follows:
- weaken terminal connections of pull-rod, unscrewing nuts 4 (figure 9.14) bolts 2;
- turn out nozzles 1, 6 of pull-rod.
Figure 9.14 - Pull-rod of steering trapezoid:

1, 6 - nozzles of pull-rod; 2 - bolt; 3 - clip; 4 - nut; 5 - tube of pull-rod
Disassemble nozzles of pull-rod of steering trapezoid in following sequence:

- turn out greaser 1 (figure 9.15) from cover 4;
- unscrew bolts of fastening of cover of hinged spherical bearing 3;
- remove cover 4;
- unlock bolts of fastening hinged spherical bearing on conic finger 6;
- squeeze conic finger 6 from inner race of hinged spherical bearing 3;
- remove protective washer 8 and scratcher 9;
- squeeze hinged bearing 3 from nozzle of pull-rod 5.
Figure 9.15 - Nozzle of pull-rod:

1 - greaser; 2 - thrust washer; 3 - spherical bearing;
4 - cover; 5 - nozzle; 6 - finger; 7 - nut; 8 - protective washer;
9 - scratcher
9.4.2 Disassembly of units of steering of BELAZ-75131, 75132
9.4.2.1 Disassembly of column of steering

Disassembly of column of steering with bracket is to be carried out as follows:
- unsplint and unscrew nut 22 (figure 9.16) on shaft 13;
- unscrew screw from butt of shaft 20 and remove hand lever 5 (see figure 9.2);
- unscrew nut 11 (see figure 9.16) stock 4;
- extract shaft 13 and separate steering tube 12 from bracket 8;
9-14
Steering
7513-3902080 RM
- remove stock 4;
- take out splint 18 from finger 19;
- remove finger 19 and stop member 6;
- unscrew screw 14 on shaft 20 and remove bar 15, spring 16 and barrel 17;
- extract shaft 20 of bore in bracket 8;
- remove barrel 1 and arrester 2;
- unscrew nut 7 and remove pusher 9.
Figure 9.16 - Steering tube with bracket:

1, 17 - barrels; 2 - arrester; 3 - tab; 4 - stock; 5 - bolt; 6 - stop member; 7, 11, 22 - nuts; 8 - bracket; 9 - pusher; 10 - bearing part;
12 - column of steering; 13, 20 - shafts; 14 - screw; 15 - bar; 16 - spring; 18 - splint; 19 - finger; 2123 - washers
The further disassembly of column of steering is to be carried out as follows:

- unscrew screw 11 (figure 9.17) and remove it with ring 12;
- turn hand lever 13 clockwise, keeping it in this position remove housing 2 as assembly with shaft 3;
- extract from bore of shaft 10 two springs 7 and washer 1;
- extract retaining ring 5 from housing 2 and take out shaft 3 with bearing 6;
- remove retaining ring 4 and bearing 6 from shaft 3;
- unscrew screw 14 from shaft 19;
- remove hand lever 13, spring 15, barrel 16 from shaft 19;
- take out shaft 19 of barrel 17;
- get tab 18 from key of shaft 19;
- extract retaining ring 5 of tube of column 8 and take out barrel 9 with shaft 10 and bearing 6;
- remove from shaft 10 retaining ring 4 and bearing 6.
9-15
Steering
7513-3902080 RM
Figure 9.17 - Column of steering:

1 - washer; 2 - housing; 3, 10 - shafts; 4, 5 - retaining rings; 6 - bearing; 7, 15 - springs; 8 - tube of column; 9, 16, 17 - barrels; 11,
14 - screws; 12 - ring; 13 - hand lever; 18 - tab; 19 - shaft
9.4.2.2 Disassembly of propeller shaft of steering

Disassembly of propeller shaft is to be carried out as follows:
- turn out bolts 2 (figure 9.18) fastening of cardan joints and remove cardan joints from shaft of steering
tube;
- take out from spline shaft 6 and nozzle of tube 3 of tab 10;
- remove wire splint 4 from protective clutch 5 and take out spline shaft 6 of tube 3;
- remove protective clutch from spline shaft.
If it is necessary to replace needle bearers execute disassembly of cardan joint, for what remove retain-
ing rings 13 of needle bearers 11 and, tapping slightly in butt of one bearing, squeeze from fork and remove
from remotely spider opposite bearing.
In the same way remove other needle bearers.
9-16
Steering
7513-3902080 RM
Figure 9.18 - Propeller shaft of steering:

1 - cardan joint; 2 - handrail bolt; 3 - tube; 4 - wire splint; 5 - protective clutch; 6 - spline shaft; 7 - fork; 8 - plug; 9 - pressure-relief
valve; 10 - tab; 11 - remotely spider; 12 - end seal; 13 - retaining ring; 14 - needle bearer
9.4.2.3 Disassembly of hydraulic steer

Disassembly of hydraulic steer of dump trucks BELAZ-75131, 75132 is executed analogously to disas-
sembly of hydraulic steer of dump trucks BELAZ-7514-10, 75145.
9.4.2.4 Disassembly of booster of stream

Disassembly of booster of stream is to be carried out as follows:
- unscrew bolts 30 and 31 with locking washers, remove cover 32, sealing plate 35 and sealing rings 33
and 34 (figure 9.19);
- extract from case 10 bearing part of spring 36 and spring 37, bearing part of spring 29 and springs
27, 28;
- unscrew bolts 1 and 2 with locking washers, remove cover 3, sealing plate 7 and sealing rings 4, 5, 6;
- extract from case bearing part of spring 18 and springs 19 and 21;
- take out spring 42;
- take out valve core of priority valve 38;
- take out valve core of direction 23 and thrust blocks of spring 21 and 26;
- extract valve core of booster 41. Set aside for consequent disassembly;
- extract shock-proof valves 8 and 24. Set aside for consequent disassembly;
- turn out choke 13, remove sealing ring 12 and extract valve of backpressure 11;
- turn out choke 14, remove layer pad 15 and turn out with help hexahedral key pressure-relief valve 16;
- turn out throttle with back-pressure valve 40;
- turn out throttles 9 and 39;
- turn out from valve core of direction 23 throttles 22 and 25.
9-17
Steering
7513-3902080 RM
Figure 9.19 - Booster of stream:

1, 2, 30, 31 - bolts; 3, 32 - covers; 4, 5, 6, 12, 33, 34 - sealing rings; 7, 35 - sealing plates; 8, 24 - shock-proof valves; 9, 22, 25,
39 - throttles; 10 - case; 11 - valve of backpressure; 13, 14 - choke; 15 - layer pad; 16 - pressure-relief valve; 17 - valve spring of back-
pressure; 19, 20, 27, 28, 37 - springs; 21, 26 - thrust blocks of spring; 23 - valve core of direction; 18, 29, 36 - bearing part of spring;
38 - valve core of priority valve; 40 - throttle with back-pressure valve; 41 - valve core of booster
9-18
Steering
7513-3902080 RM
Shock-proof valves (figure 9.20) are maintained as separate units entirely. Sealing rings 1 and 3 can be
substituted separately.
Figure 9.20 - Shock-proof valve:

1, 3 - sealing rings; 2 - part of supplementary valve
The pressure-relief valve 16, throttle with back-pressure valve 40 and valve of backpressure 11 (figure
9.19) also are maintained as separate units entirely.
Disassembly of valve core of booster 41 is necessary only in event that it is required to replace sealing
ring 2 (figure 9.21), spring 9 or throttle 11, otherwise this unit is subject to substitution entirely.
- take out retaining ring 7;
- take out pin 5;
- take out choke 10 and spring 9;
- take out retaining ring 6 and pin 4;
- extract internal valve core 8;
- turn out butterfly valve of one-sided operation and extract ring 2;
- turn out throttle 11 of choke 10.
Eliminate opportunity of pollution of unit, install time plastic choke in ports of booster of stream.
Figure 9.21 - Valve core of booster:

1 - butterfly valve of one-sided operation; 2 - sealing ring; 3
- valve core; 4, 5 - pins; 6, 7 - retaining rings; 8 - internal valve
core; 9 - spring; 10 - choke; 11 - throttle
9-19
Steering
7513-3902080 RM
9.4.2.5 Disassembly of collector

- turn out screws 5 with locking washers (figure 9.22);
- remove hydrodistributor 6 and take out rubber sealing rings 4;
- turn out plug 9;
- turn out plug 8 and take out barrel 11, spring 3 and valve 2.
Eliminate opportunity of pollution of unit, install time plastic choke in ports of collector.
Figure 9.22 - Collector:

1 - case; 2 - valve; 3 - spring; 4, 7, 10 - sealing ring; 5 - screw; 6 - electromagnetic hydrodistributor; 8, 9 - plugs; 11 - barrel
9.4.2.6 Disassembly of filter

- unscrew fuse 1 and merge oil from filter (figure 9.23);
- unscrew cover 10, take out filter cartridge 6, choke 4 and spring 3;
- turn out barrel 11 of cover 10;
- unscrew nuts 14 to take out valve 12 and bearing sleeve 13.
Figure 9.23 - Filter:

1 - fuse; 2 - filter casing; 3 - spring; 4 - choke; 5, 7, 9 - sealing rings; 6 - filter car-
tridge; 8 - protective washer; 10 - cover; 11 - barrel; 12 - valve; 13 - bearing sleeve; 14 - nut
9-20
Steering
7513-3902080 RM
9.4.2.7 Disassembly of hydraulic cylinder of turning movement

Disassembly of cylinder of turning movement is to be carried out as follows:
- merge oil from cylinder of turning movement;
- unscrew bolts of 7 fastening of front end cover 6 (figure 9.24) hydraulic cylinder of turning movement;
- extract stock 3 as assembly with piston and front end cover from cylinder body 4;
- unscrew nut 1 of fastening of piston 2 on stock 3 and remove piston from stock;
- remove piston curbs 15, elastic rubber rings 16 and sealing rings 17, 14;
- remove front end cover 6 from stock 3;
- extract from grooves in bore of cover 6 rubber sealing ring 5, wiper ring 10, sealing ring 12, curb 13 and
press rings 11;
- unscrew bolts 8 terminal joints of nozzle 9 and remove nozzle of stock.
Disassemble bearing mount assembly on head of cylinder rod of turning movement in following se-
quence:
- turn out greaser 23 of cover 24;
- unscrew bolts of fastening 25 of cover of hinged spherical bearing 20, remove cover 24 and sealing 26;
- unlock bolts 22 fastening hinged spherical bearing on conic finger 18;
- squeeze conic finger 18 from inner ring of hinged spherical bearing 20;
- squeeze hinged spherical bearing 18 of nozzle of stock and remove scratcher 19.
Analogously disassemble bearing mount assembly on nozzle of stock 9 of cylinder of turning movement.
Figure 9.24 - Cylinder of turning movement:

1 - nut; 2 - piston; 3 - stock; 4 - case; 5, 14 - sealing ring; 6 - front end cover; 7, 8, 22, 25 - bolt; 9 - nozzle of stock; 10 - wiper ring;
11, 16 - elastic rubber rings; 12 - sealing ring of stock; 13, 15 - curbs; 17 - sealing ring of piston; 18 - finger; 19 - scratcher; 20 - spherical
bearing; 21 - thrust washer; 23 - greaser; 24 - cover
9.4.2.8 Disassembly of pull-rod of steering trapezoid

Disassembly of pull-rod of steering trapezoid is to be carried out as follows:
- weaken terminal joints of pull-rod, having unscrewed nuts 2 (figure 9.25);
- turn out nozzles 12 of pull-rod.
Disassembly nozzles of pull-rod of steering trapezoid in following sequence:

- turn out greaser 5;
- remove stop ring 6 and stuffing box 3;
- extract retaining ring 10;
- squeeze spherical hinged bearing 11 from nozzle of pull-rod 12.
9-21
Steering
7513-3902080 RM
Figure 9.25 — Pull-rod of steering trapezoid:

1 – pull-rod tube; 2, 7 – bolts; 3 – stuffing-box; 4 – finger; 5 – greaser; 6 – thrust ring; 8 – pressure plate; 9 – spacing barrel;
10 – locking ring; 11 – hinged spherical bearing; 12 – nosepiece of pull-rod
9.5. Inspection of technical condition of parts

9.5.1 Inspection of technical condition of parts BELAZ-7514-10, 75145
Test level of "slide" of steer. Greatest possible speed of twirl of shaft of steer at inlet pressure and
blanked off exits to dispenser of steering (R and L) should not be more than 4 rpm. External escapes of work-
ing fluid are not supposed.
Test level of internal escapes of working fluid in liquid damper. Maximum permissible values of level of
escapes are shown in section 9.6.1.5.
Test level of internal escapes of working fluid in dispenser of steering. Maximum permissible values of
level of escapes are shown in section 9.6.1.3.
Test condition of parts of dispenser of steering (see figure 9.6). Presence of rust, indents on mated sur-
faces, burrs and having chopped off on surfaces of barrels 2 and 36, valve cores 3 and 37 and leveling valve,
having chopped off and indents on saddle 39 in zone of fit of bead is not supposed.
Test condition of parts of automatic machine of unload of pump (see figure 9.7). Presence of rust, in-
dents on mated surfaces, burrs and having chopped off on surfaces of barrels 17 and 50, barrels 21, covers
53, piston 46, valve 49, plunger 18, pusher 22, and also having chopped off and indents on saddle 6 and 25 in
zone of fit of beads is not supposed.
Working parameters should match to requirements specified in section 9.6.1.4.
Test condition of stock, piston, covers and cases of cylinders of turning movement (see figure 9.13).
Presence of rust, indents on mated parts, having chopped off, shells and indents on stock 36, piston 6,
burrs on case 37 and internal surfaces of cover 34, flange 13 and flange of case of tracking cylinder 31 is not
supposed.
Nominal and maximum permissible sizes of basic parts of steering are shown in table 9.3.
Table 9.3 - Nominal and maximum permissible sizes of basic parts of steering
Number, name of part Sizes, mm

Figure and
and inspected Material Hardness
position Nominal Admissible
parameters
7512-3416032 40
9.6 - 3 Valve core Steel 20Х 56-62 HRC
outer diameter
75125-3416024-20
difference difference
Barrel
of diameters of diameters
9.6 - 2 difference of inner and Steel 20Х 56-62 HRC
0,04 max
outer diameters of valve 0,015…0,03
core 7512-3416032
9-22
Steering
7513-3902080 RM

Figure and
parameters
7512-3416254
9.6 - 36 Barrel 20+0,021 Steel 20Х 56-62 HRC
inner diameter difference
of diameters
7512-3416100 20-0,007 0,05 max
-0,020
9.6 - 37 Valve core Steel 20Х 56-62 HRC
outer diameter
7512-3416056 diameter of imprint

9.6 - 39 Saddle 6+0,18 of bead Steel 40Х 34-42 HRC
diameter of hole 7 max
75212-3428034-10
9.7 - 18 Barrel 8+0,015 Steel 20Х 56-62 HRC
of diameters
75212-3428032-10 8-0,013 0,04 max
-0,028
9.7 - 17 Plunger Steel 20Х 56-62 HRC
outer diameter
75212-3428098-10 9,3+0,09
9.7 - 21 Barrel difference Steel 20Х 56-62 HRC
of diameters of diameters
75212-3428096-10 0,01…0,02
0,03 max
9.7 - 22 Pusher process on part Steel 40ХН 48-54 HRC
outer diameter 75212-3428098-10
75212-3416254
9.7 - 50 Barrel Steel 20Х 56-62 HRC
inner diameter 32+0,027 difference
of diameters
75212-3416092 process on part
75212-3416254 0,03 max
9.7 - 48 Valve
outer diameter
75125-3428026 diameter of imprint
9.7 - 25 Saddle 7+0,22 of bead Steel 40Х 34-42 HRC
inner diameter 7,5 max
7512-3429020/021
9.13 - 37 Body of cylinder 140+0,1 140,5 Steel 35 —
inner diameter
70-0,030 69,88
-0,076
7512-3429046
9.13 - 36 Rod 75 -0,030 74,87 Steel 40ХН 59-65 HRC
-0,104
outer diameter fault of chromic
coverage is not
permitted
radial clearance in
9.13 – 16 GШСЛ-70
— spherical joint ШХ15 59-65 HRC
9.15 – 3 Hinged bearing
0,5 max
9.5.2 Inspection of technical condition of parts of BELAZ-75131, 75132

Test level of internal escapes in steer. Max admissible level of escapes in bleed holder of steer at inlet
pressure of 16 MPa is 5 sm3/s.
Test level of internal escapes in booster of stream. Max admissible level of escapes in bleed holder of
booster at inlet pressure of 16 MPa is 20 sm3/s.
Test level of internal escapes through hydrodistributor of collector. Max admissible level of escapes in
drainage bore of booster at inlet pressure of 16 MPa is 2 sm3/s.
Nominal and maximum permissible sizes of basic parts of steer are shown in table 9.4.
9-23
Steering
7513-3902080 RM
Table 9.4 - Nominal and maximum permissible sizes of basic parts of steering

Figure and
parameters
7513-3429046/048 69,88
70-0,030 fault of chromic 241-285 HRC
9.24 - 3 Rod -0,076 Steel 40Х
coverage is not ТВЧ 47-57 HRC
outer diameter
permitted
75132-3429020
9.24 - 4 Body of cylinder 140
+0,1
140+0,5 Steel 35Х
inner diameter
radial clearance in
GШСЛ-70
9.24 – 20
Hinged bearing spherical joint 0,5 ШХ15 59-65 HRC
max
radial clearance in
ШСЛ-90К1
9.25 – 10
Hinged bearing spherical joint 0,5 ШХ15 59-65 HRC
max
9.6 Assembly of units of steering

Assembly of units of steering should be performed on specially equipped places with application of spe-
cial instrument, removers, device, assembly and test-beds. Places of assembly should eliminate hit of mud and
dust on collected parts.
The parts delivered on assembly, should be washed carefully out in diesel fuel and blown through by
compressed air. Wiping parts by cleaning cloth before assembly is not recommended in order to prevent
blockage of ports and jam of valve cores. Oil galleries should be cleaned and blown through by compressed
air.
GENERAL MECHANICAL RUBBER GOODS (SEALING RINGS, STUFFING BOXES, LAYER PADS) AT AS-
SEMBLY ARE SUBJECT TO OBLIGATORY REPLACEMENT.
9.6.1 Assembly of units of steering of dump trucks BELAZ-7514-10, 75145
9.6.1.1 Assembly of steering tube of dump trucks

Assembly of steering tube is to be carried out as follows:
- press on shaft of steering tube 9 bearings 7, preliminary having greased with lubricant Литол-24 (see
figure 9.3);
- into tube of column of steering 8 insert shaft 9;
- turn in tube of steering tube nozzle 6 and fix its loose strap with bolt 10 and nut 11;
- shaft of steering tube put on barrel 4 and fix it with screw 5;
- install steerable wheel 2 on shaft of steering tube;
- turn and tighten up nut 3.
9.6.1.2 Assembly of hydraulic steer

The steer is precision device, manufactured on close tolerances, therefore it is necessary to provide full
parallax purity at dealing with it. All operations should be performed only on clean work bench, and for wiping
apply soft cleaning cloth not leaving frieze.
Assembly of hydraulic steer is to be carried out as follows:

- wash out carefully all parts in clean diesel fuel and blow by compressed air;
- install sealing 15 (see figure 9.5) in special propoint in case 18;
- install leaf springs 11 on valve core 13. First flat springs are established, and then between them
(moved apart with help of screw-driver) are interposed curved;
- install in barrel 9 valve core greased with hydraulic oil 13 with springs. Contract waste of springs 11
and move springs into chases of barrel;
- install in barrel 9 pin 10;
- having centered springs install on barrel 9 restrictive ring 12;
9-24
Steering
7513-3902080 RM
- install on shank of valve core 13 axial bearer 16, thus facet on lower cartridge clip of bearing should be
located on side opposite to bearing (it conversion to seating of valve core);
- grease external surface of barrel 9 and shank of valve core with 13 hydraulic oil and half-assembly in
horizontal position install in case 18, using easy rotary motions. Thus it is necessary to observe that pin 10 is
placed in horizontal plane (for prevention of its shedding in propoints of case);
- install half-assembly in verticality shank of valve core 13 downwards;
- insert bead of back-pressure valve 17 into bore in case 18 and screw in this bore thread barrel 19;
- grease rubber sealing ring with grease and install in groove on case;
- install on case 18 distributor disk 7 so that bores in disk coincided with corresponding bores in case;
- install cardan 8 in valve core 13 so that universal-joint fork enveloped pin 10;
- expose propeller shaft in verticality with help of mounting fork which can be manufactured of thin sheet
metal;
- install sealing rings 20 greased with grease in grooves of wreath 5 of hydromotor of closed loop 1;
- install wreath 5 with spider 6 on case 18 so that spline joint cardan 8 and spider 6 has gathered;
- install cover 4;
- turn special bolt 21 with rolled head with seal washer in thread barrel 19;
- turn bolts 3 with seal washers;
- test smoothness of twirl of shaft of steer. At non-uniform force, required for twirl to release fastening of
bolts, carry out retightening at fixed twirl of shaft of steer.
9.6.1.3 Assembly of hydraulic dispenser

Assembly of hydraulic dispenser is to be carried out as follows:
- install on valve core 3 choke 4 with sealing rings (figure 9.6);
- install valve core 3 in barrel of 2 cases 19. Valve core in barrel should displace smoothly without jams;
- serially, advancing valve core from case in both sides on 13 - 15 mm install sealing rings 12;
- install in barrel sealing rings 18, and on valve core of washer 13;
- install in external groove of cover 15 sealing rings 17;
- install covers 15 with springs 16 and press flanges 5 to distributor body. Covers should be installed so
that plugs 14 are placed above (for exclusion of air blocks in cavities of covers);
- clamp flanges bolts 6;
- turn in case points 20 with sealing rings 21;
- put on triangles 8 lock-nut 35 and turn triangles in case with sealing rings 36 and protective fluoroplas-
tic rings as shown in figure 9.6;
- postpone half-assembled unit aside;
- press barrels 36 in bores of case 30;
- install valve cores 37 in bores of barrels 36. Valve cores in barrels should displace smoothly without
jams;
- install leveling valve 44 in bores of barrels 36. Valve in barrels should displace smoothly without jams;
- install in ring propoints at butt of case 30 sealing rings 45;
- install cover 25 and clamp it with bolts 24;
- install in case 31 of saddle 39 with sealing rings 22;
- install in ring propoints at butt of case 30 sealing rings 32 and 45;
- install on valve cores 37 and valves of 44 springs 38;
- install on butt of case 30 case 31;
- install and turn bolts 33 with locking washers;
- install in bores of case 31 beads 43. Stamp beads to nest. Stamped crimp should be continuous and
equal on all round;
- install on beads sequentially nests of valves 40, springs 31 and adjusting screws 42. Screws should be
started and turned in case;
- install on adjusting screws 42 layer pads and screw nuts 47 and bell jars 46;
- turn glasses 27 with sealing rings 26 in case 30;
- start on triangles 29 lock-nut and turn triangles with protective washers and sealing rings 28 in
glasses 27;
- tighten lock-nut against stop; Turn in case 30 fuse 7 with sealing ring;
- install in ring propoints of case 19 sealing rings 22 and 23;
- install on case 19 half-assembled case 30;
- turn bolts 10 with locking washers.
9-25
Steering
7513-3902080 RM
Trial of hydraulic dispenser.

The valve core 3 hydraulic directional valves should displace on (7±0,5) mm to right (to left) from mid-
position at feeding controlling pressure 0,4 - 0,8 MPa in cavity Д (cavity Е) through triangle X1 or point X2 (tri-
angle Y1 or point Y2).
At feeding controlling pressure 0,4 - 0,8 MPa in cavity Д through triangle X1 or point X2 hydraulic direc-
tional valve should ensure pass of working fluid from triangles Р1 and Р3 to point V1, and also from triangle Р2
to point V2, thus pass from triangle Р1 to point A1 and triangle Т1 should be overlapped, and also from pass
from triangle Р1 to point V1 and triangle Т1, and also from triangle Р2 to point V2 and triangle Т2 should be
overlapped.
Pressure-relief valves of indirect operation should triangle Р2 to point A2 and triangle Т2.
At feeding controlling pressure 0,4 - 0,8 MPa in cavity Е through triangle Y1 or point Y2 hydraulic direc-
tional valve should ensure pass of working fluid from triangle Р1 to point A1, and also from triangles Р2 and Р3
to point A2, thus to be adjusted on pressure (13±0,5) MPa at expenditure of working fluid (70±10) by l/min. Ad-
justment should be performed by screws 42, working fluid should give through triangles Р1 and Р2, thus trian-
gles Т1 and Т2 should be connected with drain in tank, and valve core 3 is moved to extreme position (to left
or to right).
Leveling valves 44 should ensure pass of working fluid from triangles Р1 and Р2 in cavity Г at pressure
0,5 - 1,0 MPa. Rise of pressure produces corresponding offset of valve core 3 to left or to right from midposi-
tion. Triangles Т1 and Т2 at trials should be connected with drain in tank.
Total escapes of working fluid from cavity K, brought through triangle Р3 under pressure (13±1) MPa in
cavities Л and M (points V1 and А2) should be no more than 0,25 l/min.
At trials all bores not stipulated in them should be damped.
0
Temperature of working fluid at trials (oil И-20А) - 35 - 50 С.
9.6.1.4 Assembly of automatic machine of unload of pump

Assembly of automatic machine of unload of pump is to be carried out as follows:
- in ring external groove of barrel 50 install rubber sealing ring 24;
- install barrel in case 35;
- in ring external groove of valve 49 install rubber sealing ring 31;
- install valve with ring in bore of barrel 50;
- install saddle of back-pressure valve 6 in case 35;
- in external groove of saddle of back-pressure valve 6, install rubber sealing ring 5;
- in ring external groove of saddle 25 install rubber sealing ring 30;
- install saddle in case 35;
- install and stamp bead 4 to saddle of back-pressure valve 6;
- in bore of case with saddle of back-pressure valve and bead to install glass 3, then in bore of glass in-
stall spring 2;
- in circular slots of case install rubber sealing rings 1 and 48;
- install spring 47;
- in external groove of piston 46 install rubber sealing ring 45, then piston with ring install in cover 53;
- in ring bore of cover 53 install rubber sealing ring 44;
- install covers 53 and 32 on case 35 and turn bolts 52 and 43 with locking washers;
- turn in tapped hole of cover 53 connective valve 54;
- install in circular slots of case 35 rubber sealing rings 7 and 48;
- with adjustment of width of adjusting collar 19 provide execution of difference of sizes в – б = 0,5±0,2
mm (figure 9.7 aspect А);
- install in bore of case barrel 17 plunger 18, grid 14 and spring 15;
- in ring external groove choke 11 install rubber sealing ring 13 and install choke in bore of case 16;
- install cover 12 and clamp bolts 9 and 10;
- in ring external groove choke 28 install rubber sealing ring 55;
- install in bore of case 16 split key 23, then spring 27 and choke 28;
- install cover 12 and clamp bolts 10 with locking washers;
- turn on 6 - 10 revolutions adjusting bolt 29 with nut in bore of right cover 12;
- in bore of case 16 install barrel 21, with rubber sealing ring 20, adjusting collar 19 and pusher 22;
- install half-assembled case 16 on case 34, having combined fastening bores and to clamp their
bolts 26;
- on bore of saddle 25 install bead 32;
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- stamp bead to saddle;

- in bore of case install guiding 34 and split key 33;
- in guiding 34 install spring 41;
- in ring external groove choke 39 install rubber sealing ring 38;
- install choke 39 inside of glass 37;
- turn in tapped hole of glass 37 bolt 40 with nut. Bolt should be turned on 8 - 12 revolutions.
- in external groove of glass install rubber sealing ring 36;
- turn glass with plug in case 35 against stop.
Trial of automatic machine of unload of pump.

The pressure-relief valve of direct operation should be adjusted on pressure (16±1) MPa at expenditure
of working fluid (40±10) l/min. Adjustment should be performed by adjusting bolt 40, thus adjusting bolt 29
should be wrapped up against stop.
The automatic machine of unload of pump should be adjusted on cutting off of feeding of working fluid
from bore II at pressure (13±1) MPa. Resetting to manufacture twirl of bolt 29. Expenditure of working fluid at
resetting and inspection (70±10) l/min.
The automatic machine of unload should ensure turning on of feeding of working fluid through bore II at
pressure 9 - 11 MPa.
Internal escapes of working fluid from cavity II after wear of automatic machine of unload at pressure
(12±1) MPa in bore III should not be more than 0,1 l/min. Feeding of working fluid from pump at inspection
should be stopped.
At trials working fluid is given through bore I, thus bore II should be connected to pneumohydraulic ac-
cumulator (nominal capacity 16 - 32 dm3, pressure nitrogen charging 6 - 8 MPa), and bore III should be con-
nected with drain.
9.6.1.5 Assembly of liquid damper

Assembly of liquid damper is to be carried out as follows:
- install in piston 27 on sealer "Унигерм-9" TУ - 6-01.1326-85 saddle 13 (see figure 9.8);
- stamp bead 12 to saddle 13. Stamped crimp should be continuous and equal on round;
- install in saddle bead 12, spring 26 and layer pad 11;
- install on sealer "Унигерм-9" TУ - 6-01.1326-85 and clamp thrust block 10 with torque of 50 - 70 N.m;
- install in circular slot of piston 27 sealing ring 15;
- analogously assemble second piston;
- install in cover 1 bead 3 and stamp it to saddle 2. Stamped crimp should be continuous and equal on
round;
- install on bead sequentially valve cage 4, spring 5 and adjusting screw 8. Start screws and turn in
case;
- install on adjusting screw 8 of layer pads 6, screw nut 9 and bell jar 7;
- in circular slot of barrel 14 install sealing ring 21;
- install barrel in cover 1;
- install half-assembled piston in barrel 14;
- analogously assemble second cover;
- install in grooves on case 25 sealing rings 22;
- install half-assembled cover on case 25 and start bolts 16;
- install in case 25 barrel 24 and spring 23;
- install in case second half-assembled cover and, having contracted spring in jaws clamp bolts 16 from
both sides.
Trial of liquid damper.

Safety valve of direct operation should be adjusted on pressure (8±1) MPa with adjusting screw 8, at
expenditure of working fluid (25±5) l/min.
Internal escapes of working fluid from cavities I in cavity II at pressure fall (4±0,5) MPa should be no more
(0,03) l/min.
9.6.1.6 Assembly of filter

Assembly of filter is to be carried out as follows:
- assemble on rod 3 filter cartridges 4 and turn nut 2 (see figure 9.9);
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- turn filter cartridge as assembly in case 1;

- in circular slot of cover 6 install sealing ring 5;
- turn cover 6 in case 1.
9.6.1.7 Assembly of valve of difference of pressures, release valve and back-pressure valve,
Assembly of valve of difference of pressures is to be carried out as follows:
- in bore of case 5 install valve 6, spring 7 and guiding 4 (see figure 9.10);
- on thread surface of transition nut 3 install washer 1, sealing ring 2 preliminary greased with lubricant
"Литол-24" and turn it in case 5.
The difference of pressures between cavities II and I at expenditure of working fluid 15 - 25 l/min should
be 0,35 - 0,4 MPa.
Assembly of release valve is to be carried out as follows:

- in bore of case 5 install valve 6, spring 7 and guiding 4 (see figure 9.11);
- on thread surface of transition nut 3 install washer 1, sealing ring 2 preliminary greased with lubricant
"Литол-24" and turn it in case 5;
- in case 5 turn connective valve 8.
The difference of pressures between cavities II and I at expenditure of working fluid 15 - 30 l/min should
be 2 - 2,5 MPa.
Escapes of working fluid from cavity II in cavity I at pressure fall 1,2 - 1,5 MPa should not be more than
0,5 l/min.
Assembly of back-pressure valve is to be carried out as follows:

- in bore of case 2 install valve 4 (see figure 9.12);
- stamp valve to nest. Stamped crimp should be continuous and equal on round;
- install spring 3;
+2
- start and turn thrust block 2, having sustained size of 21 mm;
- punch thrust block in two points.
Internal leakage of working fluid from cavity II in cavity I at pressure fall (8±1) MPa should not be more
than 0,3 l/min.
9.6.1.8 Assembly of hydraulic cylinder of turning movement

- install in groove of round flange of tracking cylinder 31 (see figure 9.13), sealing ring 12 (propoint out
cylinder) and press ring 11;
- install on stock 36 sequentially: press cover 15, scratcher 29 acute part up, flange 13, preliminary hav-
ing installed in internal grooves two rubber rings 14;
- install on butt of flange of 13 cases of tracking cylinder ring 30;
- install on stock half-assembled case 31, combine bores and fix on case cover 15 and flange 13 by
bolts 28 with locking washers;
- in face groove of case 31 install sealing ring 10;
- in internal grooves of cover 34 install curb 7, press ring 9 and stock sealing ring 8 (bore in inside cylin-
der), in external groove install ring 35;
- install half-assembled cover 34 on stock 36;
- fix tracking cylinder 31 to cover 34 by bolts 32 with locking washers;
- install in internal groove of piston 6 ring 4, in external grooves install two elastic rubber rings 39, two
sealing ring 38 and two curbs 40;
- install half-assembled piston on shank of stock and fix nut 3 with torque of 2400-3000 N.m;
- install half-assembled stock in cylinder body 37, oiled internal surface of case with И-20;
- correct bores in cover 34 concerning bore of input of pressure in cylinder body and fix cover as assem-
bly with case of tracking cylinder to case 37 by bolts 33 with locking washers;
- install in face groove on flange of tube 5 ring 1;
- install tube on cylinder body and fix bolts 2 with locking washers, fix to case clinch with bolt;
- turn on stock nozzle 27 and fix terminal joint by bolts 26.
Assemble bearing mount assembly of nozzle of stock in following sequence:

- press conic finger 23 in inner race hinged spherical bearing 16;
- install thrust washer 17 and fix with bolts 18;
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- lock bolts 18 of fastening of hinged bearing 16 on conic finger 23;

- install scratcher 24 with protective washer 25;
- press hinged spherical bearing 16 with finger 23 in nozzle of stock, preliminary having greased with lu-
bricant Литол-24 spherical surfaces of bearing;
- install sealing ring 22;
- install cover 20 and turn bolts 21 of fastening of cover hinged spherical bearing;
- turn greaser 19.
Analogously assemble bearing mount assembly on cover of cylinder of turning movement.
ATTENTION: JOINTING PLANE OF HINGED BEARINGS SHOULD BE PERPENDICULAR TO SHAFT OF CYL-

INDER OF TURNING MOVEMENT.
9.6.1.9 Assembly of pull-rod of steering trapezoid

For assembly of pull-rod of steering trapezoid first of all execute assembly of nozzles of pull-rod.
Assembly of nozzles of pull-rod of steering trapezoid perform in following sequence:

- press conic finger 6 (see figure 9.15) in inner race hinged spherical bearing 3;
- install thrust washer 2 and fix bolts;
- lock bolts of fastening of hinged bearing 3 on conic finger 6;
- install scratcher 9 with protective washer 8;
- press hinged spherical bearing 3 with finger 6 in nozzle 5, preliminary having greased with lubricant
Литол-24 spherical surfaces of bearing;
- install cover 4 and turn bolts of fastening of cover of hinged spherical bearing 3;
- turn greaser 1.
ATTENTION: JOINTING PLANE HINGED BEARINGS SHOULD BE PERPENDICULAR TO SHAFT OF PULL-

ROD OF STEERING TRAPEZOID.
Assembly of pull-rod of steering trapezoid should be performed in following sequence:

- screw nozzles of pull-rod 1, 6 (figure 9.14) in thread mouths of pipe of pull-rod 5 according to direction
of thread (left or right) on equal number of revolutions;
- screw nuts 4 on bolts of 2 terminal joints of pull-rod of steering trapezoid.
Only after regulating convergence of steered wheels tighten terminal connections of track rod with
torque of 110 - 140 N.m.
9.6.2 Assembly of units of steering of dump trucks BELAZ-75131, 75132
9.6.2.1 Assembly of column of steering

Before assembly clear parts of steering tube of old lubrication and other pollutants. Cover with thin stra-
tum of lubricant grease rubed surfaces of parts of steering tube.
Assembly of column of steering with bracket is to be carried out as follows:

- press ball bushing 6 (see figure 9.17) on shaft 3;
- fix bearing 6 retaining ring 4, having installed it in groove of shaft 3;
- press bearing 6 as assembly with shaft 3 in bore in housing 2;
- install retaining ring 5 in groove in housing 2;
- install tab 18 in chase on shaft 19;
- start off-center barrel 17 between eyelets on housing 2;
- having combined bores in barrel 17 and eyelets of housing 2 install shaft 19 as assembly with tab so
that tab has got in key in barrel 17;
- turn off-center barrel 17 with shaft 19 so that as much as possible appearing side of barrel has come in
chase in housing 2;
- put on shaft 19 barrel 16, spring 15 so that direct section of proximal to eyelet of coil of spring rested
against case of housing 2;
- put on spline shank of shaft 19 hand lever 13, having provided hit of unbend on spring 15 in bore in
plate of hand lever 13;
- fix hand lever 13 with screw 14;
- press bearing 6 on shaft 10;
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- install retaining ring 4 in groove on shaft 10;

- install bearing 6 as assembly with shaft 10 in tube of column;
- install barrel 9 and retaining ring 5 on part of bearing 6 in bore in tube of column 8;
- install flat washer 1 and two springs 7 in axial bore in shaft 10;
- having provided coincidence of slits of shafts 3 and 10 install tube of column 8 as assembly with shaft
10 in housing 2. Thus hand lever 13 should be revolved clockwise and be kept in such position before full joint
of tube of column 8 and housing 2;
- having combined radial tapped hole in tube of column 8 with chase in housing 2 turn screw 11, having
installed ring 12;
At turning movement of hand lever 13 mutual conveyance of tube of column 8 and housing 2, and also
reliable their mutual fixing should be ensured at absence of effect on hand lever.
- put on stop member 6 (see figure 9.16) arrester 2 and install them between walls of bracket 8, having
combined bore in stop member with bore in bracket;
- install in bore finger 19 and stop it with splint 18;
- install tab 3 in chase on shaft 20;
- place between walls of bracket 8 off-center barrel 1 and flat washer 21;
- having combined bores in them and in addition in arrester 2 install shaft 20 as assembly with tab so
that tab has got in key in barrel 1, thus arrester 2 should be between barrel 1 and flat washer 21;
- turn off-center barrel 1 with shaft 20 so that barrel is as much as possible appearing at side opposite to
stop member 6;
- put on shaft 20 barrel 17 and spring 16 so that direct section of extreme coil of spring touch thrust
block on side wall of bracket;
- put on spline shank of shaft 20 bar 15, having provided hit of unbend on spring 16 in bore in plate of
bar;
- fix bar 15 with screw 14;
- install hand lever 5 (see figure 9.2) from opposite side of shaft 20 (see figure 9.16) and turn from butt of
shaft 20 bolt;
- install shackle of tube of column 8 (see figure 9.17) between walls of bracket 8 (see figure 9.16), hav-
ing placed between walls of bracket and shackle flat washers 23;
- install shaft 13, having combined bores in bracket 8, shackle of tube of column 8 (see figure 9.17) and
washers 23 (see figure 9.16);
- screw on shaft 13 nut 22, having tightened it so that turning movement of bracket 8 concerning tube of
column from force of arm was ensured;
- splint nut 22;
- install in bores of eyelets of shackle bearing part 10;
- turn shaft 20 with barrel 1 clockwise;
- install stock 4 between stop member 6 and barrel 1 so that longitudinal flat on stock placed on part of
barrel 1, and h-pole serrated surfaces of stop member 6 and stock 4 have coincided;
- install thread shank of stock 4 in bore in bearing part 10 and fix its position, having turned nut 11;
- turn in butt of stock 4 bolt 5, having installed flat washer;
- install in bore pusher 9, bracket 8 nut bolt 7 and, as much as possible having approximated pusher to
stock 4, turn nut.
In assembled column turning movement of column 12 concerning bracket 8 from force of arm should be
ensured at turning movement of hand lever installed on shaft 20, and also reliable their mutual fixing at ab-
sence of effect on hand lever.
9.6.2.2 Assembly of propeller shaft of steering

Assembly of propeller shaft is to be carried out as follows:
- if it is necessary replace needle bearers to install remotely spider 11 (see figure 9.18) in fork of cardan
joint 1, install needle bearers 14 in bore of fork 7 of cardan joints, having provided hit of remotely spider in
crank chamber of needle bearer, preliminary having filled in lubricant № 158М;
- install retaining ring 13 on needle bearer from interior of fork 7 of cardan joints;
- install in same way other needle bearers;
- install protective clutch 5 on slit shaft 6 and fix clutch with wire splint 4;
- insert slit shaft 6 in slit bore of tube 3 so that key on shaft 6 and tube 3 placed in one plane, preliminary
having greased with lubricant Литол-24 slots of shaft 6;
- put on protective clutch 5 tube 3 and fix clutch with wire splint 4;
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- install in chases on shaft 6 and tube 3 semicircular keys 10;

- turn handrail bolts of 2 fastening of cardan joints 1 and pull together terminal connections of cardan
joints.
9.6.2.3 Assembly of hydraulic steer
Assembly of hydraulic steer of BELAZ-75131, 75132 is executed analogously to assembly of steer BE-
LAZ-7514-10, 75145.
9.6.2.4 Assembly of booster of stream
The booster of stream is precision device, manufactured on close tolerances, therefore it is necessary to
provide full parallax purity at dealing with it. Operations should be performed only on clean work bench, and for
wiping apply soft cleaning cloth not leaving frieze.
Before assembly part should be washed out and blown with compressed air.
Assembly of booster of stream is to be carried out as follows:

- carefully grease each part with clean hydraulic oil before installing it;
Assembly of valve core of booster:

- turn throttle 11 in choke 10 (see figure 9.21);
- turn butterfly valve of one-sided operation 1 with sealing ring 2 in valve core 3;
- insert into valve core 3 internal valve core 8;
- fix internal valve core 8, having installed pin 4 and retaining ring 6;
- insert spring 9 and choke 10, having fixed its pin 5 with retaining ring 7;
Assembly of booster of stream:

- screw throttle 9 (see figure 9.19), having tightened with torque 0,5 N.m;
- screw throttle 39, having tightened with torque 1 N.m;
- screw throttle with back-pressure valve 40, having tightened with torque 1 N.m;
- screw pressure-relief valve 16, install layer pad 15 and turn choke 14 with torque of 2,5 N.m;
- install valve of backpressure 11 with spring 17 and turn choke 13 with sealing ring 12;
- install shock-proof valves 8 and 24;
- screw in valve core of direction 23 throttles 22 and 25;
- install valve core of direction 23 in case 10;
- install valve core of booster 41 in case;
- install valve core of priority valve in case;
- install spring 42 on valve core of booster 41;
- install thrust block of spring 21, springs 19 and 20, bearing part of spring 18 on valve core of
direction 23;
- grease sealing rings 4, 5 and 6 and install them in sealing plate 7 on cover 3;
- install cover 3 with plate 7 and rings 4, 5, 6 on case 10;
- turn bolts 2 with locking washers and tighten them with torque of 2,5 N.m;
- turn bolt 1 locking washer and tighten it with torque of 8 N.m;
- install thrust block of spring 26, springs 27, 28 and bearing part of spring 29 on valve core of
direction 23;
- install spring 37 and bearing part of spring 36 on valve core of priority valve 38;
- grease sealing rings with 33 and 34 and install them in sealing plate 35 on cover 32;
- install cover 32 with plate 35 and rings 33 and 34 on case 10;
- turn bolts 31 with locking washers and tighten them with torque of 2,5 N.m;
- turn bolt 30 locking washer and tighten it with torque of 8 N.m;
- eliminate opportunity of pollution of unit, install time plastic choke in ports of booster of stream.
9.6.2.5 Assembly of collector

- carefully grease each part with clean hydraulic oil before installing it;
- insert into case 1 valve 2, spring 3 and barrel 11 (see figure 9.22);
- turn fuses 8 and 9 with sealing rings 7 and 10;
- install on case rubber sealing rings 4;
- install hydrodistributor 6 and clamp its screws 5 with locking washers.
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9.6.2.6 Assembly of filter

- install in cover 10 valve 12, basic barrel 13 and turn nuts 14 (see figure 9.23);
- turn in cover barrel 11 with sealing ring 7;
- install in filter cartridge 6 choke 4 with sealing ring 5;
- install in case 2 spring 3 and half-assembled filter cartridge;
- in circular slot of cover 10 install protective washer 8 and sealing ring 9;
- turn case 2 in cover 10;
- turn in case 2 fuse 1 with rubber sealing ring.
9.6.2.7 Assembly of hydraulic cylinder of turning movement

Before assembly of cylinder of turning movement to wash out in diesel fuel and blow with compressed
air all ports and surfaces of cover and cylinder body of turning movement. Sealing rubber rings before mount-
ing keep in oil for not less than 48 hours.
Assembly of cylinder of turning movement is to be carried out as follows:

- install in external groove of front end cover 6 (see figure 9.24) sealing ring 5;
- install in internal grooves of front end cover elastic rubber rings 11, wiper ring 10, sealing rings of stock
12, curb of stock 13. Pay attention to orientation of working crimps of rod sealing;
- install front end cover 6 on stock 3;
- install in internal groove of piston 2 rubber sealing ring 14;
- install completely elastic rubber rings 16, sealing rings of piston 17, curbs of piston 15 (locks of them
should place on opposite sides of piston) in propoints on piston 2;
- install piston 2 with sealing on stock 3 and fix it with nut 1;
- turn on stock nozzle 9, fix terminal joint by bolts 8 and tighten self-locking nut 1 with torque of 2400 -
3000 N.m;
- install stock 3 with front end cover 6 and piston 2 in cylinder body of turning movement 4;
- fix with bolts 7 front end cover 6 to cylinder body of turning movement 4;
Assemble bearing mount assembly on cylinder body of turning movement in following sequence:
- press conic finger 18 in inner ring of hinged spherical bearing 20;
- install thrust washer 21 and fix with bolts 22;
- lock bolts 22 of fastening of hinged bearing 20 on conic finger 18;
- install scratcher with protective washer 19;
- press hinged spherical bearing 20 in cylinder body, preliminary having greased with lubricant Литол-24
spherical surfaces of bearing;
- install sealing ring 26;
- install cover 24 and turn bolts 25 of fastening of cover of hinged spherical bearing;
- turn greaser 23.
Analogously assemble bearing mount assembly on nozzle of cylinder rod of turning movement.
ATTENTION: JOINTING PLANE OF HINGED BEARINGS SHOULD BE PERPENDICULAR TO SHAFT OF CYL-

INDER OF TURNING MOVEMENT.
Trial of hydraulic cylinder of turning movement.

After assembly cylinder of turning movement should be tested.
The purpose of trials: inspection of leakproofness of joints and operation of cylinder of turning move-
ment.
At trial of cylinder of turning movement on leakproofness and operation working fluid under pressure
(16 MPa) is supplied serially in piston and rod cavities of cylinder of turning movement. Stock should displace
freely, without jams. Pressure of piston stripping should not be more 1 MPa. Amount of double strokes of cyl-
inder rod of turning movement should be not less than 5.
9.6.2.8 Assembly of pull-rod of steering trapezoid of BELAZ-75131, 75132

For assembly of pull-rod of steering trapezoid first of all perform assembly of nozzles of pull-rod.
Assembly of nozzles of pull-rod of steering trapezoid is to be carried out as follows:

- press hinged spherical bearing 11 (see figure 9.25) in nozzle 12, preliminary having greased with lubri-
cant Литол-24 spherical surfaces of bearing;
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- install retaining rings 10;

- install stop rings 6 and stuffing boxes 3;
- turn greaser 5.
ATTENTION: JOINTING PLANE OF HINGED BEARINGS SHOULD BE PERPENDICULAR TO SHAFT OF PULL-

ROD OF STEERING TRAPEZOID.
Assembly of pull-rod of steering trapezoid is to be carried out as follows:

- screw nozzles of pull-rod 12 in thread mouths of pipe of pull-rod 1 according to direction of thread (left
or right) on equal number of revolutions;
- screw nuts 2 on bolts of terminal joints of pull-rod of steering trapezoid.
Only after regulating convergence of steered wheels tighten terminal joints of track rod with torque of
110 - 140 N.m.
9.7 Mounting of units of steering on dump truck
9.7.1 Mounting of units of steering on dump truck BELAZ-7514-10, 75145
9.7.1.1 Mounting of column of steering

Column of steering is installed on dump truck in following sequence:
- connect column of steering 3 (see figure 9.1) loose strap with nuts to bracket of panel of gears;
- turn and clamp bolts 2 of fastening of column of steering to floor of cabin;
- install steerable wheel 2 (see figure 9.3) at shaft of steering tube 9 and tighten nut 3 of fastening of
steerable wheel;
- install cover of steerable wheel 1;
- install switches of turn indicators, light of headlights, window wiper and window washer.
9.7.1.2 Mounting of steer
Steer is installed on dump truck in following sequence:

- install steer on bracket under floor of cabin;
- turn and clamp bolts 2 (figure 9.1) fastening of steer to steering tube;
- connect sleeves of high pressure to steer.
9.7.1.3 Mounting of hydraulic dispenser

The hydraulic dispenser is installed on dump truck in following sequence:
- install hydraulic dispenser on bracket of frame and turn bolts of fastening;
- connect sleeves of high pressure to hydraulic dispenser.
9.7.1.4 Mounting of automatic machine of unload of pump

Automatic machine of unload of pump is installed on dump truck in following sequence:
- install automatic machine of unload of pump on bracket of frame and turn bolts of fastening;
- connect sleeves of high pressure and pipe duct to automatic machine of unload of pump.
9.7.1.5 Mounting of liquid damper

The liquid damper is installed on dump truck in following sequence:
- install liquid damper on bracket of frame and turn bolts of fastening;
- connect sleeves of high pressure to liquid damper.
9.7.1.6 Mounting of valve of difference of pressures

The valve of difference of pressures is installed on dump truck in following sequence:
- turn valve of difference of pressures in oil filter;
- connect sleeve of high pressure to valve of difference of pressures.
9.7.1.7 Mounting of filter

The filter is installed on dump truck in following sequence:
- turn filter in bracket;
- connect sleeve of high pressure to filter.
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9.7.1.8 Mounting of release valve

Release valve is installed on dump truck in following sequence:
- install release valve on bracket of frame and turn nut of fastening;
- connect sleeve of high pressure and pipe ducts to release valve.
9.7.1.9 Mounting of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
Hydraulic cylinders of turning movement is installed on dump truck in following sequence:
- install bars of steering trapezoid on swivel members;
- install on studs conic barrels;
- screw nuts and fix them bars of steering trapezoid with torque of 350-430 N.m;
- moor cylinder of turning movement (see figure 9.13) with help of fastening device and hoisting gear;
- install conic fingers of cylinder body of turning movement in bracket of spar of frame, and conic fingers
of nozzle of stock - in pivot rod of steering trapezoid;
- tighten nuts on conic fingers with torque of 500-700 N.m;
- similarly install second cylinder of turning movement;
- connect sleeves of high pressure to cylinders of turning movement thus rod end of left cylinder of turn-
ing movement head end left - with rod end of right cylinder should be connected to head end of right cylinder.
Pull-rod of steering trapezoid is installed on dump truck in following sequence:

- install pull-rod of steering trapezoid (see section "Running gear") in conic bores of pivot rod of steering
trapezoid;
- turn nuts on conic fingers and tighten with torque of 500 - 700 N.m.
After mounting of cylinders of turning movement and pull-rod of steering trapezoid it is necessary to ad-
just convergence of steered wheels.
9.7.2 Mounting of units of steering on dump truck BELAZ-75131, 75132
9.7.2.1 Mounting of column of steering with propeller shaft

Column of steering on dump truck is installed in following sequence:
- connect column of steering 3 (see figure 9.2) by bolts and nuts to lower panel of gears;
- fix front of bracket of steering tube to fast-head wall of cabin bolts;
- install semicircular key in chase on shaft of steering tube and install propeller shaft 2 on shaft of steer-
ing tube 3;
- tighten handrail bolt of terminal joint of cardan joint;
- install steerable wheel 4 on shaft of steering tube 3 and tighten nut of fastening of steerable wheel;
- install cover of steerable wheel 4;
- install switches of turn indicators, light of headlights, window wiper and window washer;
- install plastic housings and fix with screws.
9.7.2.2 Mounting of steer

The hydraulic steer is installed together with flange.
Steer is installed on dump truck in following sequence:

- install hydraulic steer 1 (see figure 9.4) together with flange 2 in bracket under floor of cabin;
- turn bolts of fastening of steer 1 (see figure 9.2);
- connect sleeves of high pressure to steer;
- connect propeller shaft 2 to shaft of steer 1.
9.7.2.3 Mounting of booster of stream

The booster of stream is installed on dump truck in following sequence:
- install booster of stream on bracket of frame and turn bolts of fastening;
- connect sleeves of high pressure to booster of stream.
9.7.2.4 Mounting of collector

Collector is installed on dump truck in following sequence:
- install collector on bracket of frame and turn nut of fastening;
- connect sleeves of high pressure to collector.
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9.7.2.5 Mounting of filter

The filter is installed on dump truck in following sequence:
- install filter on dump truck and to turn bolts of fastening of filter;
- connect sleeves of high pressure to filter.
9.7.2.6 Mounting of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
Hydraulic cylinders of turning movement are installed on dump truck in following sequence:
- install bars of steering trapezoid on swivel members;
- install on studs conic barrels;
- screw nuts and fix them bars of steering trapezoid with torque of 350-430 N.m;
- moor cylinder of turning movement (see figure 9.24) with help of fastening device and hoisting gear;
- install conic fingers of cylinder body of turning movement in brackets of frame, and stock - in pivot rods
of steering trapezoid;
- tighten nuts on conic fingers with torque of 500-700 N.m;
- similarly install second cylinder of turning movement;
- connect sleeves of high pressure to cylinders of turning movement thus rod end of left cylinder of turn-
ing movement head end left - with rod end of right cylinder should be connected to head end of right cylinder.
Pull-rod of steering trapezoid is installed on dump truck in following sequence:

- install pull-rod of steering trapezoid (see section "Running gear") in eyelets of bar of steering trapezoid;
- install fingers 4 pull-rods (see figure 9.25);
- install distance sleeves 9 in cylindrical bores of bar of steering trapezoid;
- install pinch plates 8;
- turn and clamp bolts 7 (first clamp lower bolt, then upper);
- grease through greasers 5 hinged spherical bearings 11 with lubricant Литол-24.
After mounting of cylinders of turning movement and pull-rod of steering trapezoid it is necessary to ad-
just convergence of steered wheels.
ATTENTION:
1 FILLING OF OIL IN TANK OF HYDRAULIC SYSTEM PERFORM THROUGH FILTER ONLY!
2 MUD AND ADMIXTURES OF ALL ASPECTS IS THE PRINCIPAL REASON OF MAJORITY OF
FAILURES IN HYDRAULIC SYSTEM!
3 DELAYED REPLACEMENT OF FILTERS OF HYDRAULIC SYSTEM AND POLLUTION OF WORK-
ING FLUID RESULT IN CUTTING-DOWN OF RESOURCE OF HYDRAULIC APPARATUSES, JAMMING
AND OTHER FAILURES OF STEERING!
9-35
Steering
7513-3902080 RM
9-36
Braking systems
7513-3902080 RM
10 BRAKING SYSTEMS
Dump trucks BELAZ-7514-10, BELAZ-75145, BELAZ-75131 and BELAZ-75132 are arranged with ser-
vice, parking, auxiliary and emergency braking systems.
The service braking system with the hydraulic actuator has front brake circuit and a rear brake circuit,
operates on all wheels. It is intended for speed regulation of driving or a shut-down of a dump truck in any road
conditions, and also at insufficient efficiency of a auxiliary brake.
The parking braking system has the hydraulic actuator and operates on wheels of a rear axle. It is in-
tended for braking a dump truck on parking places, at loading and unloading, and also in emergency situations
at failure of a service braking system.
Auxiliary brake - electric in a condition of braking operation of traction motors.
As an emergency braking system the parking and intake circuit of service system is used.
10.1.1 Braking systems of dump trucks BELAZ-7514-10, BELAZ-75145

10.1.1.1 A service braking system
The service braking system consists of four brake gears of drum type, with two internal shoes, built-in in
front and rear wheels, a hydraulic drive, operating controls and monitoring devices of system operation.
Controlling of a service braking system is carried out by a pedal of a brake valve.
Brake gears of front wheels with a symmetric one-sided arrangement of supports of shoes are built on
a steering knuckle 17 (figure 10.1). Brake shoes 4 with cover plates are installed on axles 16 and with the help
of a cover plates of shoes axle 15 are fixed with bolts 14, washers 13 and engraving washers.
Figure 10.1 – Braking gear of front wheel of dump trucks

BELAZ–7514-10 and BELAZ–75145:
1 - finger of a spring; 2, 8, 11 - splints; 3 - a spring; 4 - a
shoe with cover plates; 5 – wheel cylinder of front brake; 6, 14,
22 - bolts; 7 – a protective shroud; 9 - a block; 10 - a plunger;
12 - a bar of a steering trapezoid; 13 - a washer; 15 - a cover
plate of shoe axle; 16 - a shoe axle; 17 - a steering knuckle;
18 – a centering bush; 19 - an adapter; 20 - a plug; 21 - a brake
drum; 23 – a front wheel hub
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Braking systems
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The brake cylinder 5 is fixed on a steering knuckle 17 with the help of four bolts 6, has two pistons and
effects on both shoes simultaneously. The spacing between brake shoes and a drum 21 is ensured with auto-
matically-controlled special device installed in a brake cylinder. Coupling springs 3 are fixed on the one hand
on fingers of 1 of brake shoes, and on the other side on plates of a brake cylinder and intended for returning of
shoes in a home position when unbraking a dump truck. To prevent of hit of a mud to a brake cylinder the pro-
tective shroud 7 is installed onto it. The force to a brake shoe from the cylinder is transmitted through a plunger
10.
Brake gears of rear wheels are built on the case of a reducer of a motorized wheel 17 (figure 10.2).
They are executed with the carried shoe supports and have automatic regulation of a spacing between brake
shoes 6 and a drum 5 which is ensured with the special device installed in a brake cylinder.
The brake cylinder 2 is installed in an eyelet of the case of a reducer 17 and fixed to it by bolts 1. The
brake shoe with cover plates 6 is installed on an axle 18. The coupling spring 3 is fixed on the one side to a
brake shoe, on the other side on a finger of a spring 4 and intended for returning of a shoe in a home position
at unbraking a dump truck. To prevent of hit of a mud to a brake cylinder the protective shroud 9 is installed
onto it. The force to a brake shoe from the cylinder is transmitted through a plunger 8.
Figure 10.2 - Brake gear of a rear wheel of dump trucks BELAZ-7514-10 and BELAZ-75145:
1, 11 - bolts; 2 – a wheel cylinder of rear brake; 3 - a coupling spring; 4 - a finger of a spring; 5 - a brake drum; 6 - a shoe with
cover plates; 7 - a block of shoe; 8 - a plunger; 9 - a protective shroud; 10 – a rear wheel hub; 12 - an adapter; 13 - a splint; 14 - an
adapter; 15 - a tube; 16 - a angle piece; 17 - the case of a reducer of a motorized wheel; 18 - a shoe axle; 19 - a locking bolt
10.1.1.2 A parking braking system

The parking braking system has the hydraulic actuator consisting of the control cock and two brake cyl-
inders.
Brake gear of a parking braking system - drum-type with two internal shoes, effects on axles of arma-
tures of traction motors of driving wheels.
The brake gear is built on a carriage 13 (figure 10.3), attached by bolts 26 to the rear end bracket 24 of
10-2
Braking systems
7513-3902080 RM
traction motors rigidly. On a axle 28, fixed in a carriage, two brake shoes 1 fixed with springs 2 and 12 are
rested. The upper ends of shoes are clamped to an expansion-type knuckle 21 installed into an opening of a
carriage through rollers 11by coupling springs.
On castle-type end of the axle of an expansion-type of knuckle the adjusting bar 22, jointed with a cylin-
der rod of a parking brake 9 is fastened by means of a fork 4 and the extension lead of a rod 6 with a finger 3.
The brake drum 15 with a flange 17 is installed on castle-type end of an armature axle 20 of traction motor and
fixed by a bolt 19 through plates 18.
When braking the force of springs of the cylinder 9 is transmitted to an adjusting bar 22 which turns an
expansion-type knuckle 21 and clamps shoes 1 to a brake drum 15.
Figure 10.3 - Brake gear of a parking braking system of dump trucks BELAZ-7514-10 and BELAZ-75145:
1 - a brake shoe; 2, 12 - coupling springs; 3 - a finger; 4 - a fork of a rod; 5 – an indicator; 6 - the extension lead of a rod; 7 - a
washer; 8 - a nut; 9 - a parking brake cylinder; 10, 14, 23 - splints; 11 - a roller; 13 - a carriage; 15 - a brake drum; 16, 19, 26 - bolts; 17 - a
flange; 18 - a plate; 20 - an armature axle of the traction motor; 21 - an expansion-type knuckle; 22 - an adjusting bar; 24 - the end bracket
of the traction motor; 25 - a ring; 27 - a sensor of a speed limitation; 28 – a shoe axle; 29 - a support washer
10.1.2 Braking systems of dump trucks BELAZ-75131, BELAZ-75132

10.1.2.1 A service braking system
The service braking system consists of four brake gears of disk type, with two internal shoes, a hydraulic
drive, operating controls and monitoring devices of system operation.
Controlling of a service braking system is carried out by a pedal of a brake valve.
10-3
Braking systems
7513-3902080 RM
Brake gears of front wheels - one-disk, dry friction with the hydraulic actuator.
The case of a brake 2 (figure 10.4) is fastened to a steering knuckle 1 of front axle with two bolts 13. The
brake disk 4 is fastened to the hub of a front wheel with bolts. There are six cylinders (three from each side) in
the case of a brake into which pistons 6 are inserted, on supports 10 of case of a brake two brake linings 5 are
installed. The piston is sealed by a rubber cuff 15 with the guard ring 14 on an outer diameter, and the clutch 3
protects from hit of a mud on a service surface of the piston. Cylinders are protected by covers 7 outside. Cyl-
inders are interconnected by ports for input of a hydraulic fluid under the piston.
Figure 10.4 - Brake gear of a front wheel of dump trucks BELAZ-75131 and BELAZ-75132:
1 - a steering knuckle; 2 - the case of a brake; 3 - a protective clutch; 4 - a brake disk; 5 - a cover plate; 6 - the piston; 7 - a cover;
8, 13 - bolts; 9, 11 - rings; 10 - a support; 12 - an adjusting washer; 14 - a protective ring; 15 - a cuff
Brake gears of rear wheels - one-disk, dry friction with the hydraulic actuator.
On the end bracket of each traction motor 13 (figure 10.5) it is built two service brakes through brackets
22 and 23. The service brake consists of two cheeks 3 and 17 which are fastened with studs 8 through inserts
19 and supports 20. To cheeks eight cylinders 11 (four from each side) are fastened inside which pistons 29
are installed. The piston is sealed by a rubber ring 63 with a protective washer 62 on an outer diameter, and
the clutch 26 protects from hit of a mud on a service face of the piston. Cylinders are interconnected by internal
ports for input of a hydraulic fluid under the piston. Each cylinder has the device of an automatic adjustment of
a spacing between a brake shoe 28 and cover plates 27.
The brake disk 28 is fastened by bolts to a flange 16 installed on splines of the axle of a rotor of the trac-
tion motor.
10.1.2.2 Parking braking system

The brake gear of a parking braking system – of disk type, dry friction with two spring power accumu-
lators has the hydraulic actuator. The brake disk 28 is common for parking and service brakes. The parking
brake gear is fastened to a bracket 22. Cheeks 50 and 52 are connected by studs through supports 20. Two
cylinders 5 of parking brakes with pistons 48 and springs 47 are installed onto an external cheek.
10-4
Braking systems
7513-3902080 RM
Figure 10.5 - Brake gears of rear wheels and a parking brake of dump trucks BELAZ-75131 and BELAZ-75132:
1 - hoses of a high pressure; 2, 6, 18 – angle pieces; 3, 17, 50, 52 - cheeks; 4, 10, 14, 21, 25, 54 - bolts; 5 - a parking brake cylin-
der; 12 - T-connector; 7, 32, 34, 41 - nuts; 8 - a stud; 9, 20 - supports; 11 – a cylinder of a working brake; 13 - the traction motor; 15 - a
plate; 16 - a disk with a flange; 19 - an insert; 22, 23 - brackets; 24, 36, 38, 59, 63 – sealing rings; 26, 51 - protective clutches; 27 - a brake
cover plate; 28 - a brake disk; 29, 48 - pistons; 30 - a rod; 31, 49 - cases; 33 - a thrust block; 35, 39, 62 - protective washer; 37 - a plug;
40 - the locking bolt; 42 - the indicator; 43 - a splint; 44 - a nut of unbraking; 45 - a washer; 46 - a cover; 47, 55, 64 - springs; 53 - adjusting
shims; 56 - a lock ring; 57 - a stop ring; 58 - an adjusting washer; 60 - the frictional bush; 61 - a cup
10-5
Braking systems
7513-3902080 RM
10.2 Possible troubles of braking systems and methods of their removal
Possible troubles of braking systems and methods of their removal are given in Table 10.1.
Table 10.1 — Possible troubles of braking systems and methods of their removal
Trouble and symptom Probable cause Remedy
Insufficient braking efficiency Cover plates are oiled or worn out Replace cover plates
Wheel brake gears do not unbrake The piston of brake gear is jammed Eliminate jamming of the piston
Nonhermeticity of pair (sleeve–valve) of brake Replace the pair (sleeve -valve)
valve
Low efficiency of parking brake system Big clearance between braking disk and To adjust a clearance
braking cover plates of parking brake
Shoes are oiled or worn out To replace braking shoes
To replace a knuckle
The knuckle of parking brake valve
Insufficient capacity of hydropneumatic Low (high) pressure of nitrogen in a gas space Discharge oil from oil space, check-
accumulator, drop of pressure when of hydropneumatic accumulator pressure og nitrogen, bring it to the
braking norm
Drop of pressure in hydropneumatic Nonhermeticity of pair (sleeve–valve) of brake Replace the pair (sleeve -valve)
accumulator when engin is shut down valve
Drop of pressure of nitrogen in hy- External nonhermeticity of priming valve To check with soap solution, to elimi-
dropneumatic accumulator nate nonhermeticity
Nonhermeticity between gas and oil spaces
Replace sealing of piston of hy-
dropneumatic accumulator or replace
a hydropneumatic accumulator
10.3 Repairing of braking systems of dump trucks BELAZ-7514-10, BELAZ-75145

Before repairing the braking systems eliminate spontaneous driving of a dump truck from a place.
10.3.1 Repairing of brake gears of front wheels

Disassembling of a brake gear of front wheels
Disassembly of brake gears of front wheels is performed in the following sequence:
- to remove a front wheel from the hub (the order of removal of wheels look in section « Wheels and
tires);
- to remove the hub of a front wheel (the order of removal of hubs of front wheel look in section "Front
axle");
- to release pressure in a hydraulic system of brakes (removal of pressure is made by turning out stop
needles of the brake valve);
- to disconnect a sleeve of a high pressure from an adapter 19 (look figure 10.1);
- to turn out an adapter from the case of the wheel cylinder 5 of front brake;
- to unscrew bolts of 14 fastenings of brake shoes on two - three revolutions;
- to remove springs 3;
- to unlock and to remove a protective shroud 7 and to turn brake shoes 4 around axles, having lowered
them down;
- to turn out bolts 14, to remove a cover plate of shoes axle 15;
- to remove brake shoes 4 with cover plates with the help of load-lifting means;
- to take blocks 9 out of opening of brake shoes;
10-6
Braking systems
7513-3902080 RM
- to take out a splint 2 and to take a finger of 1 springs from an opening of a brake shoe;
- to take plungers 10 out of a brake cylinder 5;
- to unscrew bolts 6 and to remove a brake cylinder;
- to take centering bush 18 out of opening in steering knuckle 17.
Disassembling of a brake cylinder is made in the following sequence:
- to unscrew bolts 12 (figure 10.6) and to remove a plate 13, a cover 14 and a spring 8;
- using a mandrel (figure 10.7) to take semi-rings 11 out of a groove of a rod 18 (look figure 10.6);
- to remove a washer 10 and to take a spring 9 from a rod;
- to take guiding 17 with a frictional ring 15, a separator 16, rollers 7 and a block 6 out of the cylinder;
- to press a frictional ring 15 with guiding 17;
- to take a piston 5 in assembly with a nut 20, a sealing ring 19, a cuff holder 3, a cuff 4 and a rod 18 out
of a cylinder body 1;
- to unscrew a nut 20 to remove cuff holder 3 and a cuff 4 from the piston 5;
- to remove the piston 5 from a rod 18;
- to take a sealing ring 19 out of a groove of a rod;
- analogous operations are performed for the second section of the cylinder
Figure 10.6 - Cylinder of a front brake gear:

1 - a cylinder body; 2 - a restrictive bolt; 3 – a cuff holder; 4 - a cuff; 5 – a piston; 6 - a block; 7 - a roller; 8, 9 - springs; 10 - a
washer; 11 - a semi-ring; 12 - a bolt; 13 - a plate; 14 - a cover; 15 - a frictional ring; 16 - a separator; 17 - guiding; 18 - a rod; 19 – a sealing
ring; 20 - a nut
А – size, which defines clearance between a shoe and drum
Figure 10.7 – Mandrel for removal and setting of semi-rings
10-7
Braking systems
7513-3902080 RM
Assembling of a brake gear of front wheels

Assembly of gears of a service braking system is made on the specially equipped places with applica-
tion of the special instrument, accommodations and test-beds. Places of assembling should eliminate hits of a
mud and a dust on collected parts.
The assembling parts should be washed carefully out in a diesel fuel and blown up by compressed air.
Oil channels should be cleaned and blown up by compressed air.
When assembling the case of a brake it is necessary to use a new package of general mechanical rub-
ber goods (sealing ring, cuffs).
Assembling of a brake cylinder is performed in the following sequence:
- to place a new sealing ring 19 into a groove of a rod 18 (look figure 10.6);
- to insert a rod 18 into an opening of the piston 5;
- to put a cuff 4, a cuff holder 3 on the piston and to fix with a nut 20;
- to tighten a nut with torque of 100 - 140 N.m and to stipple in three places;
- to insert the piston 5 into an opening of a cylinder body 1 and to move a restrictive bolt 2 against the
stop;
- to put guiding 17 on a rod 18;
- to combine flats of a guiding with flutes of a cylinder body 1;
- to insert blocks 6 into flutes of a cylinder body, to install rollers 7 and a separator 16;
- to put frictional ring 15 onto guiding 17 and to install on 5 - 10 mm more to the left of a butt-end of
guiding. A frictional ring 15 will occupy the final position after setting a cover 14;
- to install a spring 9, a washer 10, semi-rings 11;
- to install a spring 8, a cover 14, a plate 13 and to fix them with bolts 12;
- analogous operations are performed for the second section of the cylinder.
Replacement of cover plates of brake shoes of brake gears

If brake cover plates are worn out on the size of rivet rolling, they must be replaced both of left and right
brake gear simultaneously.
After replacement of cover plates, brake shoes are treated and installed two by two. Sizes of brake
shoes, rivets and openings in cover plates for setting with a new drum are given in figure 10.8. In case of a
brake drum boring the radius of pads should be increased accordingly.
Figure 10.8 - Sizes of brake shoes, rivets and openings in cover plates:
10-8
Braking systems
7513-3902080 RM
Assembling of a brake gear of front wheels is performed in the following sequence:

- to install blocks 9 (look figure 10.1) into openings of shoes 4 against the stop;
- to install fingers 1 of a spring into openings of shoes and to stop them with splints 2;
- to install cylinders 5 on a mounting surface of centering bushes 18 and to fix them with bolts 6 with
torque of 49 - 69 N.m;
- to install plungers 10 into a brake cylinder;
- to turn an adapter 19 in a brake cylinder casing;
- to install new shoes 4 with cover plates (or old shoes with new cover plates) onto axles 16. Before set-
ting of a shoes, mounting surfaces of axles should be greased with lubricant Litol-24;
- to install a cover plate of a shoe axle 15, washers 13 and to fix them with bolts 14 (not turning in) and
washers;
- to turn shoes on axles against the stop of a shoe block to a plunger 10 of brake cylinders;
- to install protective shrouds 7 and fix them with splints 8 and 11;
- to install springs 3;
- to torque bolts 14;
- to connect sleeves of a high pressure to connectors 19 of brake cylinders.
Before setting of shoes (if substitution of cover plates on new ones was performed) to return pistons of
brake cylinders and elements of an automatic adjustment of clearance in a home position, for what:
- to unscrew bolts 12 (look figure 10.6) to remove a plate 13, a cover 14, a spring 8, a separator 16 and
to take out rollers 7;
- to move a rod with the piston against the stop to a restrictive bolt 2;
- to displace a frictional ring 15 to the right on 5 - 10 mm from a butt-end of guiding 17;
- to install rollers 7, a separator 16, a spring 8, a cover 14, a plate 13 and to fix them with bolts 12;
- analogous operations should be done for the second section of the cylinder.
Testing of a brake gear on leakproofness and serviceability
To give pressure 16 МPа to a cavity of brake cylinders, to keep within five minutes. Escapes are not ad-
mitted. After removal of pressure the clearance between shoes and a brake drum of 0,5 - 1,5 mm should be.
The further assembling is to be done to manufacture in the following sequence:

- to install the hub of a front wheel (the order of setting of hubs of front wheels look in section "Front
axle");
- to install a front wheel on the hub (the order of setting of wheels look in section « Wheels and tires).
10.3.2 Repairing of brake gears of rear wheels

Disassembling of a brake gear of rear wheels.
Disassembling of brake gears of rear wheels is to perform in the following sequence:
- to release pressure in a hydraulic system of brakes (releasing of pressure is made by turning out of
cut-off needles of the brake valve);
- to remove rear wheels from the hub (the order of removal of wheels look in section « Wheels and
tires);
- to remove the motorized wheel from a dump truck and to make disassembling of a reducer of a motor-
ized wheel (the order of removal and disassembling look in section "Motorized wheel");
- to disconnect adapter connectors and sleeves of a high pressure from the wheel cylinder of a rear
brake 2 (look figure 10.2);
- to remove coupling springs 3 from fingers 4 and to disconnect them from brake shoes 6;
- to remove protective shrouds 9;
- to take out plungers 8 out of rods of wheel brake cylinders;
- to unlock shoes axles 18, having turned out a bolt 19;
- supporting brake shoes with a load-lifting means, to press out axles of shoes by means of
accommodation (figure 10.9);
- to remove brake shoes 6 (look figure 10.2);
- to take blocks out of openings of brake shoes;
- to unscrew bolts 1 and to take brake cylinders 2 out of opening of the case of a reducer of a motorized
wheel 17;
- to take out splints 13 and to take fingers of 4 springs out of openings of the case of a reducer of a mo-
torized wheel.
10-9
Braking systems
7513-3902080 RM
Figure 10.9 - Accommodating 75191 - 3918301 to

press out the shoes axles of a brake:
1 - the case of a reducer of a motorized wheel; 2 -
a support; 3 - a nut; 4 - a screw; 5 - the extension lead; 6
- a shoe axle
Disassembling of a brake cylinder is made in the following sequence:

- to unscrew bolts 1 (figure 10.10) and to remove a cover 4, a spring 9;
- using a mandrel (figure 10.7) to tale the semi-ring 6 out of a groove of a rod 11 (look figure 10.10) of
the piston;
- to remove a washer 5 and to take a spring 7 from a rod;
- to take guiding 12 with a frictional ring 8, a separator 10, rollers 3 and blocks 2 out from the cylinder;
- to remove a frictional ring 8 with guiding 12;
Figure 10.10 - Brake cylinder:

1 - a bolt; 2 - a block; 3 - a roller; 4 - a cover; 5 - a washer; 6 - a semi-ring; 7, 9 - springs; 8 - a frictional ring; 10 - a separator;
11 - a piston rod; 12 - guiding; 13 - a cylinder body; 14 – a piston; 15 - a sealing ring; 16 - a cuff; 17 – a cuff holder; 18 - a nut;
I - oil supply cavity; A - a size, which defines a clearance between a shoe and a drum
10-10
Braking systems
7513-3902080 RM
- to take a piston 14 as an assembly with a nut 18, a sealing ring 15, a cuff holder 17, a cuff 16 and a rod
11 out of a cylinder body 13;
- to unscrew a nut 18 to remove a cuff holder 17 and a cuff 16 from the piston 14;
- to remove the piston 14 from a rod 11;
- to remove a sealing ring 15 out of a groove of a rod 11.
Assembling of braking gear of rear wheels

The assembling parts should be washed carefully out in a diesel fuel and blown up by compressed air.
Oil channels should be cleaned and blown up by compressed air.
When assembling the case of a brake it is necessary to use a new package of general mechanical rub-
ber goods (sealing ring, cuffs).
Assembly of a brake cylinder is made in the following sequence:

- to place a new sealing ring 15 into a groove of a rod 11 (look figure 10.10);
- to insert a rod 11 into an opening of the piston 14;
- to put a cuff 16, a cuff holder 17 on the piston and to fix them with a nut 18;
- to tighten a nut 18 with a torque of 100 - 140 N.m and to stipple in three places;
- to insert the piston 14 into an opening of a cylinder body 13 and to move against the stop of a cuff
holder 17 to a bottom of the body 13;
- to put a guiding 12 on a rod 11;
- to combine flats of guiding 12 with flutes of a cylinder body 13;
- to insert blocks 2into flutes of a cylinder body 13, to install rollers 3 and a separator 10;
- to put a frictional ring 8 on guiding 12 and to install on 5 - 10 mm more to the left of a butt-end of a
guiding. The final position a frictional ring 8 will occupy after setting a cover 4;
- to install a spring 7, a washer 5, semi-rings 6;
- to install a spring 9, a cover 4 and to fix them with bolts 1.
Replacement of cover plates of brake shoes of rear brake gears

Replacement of cover plates of brake shoes of rear brake gears is performed analogously to brake
gears of front wheels. Sizes of brake shoes, rivets and openings in cover plates look in figure 10.8
Before setting of shoes (if substitution of cover plates on new ones was performed) to return pistons of
brake cylinders and elements of an automatic adjustment of clearance in a home position, for what:
- to remove a cover 4 (look figure 10.10), a spring 9, a separator 10 and to take out rollers 3;
- to move a rod with the piston against the stop to a bottom of a cylinder body;
- to displace a frictional ring 8 to the right on 5 - 10 mm from a butt-end of guiding 12;
- to install rollers 3, a separator 10, a spring 9, a cover 4 and to fix them with bolts 1.
Assembling of a brake gear of front wheels is made in the following sequence:

- to install blocks 7 (look figure 10.2) into openings of shoes 6 against the stop;
- to install fingers of 4 springs into opening of the case of a reducer of a motorized wheel 17 and to stop
with splints 13;
- to install cylinders 2 into openings of the case of a reducer of a motorized wheel 17 and to fix them with
bolts 1 with torque of 49 - 69 N.m;
- to install plungers 8 into brake cylinders 2;
- to install shoes 6, having combined openings of a shoe with openings of the case of a reducer of a mo-
torized wheel;
- to insert axles 18 and to stop with bolts 19. Before setting mounting surfaces of axles must be greased
with lubricant Litol-24;
- to turn a shoe 6 before contact with a plunger 8 of a cylinders;
- to put on a protective shroud 9 and to splint wih a wire;
- to install coupling springs 3;
- to connect adapters and sleeves of a high pressure to brake cylinders 2.
Testing of a brake gear on leakproofness and serviceability

To give pressure 16 МPа to a cavity of brake cylinders, to keep within five minutes. Escapes are not ad-
mitted. After removal of pressure the clearance between shoes and a brake drum of 0,5 - 1,5 mm should be.
10-11
Braking systems
7513-3902080 RM
The further assembling is to be done to manufacture in the following sequence:

- to install the hub of a front wheel (the order of setting of hubs of front wheels look in section "Front
axle");
- to install a front wheel on the hub (the order of setting of wheels look in section « Wheels and tires).
10.3.3 Repairing of a parking braking system

Removal and disassembling of brake gears of a parking brake are possible without removal of electro-
motorized wheel in a drive axle casing.
Disassembly of a brake gear of a parking braking system
Disassembling of a parking braking system is performed in the following sequence:

- to install thrust blocks under front and rear wheels;
- to release pressure in a hydraulic system of brakes (releasing of pressure is made by turning out cut-
off needles of the brake valve);
- to unscrew a bolt 19 (look figure 10.3) and to remove it with plates 18;
- to unsplint a nut of unbraking of a parking brake cylinder 9 and turning it clockwise to unbrake a brake
drum 15;
- to remove a brake drum 15 with a flange 17 and bolts 16. The flange and a drum are balanced;
- to unsplint an axle of a shoe 28 and to remove a support washer 29;
- to remove coupling springs 2 and 12 of brake shoes 1;
- to remove shoes from an axle28;
- to unsplint a finger 3 connecting adjusting bar 22 to a fork 4;
- to turn out nuts 8 and to remove a parking brake cylinder 9;
- to turn out bolts 26 and to remove a carriage 13 with an expansion knuckle 21, an adjusting bar 22, a
axle 28 from the end bracket of the traction motor 24;
- to remove a splint 23 of an opening of an axle of an expansion knuckle 21;
- to take an expansion knuckle 21 and an adjusting bar 22 of a cariage 13.
Disassembling of a parking brake cylinder

Disassembling of a parking brake cylinder is made in the following sequence:
- to disconnect a sleeve of a high pressure from a parking brake cylinder;
- to unscrew bolts 18 (figure 10.11) and to remove a plate 17;
- to unscrew a nut 19 counter-clockwise before its removal from the screw of disengaging 16;
- to install a parking brake cylinder into accommodating (figure 10.12) for disassembling and assem-
bling;
ATTENTION: DISASSEMBLING OF THE PARKING BRAKE CYLINDER WITHOUT ACCOMMODATING IS NOT

ADMITTED, IT IS DANGEROUS!
- to fix a parking brake cylinder with nuts 1 and to fix a cover with a power transmission screw 6;
- to turn out nuts from bolts of fastening of a clamp 22 (look figure 10.11) and to remove clamps;
- to turn out the power-transmission screw 6 (look figure 10.12) up to a full release of a spring 14 (look
figure 10.11);
- to remove a parking brake cylinder from accommodating;
- to remove a cover 15, a spring 14 and a cup 13;
- to take a protective clutch 3 out of a groove of a lock nut 1 and to remove a clutch;
- to take a plunger 9 with a lock nut 1, a rod 2, a block 4, a liner 6, a nut 20, a lock washer 21, the screw
of disengaging 16 out of the case 12 of the cylinders;
- to take a felted ring 5, sealing ring 8 and protective washer 7 out of grooves of the case 12;
- to remove a cuff 10 and a protective washer 11 out of a groove of a plunger 9;
- to turn out a block 4 and to take it out of a plunger 9;
- to take a rod 2 and the liner 6 out of a plunger 9;
- to unlock a lock washer 21 to turn out a nut 20 and to take the screw of disengaging 16 out of a
plunger 9.
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Figure 10.11 - Parking brake cylinder:

1 - a lock nut; 2 - a rod; 3 - a protective clutch; 4 - a block; 5 - a felted ring; 6 - a liner; 7, 11 - protective washers; 8 - a sealing ring;
9 - a plunger; 10 - a cuff; 12 - a cylinder body; 13 - a cup; 14 - a spring; 15 - a cover of the cylinder; 16 - a screw of disengaging; 17 - a
plate; 18 - a bolt; 19 - a nut of disengaging; 20 - a nut; 21 - a lock washer; 22 - a clamp;
I - a cavity, connected to the control valve a parking braking system
Figure 10.12 - Accommodating 7555-3918120-10 for disassembling

and assembling of a parking brake cylinder:
1 - a nut; 2, 7 - bolts; 3 - guiding; 4 - a parking brake cylinder; 5 –
an abutment; 6 - a power-transmission screw; 8 - a stay nut; 9 – a support
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Assembling of a parking brake cylinder

Assembly of a parking brake cylinder should be performed in the conditions providing protection of a
gear from hit of a dust, abrasive elements, water and a mud. There should not be burrs and a rust on parts,
and on service surfaces and contact lead-in there should not be nicks, scratches and other faults. Before as-
sembling all details must be washed out in a diesel fuel or white spirit and dried up.
At assembling of a parking brake cylinder use new rubber sealing ring, a cuff and a felted ring.
Assembling of a parking brake cylinder is made in the following sequence:

- to install a felted ring 5 (look figure 10.11), sealing ring 8 and protective rings 7 into grooves of the
case 12. To impregnate a felted ring with a hydraulic oil before setting;
- to install the screw of disengaging 16 into a plunger 9;
- to turn in a nut 20 and to stop its lock washer 21;
- to install liner 6, a rod 2 into a plunger 9 and to turn in a block 4;
- to install a cuff 10 and a protective washer 11 into a groove of a plunger 9;
- to grease service surfaces of the case 12 and a plunger with 9 lubricant Litol-24 and to insert a plunger
into the case;
- to install a cylinder body of a parking brake in accommodating (look figure 10.12) and to fix it with
nuts 1;
- to install a cup 13 (look figure 10.11), a spring 14, a cover 15 and to turn the power-transmission screw 6
(look figure 10.12) of accommodating before pressing a cover 15 (look figure 10.11) to the case 12;
- to install clamps 22 and to fix them with bolts and nuts;
- to unscrew the power-transmission screw 6 (look figure 10.12) of accommodating and to take a parking
brake cylinder out of accommodating;
- to turn in a nut 19 (look figure 10.11) of disengaging up to coincidence of its butt-end with butt-end of
the screw 16;
- to install a plate 17 and to turn bolts 18.
Testing of a parking brake cylinder

To test a parking brake cylinder for leakproofness by feeding of a hydraulic fluid under pressure (16 ±
0,5) МPа into cavity I during 3 minutes. Escapes of a hydraulic fluid are not admitted.
Displacement of a rod 2 should be 55 - 65 mm.
Final assembling of a parking brake cylinder is made in the following sequence:

- to install a protective clutch 3;
- to turn in a nut 19 of disengaging up to the moment the screw of disengaging 16 will appear on 50 - 60
mm.
Adjusting bar
For disassembling an adjusting bar (figure 10.13) with the help of a
chipper and a hammer to cut down the head of rivets to take out rivets
and to remove side covers 8 of a bar. To unscrew a bolt 4 and to remove
a lock plate 6. To take a plug 2 out of the case of a bar and, using special
mandrel and a hammer to press out a axle 3 of a worm. To take out a
worm and the worm wheel 5.
Assembling of an adjusting bar is made in sequence oppositely to

disassembling with performing following demands:
- the axle of a worm in an opening of the bar case should be turned
easily without jams;
- to fill a cavity lubricant Litol-24;
- the torque of a worm at completely collected bar should be no
more than 1,5 N.m;
- rivets of the case cover of an adjusting bar should be made of
steel 10.
Figure 10.13 - Adjusting bar:

1 - a case; 2 – a plug; 3 – an axle of a worm; 4 - a bolt; 5 - the worm wheel; 6 - a
lock plate; 7 – an oiler; 8 - a cover
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Replacement of cover plates of a brake gear of a parking braking system
If brake cover plates are worn out on the size of rivet rolling, they must be replaced both of left and right
brake gear simultaneously.
After replacement of cover plates, brake shoes are treated and installed two by two. Sizes of brake
shoes, rivets and openings in cover plates for setting with a new drum are given in figure 10.14. In case of a
brake drum boring the radius of pads should be increased accordingly.
Figure 10.14 - Sizes of brake shoes, rivets and openings in cover plates
Assembling, adjustment and testing of a brake gear of a parking braking system

Assembling of a brake gear of a parking braking system is performed in the following sequence:
- to install an adjusting bar 22 (look figure 10.3) and an expansion knuckle 21 in a carriage 13. Before
setting to grooves of an axle of an expansion knuckle with a lubricant Litol-24;
- to install a splint 23 into an opening of an expansion knuckle 21;
- to install a carriage 13 as an assembly with an axle 28, an expansion knuckle 21, an adjusting bar 22,
on the end bracket of the traction motor 24 and to fix them with bolts 26;
- to install brake shoes 1 on a axle 28;
- to install coupling springs 2 and 12;
- to install a flange 17 with a reel 15 and bolts 16 on castle-type end of an armature axle of the traction
motor 20. The flange and a drum are treated and balanced;
- to install plates 18, to turn in a bolt 19;
- to install the cylinder 9 on a bracket of a rear axle casing to fix it with nuts 8;
- to screw the extension lead 6 on a cylinder rod, preliminary having installed a washer 7;
- to turn a fork 4 on a thread of the extension lead;
- to connect a fork 4 and to an adjusting bar 22 with a finger 3 and to splint a finger with a splint 10;
- to connect a sleeve of a high pressure to a parking brake cylinder.
Clearance adjustment between shoes and a drum is made in the following sequence:
- to unlock a axle of a worm 3 (look figure 10.13) of an adjusting bar;
- to turn out a bolt 4 on one revolution and to displace a lock plate 6;
- turning an axle of a worm 3 clockwise to part shoes up to contact with a drum, then to turn an axle of a
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worm counter-clockwise on half - two thirds of revolution;

- to stop an axle of a worm with a lock plate 6 and a bolt 4;
- to turn out a nut 19 (figure 10.11) of disengaging counter-clockwise up to contact of its butt-end with
butt-end of the screw of disengaging 16 and to splint it.
10.3.4 Repairing of gears of the hydraulic actuator of braking systems

The parts fed on assembling, should be washed carefully out in a diesel fuel and blown out by com-
pressed air. To wipe details a rags before assembling is not recommended in order to prevent blockage of
ports. Oil channels should be cleaned and blown out by compressed air.
At assembling to use a new package of rubber sealing ring.
BEFORE REMOVAL AND DISASSEMBLNG OF GEARS OF THE HYDRAULIC ACTUATOR TO RELEASE

PRESSURE IN A HYDRAULIC SYSTEM OF BRAKES (RELEASING OF PRESSURE IS MADE BY TURNING OUT OF
LOCK NEEDLES OF THE BRAKE VALVE).
10.3.4.1 The brake valve

At disassembling of the brake valve it is not admitted to disassemble a valve cores and bush sleeve.
Valve cores and bush sleeves are picked up by pairs with a clearance of 0,01 - 0,03 mm.
Removal and disassembling of the brake valve is made in the following sequence:
- to disconnect lubricated hoses and an electricity cable of the switch of a stop light;
- to turn out nuts of bolts of fastening of the brake valve to the panel of a floor of a cabin;
- to remove the brake valve;
- to unscrew bolts 21 (figure 10.15);
- to remove a cover of 22 valve case as an assembly with a treadle 1, a roller 2, a spring 3, holders 4
and 25, case 23 and a pusher 24;
- to take balancing element 20 and a plate 5 out of the upper case 6;
- to turn out a plug 19 of the upper case 6;
- to take a rod 18 out of the upper case 6;
- to unscrew bolts 17 , to disconnect upper 6 and the lower 11 cases of the brake valve;
- to take a valve core 8 and a bush sleeve 7 out of the upper case 6;
- to take a pusher 10, a spring 16 out of the lower case 11;
- to turn out a plug 13 of the lower case 11;
- to take a piston 12 and a spring 14 out of a plug 13;
- to take a valve core 8 and a bush sleeve 15 out of the lower case 11.
Assembling and testing of the brake valve

Assembling of the brake valve is performed in the following sequence:
- to install a bush sleeve 15 with a sealing rings in the lower case 11;
- to install a valve core 8 into a bush sleeve 15 (the bush sleeve and a valve core are selected with a
clearance of 0,01 - 0,03 mm and are installed in complete);
- to install a bush sleeve 7 with sealing rings in the upper case 6;
- to install a valve core 8 into a bush sleeve 7;
- to install a spring 16 and a pusher 10 into a bush sleeve 15 of a lower case 11;
- to connect the upper cease to lower case and to screw in bolts 17;
- to insert a spring 14 and a piston12 into a plug 13;
- to turn a fuse 13 with a rubber seal into the lower case 11;
- to insert a rod 18 with a rubber seal into a fuse 19;
- to turn a fuse 19 with a rubber seal in the upper case 6;
- to install a plate 5 and balancing element 20 into the upper case;
- to connect a cover 22 of a valve case to the upper case 6 and to screw in bolts 21;
- to receive a dense adjacency of a roller 2 to a pusher 24 with a help of a holder, conveyance not trig-
gering it.
Before setting of the brake valve on a dump truck to turn lock needles 9 against the stop and to test it for
leakproofness.
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Figure 10.15 - Brake valve:

1 - a treadle; 2 - a roller; 3, 14, 16 - springs; 4, 25 - holders; 5 - a plate; 6 - an upper case; 7,15 - bush sleeves; 8 - a valve core;
9 – a lock needle; 10 - a pusher; 11 - a lower case; 12 – a piston; 13 - a plug; 17 - bolts; 18 - a rod; 20 – a balancing element; 22 - a cover
of the valve case; 23 - a case; 24 - a pusher;
I, II - the outputs which are connected to drain into a hydraulic tank; III, V - cavities, connected to outputs to pneumohydraulic ac-
cumulators; IV, VI - cavities, connected to outputs to wheel brake cylinders
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Testing of the brake valve on leakproofness

To supply a hydraulic fluid under pressure 12 МPа into a cavity III and V. External escapes are not ad-
mitted. Total escapes from outputs I and II should be no more than 0,05 l/m. By smooth pressure a treadle
pressure in cavities IV and VI should vary smoothly from 0 up to 12 МPа.
Setting of the brake valve is made in the following sequence:
- to install the brake valve into an opening of the panel of a floor of a cabin;
- to fix the brake valve with three bolts;
- to connect cavities I and II of a brake valve with drain to a tank, cavities III and V to pneumohydraulic
accumulators, a cavity IV to brakes gears of a front axle, a cavity VI to brake gears of a rear axle;
- to connect an electricity cable of a stop light switch.
10.3.4.2 The double protective valve

Removal and disassembling of the double protective valve is performed in the following sequence:
- to disconnect oil hoses from the double protective valve;
- to turn out nuts of bolts of the double protective valve fastening to a bracket of a frame and to
remove it;
- to turn out plugs 1 (figure 10.16) with sealing rings 6;
- to take pushers 2 with springs 11, distance bushes 10, washers 9, beads 4 out of the case 3;
- to take out a piston 5 with a sealing rings 8;
- to turn plugs 7 out of the case 3.
Assembling of the double protective valve is performed in the following sequence:
- to insert a piston 5 with sealing rings 8 into the case 3;
- to insert beads 4, washers 9, distance bushes 10 into the case 3;
- to put springs 11 onto pushers 2 and to insert pushers with springs into openings of a plugs 1;
- to turn plugs 1 with sealing rings 6, pushers 5 and springs 11 into the case 3 against the stop;
- to turn plugs 7 into the case 3.
Testing of the double protective valve

At pressure in channels II and IV (12 ± 1) МPа escapes into channels I and IV are not admitted. External
escapes are not admitted.
Setting of the double protective valve is performed in the following sequence:
- To install the double protective valve onto a bracket of a frame and to fix it with bolts;
- To connect a channel I to an automatic machine of unload of the pump, channels II, IV to pneumohy-
draulic accumulators, the port III to the control valve of a parking braking system.
Figure 10.16 - The Double protective valve:

1, 7 - fuses; 2 - a pusher; 3 - a case; 4 - a
bead; 5 - a piston; 6, 8 – sealing rings; 9 - a washer;
10 - a distance bush; 11 - a spring;
I - a channel, connected to a pressure hy-
droline; II and IV - channels, connected to pneumohy-
draulic accumulators; III – a channel, connected to the
control valve of a parking brake
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10.3.4.3 The relay of pressure

Removal and disassembling of the relay of pressure is performed in the following sequence:
- to disconnect a connective shoe of an electric wire of the relay of pressure;
- to disconnect oil hoses from the relay of pressure;
- to unscrew bolts of fastening of the relay of pressure to a bracket of a frame and to remove it;
- to unscrew screws 5 (figure 10.17) and to remove a cover 2 with a lining 6;
- to turn out nuts 3 and to remove microswitches 4 from a bracket 1;
- to turn out screws 15 and to remove cups 8 with adjusting screws 9 which are inside, springs 10,
washers 11, rods 12, diaphragms 13 and plugs 14;
- to turn plugs 14 out of cups 8;
- to take diaphragms 13 out of a plugs 14 and rods 12 out of a cups 8;
- to turn adjusting screws 9 out of cups 8 and to take out springs 10 and washers 11.
Assembling of the relay of pressure is made in the following sequence:

- to install rods 12, diaphragms 13 into cups 8 and turn in plugs 14;
- to install washers 11, springs 10 into cups 8 and turn adjusting screws 9 on 15 - 18 revolutions. The
position of an adjusting screw 9 concerning a cup 8 defines a pressing force of a spring 10 and an operating
pressure of a pressure relay accordingly;
- to install cups 8 into the case 7 and fix with screws 15;
- to install microswitches 4 on brackets 1 and fix them with nuts 3.
Testing and adjustment of the relay of regulator.

Testing and adjustment is made before setting a cover 2.
Microswitches should operate at pressure in channels I and II 13,0 - 13,5 МPа. Adjustment is carried out
by adjusting screws 9. Escapes of a hydraulic fluid are not admitted.
After adjustment to install a cover 2 with a lining 6 and to fix with screws 5.
Setting of pressure relay is performed in the following sequence:

- to install the relay of pressure onto a bracket of a frame and to fix it with bolts;
- to connect channel I of the pressure relay to a pneumohydraulic accumulator of rear brakes circuit, the
channel II to a pneumohydraulic accumulator of a parking brake circuit;
- to connect a carrier socket of an electric wire.
Figure 10.17 - Relay of pressure:

1 - a bracket; 2 - a cover; 3 - a nut; 4 - the microswitch; 5, 15
- screws; 6 – a lining; 7 - a case; 8 - a cup; 9 - an adjusting screw; 10
- a spring; 11 - a washer; 12 - a rod; 13 - a diaphragm; 14 - a plug;
I - a channel, connected to a pneumohydraulic accumulator
of rear brakes circuit; II - a channel, connected to a pneumohydraulic
accumulator of a parking brakecircuit
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10.3.4.4 A pneumohydraulic accumulator

Safety precautions at removal, repairing and setting of pneumohydraulic accumulators
At disassembling and assembling of pneumohydraulic accumulators to be careful, as gas in them is un-
der a high pressure. Persons engaged in repairing and a service jobs of pneumohydraulic accumulators,
should be acquainted with safety precautions and regulations of pressurized vessels.
At removal of pneumohydraulic accumulators and their repairing observe the following rules:
- before removal of pneumohydraulic accumulators from a dump truck to release gas from a gas cavity
through the charge valve. For realising of gas to remove a cap from the charge valve and to turn the special
connecting pipe on the valve before opening the valve. After releasing of gas the connecting pipe is to be turn
out a little bit that the charge valve to be closed, and then the connecting pipe is to be turned again in three
minutes. Operation on opening and close of the charge valve with an interval in three minutes to do not less
than three times as dissolved nitrogen in oil evaporates quickly, and right after turning out the connecting pipe
a pressure is recreated in a pneumohydraulic accumulator;
- starting disassembling of a pneumohydraulic accumulator to be sure there is no pressure of gas;
- before association of a reducer to a new bulb to be sure of the identification mark of the compressed
gas corresponding to nitrogen;
ATTENTION: IT IS FORBIDDEN TO CHARGE PNEUMOHYDRAULIC ACCUMULATORS WITH OXYGEN! IT IS

EXPLOSIVE!
- to install a bulb with gas in the special place arranged with accommodating for fixing of a bulb. When
change a bulb to fix it;
- to unscrew valves and connecting nuts only by the corresponding wrenches, not hitting on them;
- to supply gas to pneumohydraulic accumulators smoothly through reducing reducer;
- to observe common safety precautions regulations on a work place.
Removal and disassembling of a pneumohydraulic accumulator

Before removal of a pneumohydraulic accumulator to release nitrogen through the charge valve of a
pneumohydraulic accumulator, observing rules described above.
Removal of a pneumohydraulic accumulator is per-
formed in the following sequence:
- to disconnect an electricity cable from the pressure
control device;
- to disconnect a oil hose;
- to turn out the extension lead 16 (figure 10.18) with
the priming valve 15;
- to turn the ring- bolt 1 (figure 10.19) into an opening of
the upper cover of a pneumohydraulic accumulator;
- to fasten a pneumohydraulic accumulator with the
help pull accommodating and the hoisting device;
- to turn out nuts on clamps of fastening of a pneumohy-
draulic accumulator and to remove a pneumohydraulic accumu-
lator.
Figure 10.18 - Pneumohydraulic accumulator:

1 - a lower cover; 2 - a thrust; 3 - a restrictive ring; 4, 17 - bolts; 5 - a
spring; 6 - a pressing ring; 7 - a piston cuff; 8 - a ring - guiding, 9 - a piston;
10 - a case; 11, 18 – sealing rings; 12 - a protective washer; 13 - an upper
cover; 14 - a lining; 15 - a priming valve; 16 - an extension lead; 19 - adjust-
ing shims; 20 - a clamping disk;
I - an output of connection of the pressure sensor; II - a gas cavity;
III - a oil cavity
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Figure 10.19 - Scheme of fastening for removal and setting of

a pneumohydraulic accumulator:
1 - a ring- bolt; 2 - a pneumohydraulic accumulator
Disassembling of a pneumohydraulic accumulator is performed in the following sequence:

- to turn out bolts 17 (look figure 10.18) of fastening of the upper cover 13;
- to remove a thrust 2;
- to take out a restrictive ring 3 of a groove of the case 10;
- to take the upper cover 13 with sealing rings11 and protective washers 12 out of the case 9;
- to unscrew bolts of 17 fastening of the lower cover 1;
- to remove a thrust 2;
- to take a restrictive ring 3 out of a groove of the case 10;
- to take the lower cover 1 with sealing rings11 and protective washers 12 out of the case 10;
- to unscrew bolts 4 up to releasing of lock washers;
- to take a piston 9 in assembly with bolts 4, a spring 5, a pressing ring 6, a cuff 7, guiding 8, sealing
rings 18, adjusting shims 19 and a clamping disk 20 out of the case 10;
- to take rings - guiding 8 out of grooves of a piston 9;
- to turn bolts 4 out of the piston 9;
- to remove a clamping disk 20, a spring 5, adjusting shims 19, a pressing ring 6, a piston cuff 7 with
sealing rings18.
Assembling and testing of pneumodraulic accumulator

Assembling of a pneumodraulic accumulator should be performed in the conditions providing protec-
tion of a components from a dust, abrasive elements, oil, water and a mud. There should not be burres and a
rust on parts, and there should not be scratches and other faults on service surfaces. Before assembling clean
all channels of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or
white spirit and dry them up.
When assembling a pneumodraulic accumulator use a new package of general mechanical rubber
goods and ring -guiding.
Assembling of pneumohydraulic accumulators is made with observance of the following rules:

- when assembling to grease all friction surfaces of parts with a working fluid;
- to wash rubber sealing rings of round cross-section, a cuff, protective washers in a hydraulic fluid be-
fore setting in a pneumohydraulic accumulator;
- when mounting rubber sealing rings keep up that rings are not twisted in grooves and not be undercut.
Assembling of a pneumohydraulic accumulator is performed in the following sequence:

- to install a cuff 7 with sealing rings 18, a pressing ring 6, adjusting shims 19, a spring 5, a clamping
disk 20 onto the piston 9 (look figure 10.18) and to screw in bolts 4 against the stop. Diameter of a cuff 7 on
deflected edges should be 167, 0 - 167,3 mm to provide a necessary tightness between the case and a cuff.
After selection of a necessary amount of adjusting shims 19 (width of 0,5 and 0,15 mm) to unscrew bolts
4 up to releasing retaining washers to insert rings - guiding 8 into grooves of the piston 9 and to insert the pis-
ton 9 in assembly with bolts 4, a spring 5, a pressing ring 6, a cuff 7, guiding 8, sealing rings 18, adjusting
shims 19 and a clamping disk 20 into the case 10;
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- to turn bolts 4 against the stop;

- to install the lower cover 1 with sealing rings 11 and protective washers 12;
- to insert a restrictive ring 3 into a groove of the case 10;
- to install a thrust 2 and to turn bolts 17 of fastening of the lower cover 1;
- to install the upper cover 13 with sealing rings 11 and protective washers 12;
- to insert a restrictive ring 3 into a groove of the case 10;
- to install a thrust 2 and to turn bolts 17 of fastening of the upper cover 13;
- through an opening of the priming valve to fill 0,5-1 l of working fluid into a gas cavity of a pneumohy-
draulic accumulator ;
- to turn the extension lead 16 with the priming valve 15 and linings 14 into the upper cover 13.
Testing of a pneumohydraulic accumulator

To test a pneumohydraulic accumulator for leakproofness by supplying of nitrogen under pressure
(6 ± 0,5) МPа into a gas cavity of a pneumohydraulic accumulator and oil under pressure (12 ± 1) МPа into an
oil cavity of a pneumohydraulic accumulator. Escapes are not admitted.
Setting of a pneumohydraulic accumulator is performed in the following sequence:

- to fasten a pneumohydraulic accumulator with the help pull accommodating and the hoisting device;
- to install a pneumohydraulic accumulator on a bracket of a frame and to fix with clamps and nuts;
- to connect an electricity cable to the pressure sensor;
- to charge a gas cavity of a pneumohydraulic accumulator with nitrogen.
Charging of pneumohydraulic accumulators with nitrogen

Inspection of pressure of nitrogen in pneumohydraulic accumulators and their charging is made at the
lower position of the piston, i.e. at absence of pressure in the fluid-flow chamber. For this purpose to turn out a
cover of the priming valve and to connect accommodating for pressure measurement (look figure 8.7) through
an adapter connector and to open the valve smoothly. Pressure of nitrogen should be 7,5 - 8,0 МPа.
If necessary to refuel pneumohydraulic accumulator with nitrogen in the following sequence:

- to connect reducing reducer 4 (look figure 8.21) of an accommodating for charge to a bulb with nitro-
gen through an adapter connector 2;
- to screw an adapter connector 17 of accommodating on the priming valve of a pneumohydraulic accu-
mulator;
- to open a valve on a bulb with nitrogen and, turning an adjusting screw of a reducer of accommodating
for charge of suspension cylinders to charge the gas chamber with pressure of 6,0 - 6,5 МPа. To check a
pressure with the help of manometer on accommodating;
- to close a valve on a bulb with nitrogen and the connecting pipe 8 to release gas from channels and a
hose of accommodating;
- to disconnect accommodating from the priming valve;
- to check leakproofness of the priming valve with the help of a soap emulsion;
- to close the priming valve by a cover.
10.3.4.5 The filter of a hydraulic drive of a service braking system
Disassembling of the filter is made in the following sequence:
- to turn out a cover 6 (figure 10.20) and to take a sealing ring 5 out of a groove of a cover;
- to turn out a rod 4 and to take it from the case 1 in assembly with filter elements 3;
- to turn out a nut 2 and to remove filter elements 3 from a rod 4.
Assembling of the filter is made in the following sequence:

- before assembling to wash out details of the filter in a diesel fuel. To blow up all channels and surfaces
of parts of the filter by compressed air;
- to install filter elements 3 onto a rod 4 and to turn in a nut 2;
- to turn a rod 4 in assembly with filter elements into an opening of the case 1;
- to place sealing ring into a circular slot of a cover 6;
- to turn a cover 6 into the case 1.
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Figure 10.20 – A filter:

1 - a case; 2 - a nut; 3 - a filter ele-
ment; 4 - a rod; 5 - a sealing ring; 6 - a cover
10.3.4.6 The control valve a parking braking system

Disassembling of the control valve of a parking braking system
Removal and disassembling of the control valve of a parking braking system is performed in the follow-
ing sequence:
- to disconnect oil hoses and an electricity cable of the switch of a stop light from the control valve;
- to unscrew bolts of fastening of the control valve to a bracket of the panel of a floor of a cabin;
- to remove the control valve from a dump truck;
- to unscrew bolts 10 (figure 10.21) and to remove a cover 14 of a valve in assembly with a pusher 15,
an axle 2, a holder 16, a bar 17, a protective case 18, a cam 20 and a nut 19 from a cup 21;
- to remove a protective case 18 from a cover 14;
- to turn out a nut 19 and to turn out a bar 17 with a holder 16;
- to take out an axle 2 and to remove a cam 20 and a pusher 15;
- to take adjusting washers 13, a spring 12 and a plate 11 of spring out of a cup 21;
- to turn out a fuse 24 with a sealing ring 9 and a pusher 8 of a glass 21;
- to take a pusher 8 with a sealing ring 22 out of a plug 24;
- to unscrew bolts 10 and to take a cup 21 out of the case 4;
- to turn a plug 3 with a spring 28, the piston 27 and a sealing ring 4 out of the case 1;
- to take a bush sleeve 7 with a valve core 6 and sealing rings 4, 5, 25, 26 out of the case 1;
- to take a valve core 6 out of a bush sleeve 7.
Assembling and testing of the control valve a parking braking system

The parts fed on assembling, should be washed out in a diesel fuel and blown up by compressed air. It is
not recommended to wipe parts by rags before assembling in order to prevent blockage of ports and jam of a
valve core. Oil channels should be cleaned and blown up by compressed air.
When assembling the control valve use a new package of rubber sealing rings.
Assembling of the control valve by a parking braking system is performed in the following sequence:
- to place sealing rings 4, 5, 25, 26 into grooves of a barrel 7;
- to insert a bush sleeve 7 with a valve core 6 into the case 1;
- to turn a plug 3 with a sealing ring 4, a spring 28 and a piston 27 into the case 1;
- to place a sealing ring 23 into a groove of a cup 21;
- to insert a cup 21 into the case 1 and to fix it with bolts 10;
- to insert a pusher 8 with a sealing ring 22 into an opening of a plug 24;
- to turn a plug 24 with a sealing ring 9 and a pusher 8 into a cup 21;
- to install a pusher 15 into an opening of a cover 14 of a valve;
- to install a cam 20 into an opening of a cover 14 and to fix by an axle 2;
10-23
Braking systems
7513-3902080 RM
Figure 10.21 - Control valve of a hydraulic parking braking system:

1 - a case; 2 – an axle; 3, 24 - plugs; 4, 5, 9, 22, 23, 25, 26 - sealing rings; 6 - a valve core; 7 - a bush sleeve; 8, 15 pushers; 10 - a
bolt; 11 - a plate of a spring; 12, 28 - springs; 13 - adjusting washer; 14 - a cover of the valve; 16 - a holder; 17 - a bar; 18 - a protective
case; 19 - a nut; 20 - a cam; 21 - a cup; 27 - a piston;
I - an output, connected to a pneumohydraulic accumulator; II - an output, connected to brake cylinders; III - an output, connected
to a drain into a hydraulic tank.
A - the position "switched off" of a bar; B - the position " switched on" of a bar
- to turn a bar 17 with a holder 16 and a nut 19 into an opening of a cam 20 so that a holder 16 has come
into axle openings 2 and openings of a pusher 15. Thus size D should be 6 - 7 mm;
- to fix a bar 17 with a nut 19;
- to put a protective case 18 on a cover 14 of a valve and to fix by a splint - wire;
- to insert a plate 11, a spring 12 and adjusting washers 14 into a cup 21;
- to insert a cover 14 in assembly with a pusher 15, a shaft 2, a cam 20, a nut 19, a holder 16, a bar 17
and a protective case 18 into a cup 21 and to fix with bolts 10.
Size C should be 0 - 0,3 mm. It is provided with selection of adjusting washers 13.
10-24
Braking systems
7513-3902080 RM
Testing of the control valve a parking braking system
If a bar 17 is in A and B positions at pressure of a hydraulic fluid in output I (12 ± 0,5) МPа escapes
through an output III should not exceed 0, 05 l within 1 minute. At displacement of a bar 17 from B position to A
position and back, pressure in a cavity II should rise up to (12 ± 0,5) МPа and lower up to 0 МPа.
Setting of the control valve of a parking braking system is performed in the following sequence:
- to install the control valve on a bracket of the panel of a floor of a cabin and to fix it with bolts;
- to connect oil hoses to the control valve: to connect output I of the control valve to a pneumohydraulic
accumulator, an output II - to a parking brake cylinder, an output III - to drain into an oil-tank;
- to connect an electricity cable of the a stop light switch.
10.3.5 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-7514-
10, BELAZ-75145
After disassembling to check technical conditions of service surfaces of parts by an external examination
and metering of their critical parameters. There should not be corrosion, burrs and other mechanical injuries on
service surfaces of parts.
The basic nominal and maximum permissible sizes of parts of braking systems of dump trucks BELAZ-
7514-10, BELAZ-75145 are given in table 10.2.
Table 10.2 - Nominal and maximum permissible sizes of basic parts of braking systems of dump
trucks BELAZ-7514-10, BELAZ-75145
Dimensions, мм
Number, name of part and parame-
Maximum permis- Material Hardness
ters to be checked Nominal
sible
549А – 3501055 −0,05
Piston
120 119,80 АК6Т1
− 0,14
External diameter
549 – 3501049
+0,06
Frictional ring 73,7 73,80 Steel 45
Internal diameter
549А – 3501056 241 – 285 НВ
−0,075
Piston rod 48 47,800 Steel 45 ТВЧ h 1,5 – 3,0mm
− 0,160 НRС>50
External diameter
549А – 3501046-10
549А – 3502046-10
СЧ20
Cylinder case +0,07
120 120,10
Internal diameter
549А – 3501070
+0,35
Brake drum 950 955,00 Steel 40Л
Internal diameter
549А – 3501090 −1,10 Frictional layer may Asbestos code
Brake shoe
950 be worn out to rivet composition
−1,65 heads 207-17
External diameter
7512 – 3514025 Clearance in cou-
+0,027 pling with valve core
Bush sleeve 12 7512–3514026
Steel 40Х 40 – 46 НRCэ
Internal diameter 0,01 – 0,03 no more
10-25
Braking systems
7513-3902080 RM

Dimensions, мм
Number, name of part and parame-
ters to be checked Nominal
sible
pling with bush
Valve core Carbonization
sleeve 7512–
Diameter of corbels 12,00 3514025
Steel 40Х h 0,7 – 0,9 mm
57 – 63 НRCэ
0,01 – 0,03
no morxe
7512 – 3514045
+0, 43
Plug 12 12,05 Steel 40Х 34 – 40 НRCэ
Internal diameter
7512 – 3514060-10
−0,016
Rod 12 11,90 Steel 40Х 45 – 50 НRCэ
− 0,059
External diameter
7513 – 3545016 +0,10
Case
165 165,10
ТВЧ h 1,5 – 3,0mm
Internal diameter Steel 45
There must not be 50 – 60 НRCэ
damages on sur-
faces
7545 – 3919324
+0,03
Cylinder case of parking brake 60 60,05 СЧ 20
Internal diameter
7545 – 3519338-10
Ram
59,90
−0,03
External diameter 60 There must not be
Steel 45 241 – 285 НВ
− 0,06
damages of chrome
coating
7555 – 3507015 Shoes steel
Shoes of parking brake Frictional layer may 40Л
420 be worn out to rivet cover plares
External diameter − 0,04 heads Ретинакс ФК–
24А
549А – 3507050 +0,15
drum of parking brake
420 420,5 Steel 40Л
Internal diameter
10.4 Repairing of braking systems of dump trucks BELAZ-75131, BELAZ-75132

Before repairing take measures, eliminating spontaneous driving of a dump truck from a place.
10.4.1 Repairing of brake gears of front wheels

Disassembling of brake gears of front wheels
Disassembling of brake gears of front wheels is performed in the following sequence:
- to release a pressure in a hydraulic system of brakes (releasing of pressure is made by turning out lock
needles of the brake valve);
tires);
- to remove two cases of a brake 31 (look figure 8.2.2). The order of removal of cases of a brake look in
section "Front axle");
- to remove brake cover plates 36;
- to remove the hub of a front wheel 13;
- to unscrew bolts 24 and to remove a brake disk 8 from the hub 13.
10-26
Braking systems
7513-3902080 RM
Disassembling of a brake case is performed in the following sequence:

- to unscrew bolts 8 (look figure 10.4) of fastening of a cover 7 and to remove a cover;
- to take a sealing ring 9 out of a groove of a cover;
- to take a protective clutch 3 out of a groove of the piston 6;
- to take the piston 6 out of the case of a brake 2;
- to take a protective ring 14, a cuff 15 and a protective clutch 3 out of the case of a brake;
- to make disassembling of other five cylinders of the case of a brake analogously.
Assembling of brake gears of front wheels
The details supplied on assembling, should be washed carefully out in a diesel fuel and blown up by
compressed air. Oil channels should be cleaned and blown through by compressed air.
When assembling a brake case use a new package of general mechanical rubber goods (sealing
rings, cuffs, protective clutches)
Assembling of the case of a brake is performed in the following sequence:

- to grease the piston 6 and a cuff with 15 working fluid;
- to install a cuff 15 and a protective ring 14 into a groove of the case of a brake 2;
- to install a protective clutch 3 into a groove of the case of a brake;
- to insert the piston 6 into an opening of the case of a brake, using guiding mandrel;
- to install a protective clutch 3 into a groove of the piston;
- to install a sealing ring 9 into a groove of;
- to install a cover 7 and fix to the case of a brake 2 with bolts 8;
- to perform assembling of other five cylinders of the case of a brake analogously;
- to move all six pistons of a brake gear to a home position against the stop to covers.
Testing of the case of a brake

Before setting of the case of a brake to test it on leakproofness. When testing the case of a brake to limit
displacement of pistons up to 20 mm with the help of a special liner 1 (figure 10.22). A working fluid is supplied
under pressure 15 МPа during five minutes into openings 3 and 4 (all other openings should be plugged). Es-
capes of a working fluid are not admitted, including in the inner space of a protective clutch. After testing of the
brake case to return pistons in a home position.
Figure 10.22 – Scheme of brake case testing:

1 – liner; 2 – brake gear; 3, 4 – openings of intake of working fluid
The further assembling of brake gears of front wheels is performed in the following sequence:
- to install a brake disk 8 (look figure 8.2.2) onto the hub of a front wheel and to fix it with bolts 24 and
washers;
- to install the hub of a front wheel in assembly with a brake disk on a steering knuckle 7 (the order of
setting look in section "Front axle");
- with the help of load-lifting means to install cases of a brake 2 (look figure 10.4) on a steering knuckle,
having fixed them with a lower bolt, not tightening a bolt against the stop on two - three revolutions, having en-
closed a washer under a bolt head;
- to turn the case of a brake hold on lower bolt smoothly in a horizontal position and to install brake
cover plates 5. If brake cover plates are worn out to replace them in brake gears of the left and right wheels
simultaneously;
- to fix the case of a brake 2 to a steering knuckle 1 with bolts 13 with torque of 1500 - 1800 N.m. With
adjusting washers 12 to provide a clearance of 1,5 mm min between butt-ends of brake cover plates 5 and a
brake disk 4;
10-27
Braking systems
7513-3902080 RM
- to connect pipe lines of a braking system to cases of brakes;

- to install a front wheel onto the hub (the order of setting look in section « Wheels and tires).
Replacement brake cover plates without disassembling of brake gears of front wheels
When brake cover plates are worn out to replace cover plates of brake gears of left and right wheels si-
multaneously.
Replacement of cover plates of brake shoes is performed in the following sequence:
- to install thrust blocks under wheels of a dump truck;
tires);
- to release a pressure in a hydraulic system of brakes (releasing of pressure is made by turning out of
lock needles of the brake valve);
- to disconnect pipes of a braking system from cases of a brake 2 (look figure 10.4);
- to release the lower bolt 13 of fastening of the brake case to a steering knuckle 1 up to releasing of a
spring lock washer;
- supporting the case a brake to unscrew the upper bolt;
- to turn the case of a brake hold on lower bolt smoothly in a horizontal position and to remove brake
cover plates;
- to return pistons of the case of a brake in a home position, having moved pistons against the stop of
butt-ends to covers 7;
- to install new cover plates;
- to tighten bolts 13 with torque of 1500 - 1800 N.m. With adjusting washers 12 to provide a clearance
of 1,5 mm min between butt-ends of brake cover plates 5 and a brake disk 4;
- to connect pipes of a braking system to cases of brakes.
10.4.2 Repairing of brake gears of rear wheels and a parking braking system
Removal and disassembling of brake gears of rear wheels and brake gears of a parking brake is rec-
ommended to perform with removal of electric motorized wheels. Fractional disassembling, and in unusual
cases full disassembling are possible without removal of electric motorized wheels in an axle casing.
Disassembling of brake gears of rear wheels and parking braking system.
Removal of a brake gear of rear wheels and brake gear of a parking brake in assembly with a electric
motorized wheel from a dump truck is made in the following sequence:
- to release pressure in a hydraulic system of brakes (releasing of pressure is made by turning out of
lock needles of the brake valve);
- to remove rear wheels from the hub (the order of removal of wheels look in section « Wheels and
tires);
- to remove a motorized wheel from a dump truck and to make disassembling of a reducer of a motor -
wheel (the order of removal and disassembling look in section "Electric motorized wheel").
Disassembling of a brake gear of rear wheels and brake gear of a parking brake is made in the following
sequence:
- to remove all sleeves of a high pressure 1 (figure 10.5);
- to unlock nuts 7 and to turn them out of studs 8;
- to remove external cheeks 3 of service brakes with cylinders 11 of service brakes, brake cover plates
27, supports 9, bolts 54, springs 55 from studs 8.
Before removal of an external cheek 50 of parking brakes to unlock and to turn a nut 44 before disen-
gaging brake cover plates 27;
- to remove external cheeks 50 of parking brakes with cylinders 5 of parking brakes, a brake cover
plates 27, supports 9, bolts 54, springs 55 from studs 8;
- to remove supports 20 and inserts 19 from studs 8;
- to turn out studs 8;
- to unscrew a bolt 14 and to remove plates 15;
- to remove a brake disk with a flange 16 from the shaft of the traction motor (the disk with a flange is
treated and balanced jointly and disassembling is not admitted);
- to unscrew bolts 10 and to remove an internal cheek of a parking brake 52 with a brake cover plate 27,
thrust blocks 33, nuts 34, supports 9 and adjusting shims 53;
- to unscrew bolts 4 and to remove internal cheeks 17 of service brakes with brake cylinders 11, brake
10-28
Braking systems
7513-3902080 RM
cover plates 27, supports 9 and brackets 22 and 23;
Disassembling of external and internal cheeks of a service brake.

- to unlock and to turn out supports 9 and bolts 54 to remove springs 55 and a brake cover plates 27;
- to unscrew bolts 25 and to remove cylinders 11 of service brakes, protective clutches 26, sealing
rings 24;
Disassembling of the cylinder of a service brake.
- to turn out a nut 32 and to take out from the case 31 piston 29 with a rod 30, a retaining ring 56, a stop
ring 57, adjusting washers 58, a sealing ring 59, the frictional bush 60, a cup 61, a spring 64;
- to take a sealing ring 63 and a protective washer 62 out of a groove of the case;
Disassembling of the piston of the cylinder of a service brake.

- to press a stop ring 57 and to remove a retaining ring 56;
- to take a stop ring 57, a spring 64, a cup 61, a rod 30 with the frictional bush 60 and a sealing ring 5
out of the piston 29;
- to remove a frictional bush 60 and a sealing ring 59 from a rod 30;
Disassembling of an internal cheek of a parking brake.

- to unlock nuts 34 and to turn out thrust blocks 33 with nuts 34;
- to unlock supports 9, bolts 54 and to turn them out, to remove a brake cover plates 27 and springs 55;
Disassembling of an external cheek of a parking brake.

- to unlock supports 9, bolts 54 and to turn them out, to remove a brake cover plates 27 and springs 55;
- to unscrew bolts of fastening of cylinders 5 of parking brake;
- to remove cylinders 5 of parking brake and protective clutches 51;
Disassembling of a parking brake cylinder.

- to turn in a nut 44 of disengaging against the stop;
- to unlock a nut 41 and to turn out the locking bolt 40 with a nut 41;
- to turn a cover 46 in assembly with the piston 48, indicators 42, a nut 44, a washer 45 and a splint 43
out of the case 49;
- to take sealing rings 36, 38 and protective washers 35, 39 out of grooves of the case 49.
TURNING OUT OF NUTS 44 OF DISENGAGING FOR DISASSEMBLING OF A COVER OF THE PISTON AND
TAKING OUT A SPRING 47 ARE STRICTLY FORBIDDEN WITHOUT THE SPECIAL ACCOMMODATING PROVIDING
RELIABLE FIXING OF THE PISTON 48 OF A COVER 46 AND SMOOTH RELEASING OF A SPRING 47.
Assembling, adjustment and testing of brake gears of rear wheels and brake gears of a parking
brake
The details supplied on assembling, should be washed carefully out in a diesel fuel and blown up by
compressed air. Oil channels should be cleaned and blown through by compressed air.
When assembling a brake gears of service and parking brakes use a new package of general me-
chanical rubber goods (sealing rings, cuffs, protective clutches)
Assembling of a brake gear of rear wheels and brake gear of a parking brake is made in the following
sequence:
Assembling of a parking brake cylinder.
- to install sealing rings 36, 38 and protective washers 35, 39 into grooves of the case 49 (look figure
10.5) (protective washers should be on the opposite side of a cavity of a high pressure);
- to turn a cover 46 in assembly with the piston 48, indicators 42, a nut 44, a washer 45 and a splint 43
into the case 49;
Assembling of an external cheek of a parking brake.
- to install parking brake cylinders 5 into openings of an external cheek 50 of parking brake;
- to install a protective clutch 51 into grooves of a cheek 50 and of the piston 48 and to fix parking brake
cylinders 5 with bolts;
- to turn supports 9, preliminary having greased the thread surface with a graphite lubricant, to install a
brake cover plate 27 on them;
- to turn bolts 54 with springs 55 into openings of a brake cover plate 27;
10-29
Braking systems
7513-3902080 RM
- to splint supports 9 and bolts 54 (splitting should not hinder from displacement of a bolt 54 in an axial
direction on distance not less than 25 mm);
Assembling of an internal cheek of a parking brake.

- to turn supports 9, preliminary having greased the thread surface with a graphite lubricant, to install a
brake cover plate 27 on them;
- to turn bolts 54 with springs 55 in openings of a brake cover plate 27;
- to turn thrusts 33 with nuts up to displacement of brake cover plate 27;
Assembling of the cylinder piston of a service brake.

- to put sealing ring 59 and the frictional bush 60 onto a rod 30. The force of displacement of the fric-
tional bush 60 on a rod 30 should be in limits 2000 - 3000 N;
- to install a rod 30 with the frictional bush 60 and a sealing ring 59 into the piston 29;
- to install a necessary amount of adjusting washers 58, a cup 61, a spring 64, a stop ring 57 into the
piston;
- to press a stop ring 57 and to install a retaining ring 56. The clearance between butt-end of a cup 61
and a stop ring 57 should be 1 - 2 mm.
Assembling of the cylinder of a service brake.

- to install a sealing ring 63 and a protective washer 62 into a groove of the case 31;
- to install the assembled piston 29 into an opening of the case 31;
- to fix a rod 30 by a nut 32;
- to move pistons 29 against the stop to the case 31;
Assembling of external and internal cheeks of service and a parking brakes.

- to install sealing rings 24 into grooves of the case 31;
- to install cylinders 11 of service brake into openings of cheeks 3 and 17 and to fix them with bolts 25;
- to install a protective clutch 26 into grooves of cheeks and pistons 29;
- to turn in supports 9, preliminary having greased the thread surface with a graphite lubricant, to install
brake cover plates 27 on them;
- to turn bolts 54 with springs 55 into openings of brake cover plates 27;
- to install brackets 23, 22 and internal cheeks 17 of service brake in assembly on the traction motor 13
and to fix with bolts 4;
- to install internal cheek of a parking brake onto a bracket 22, to install an adjusting shims 53 and to fix
with bolts 10 (adjusting shims ensure a symmetric arrangement of external and internal brake cover plates 27
concerning a disk with a flange 16);
- to put a disk with a flange 16 onto the shaft of the traction motor 13 (to grease a spline joint with graph-
ite lubricant);
- to install plates 15 and to turn a bolt 14;
- to turn studs 8 into internal cheeks 52, 17 of parking and service brakes;
- to put inserts 19 and supports 20 on studs 8;
- to put external cheeks 3 of service brake in assembly and an external cheek 50 of parking brake in as-
sembly on studs 8;
- to turn nuts 7 and to stop a splint;
- to connect all sleeves 1 of high pressure.
Adjustment of clearances between brake cover plates and a disk
Adjustment of clearances between brake cover plates and a disk is performed in the following sequence:
- turning thrust blocks 33 to adjust a clearance of 1 - 1,5 mm between a brake cover plate 27 and a
brake disk 28. After setting a necessary clearance to stop thrust blocks 33 with nuts 34;
- turning covers 46 in assembly with the piston 48 to adjust a clearance of 1 - 1,5 mm between a brake
cover plate 27 and a brake disk 28 by special wrench for openings in a cover 46. To turn out nuts 44 of disen-
10-30
Braking systems
7513-3902080 RM
gaging before coincidence of nut openings to a opening of the screw and to stop by a splint 43;
- to screw in locking bolts 40 and to stop by nuts 41.
Testing on leakprofness and serviceability of brake gears

To supply a working fluid under pressure (16 ± 2) МPа to cavities of cylinders 11 of service brake (a tri-
angle 2) and cavities of cylinders 5 of parking brake (a T-connector 6), thus the clearance between brake cover
plates 27 of parking brake and a brake disk 28 should be 1 - 1,5 mm. Escapes of a working fluid are not admit-
ted. After release of pressure the clearance between brake cover plates 27 of service brake and a brake disk
28 should be 1 - 2 mm.
When assembling brake gears of rear wheels and a parking brake tightening torque of threaded connec-
tions should match to the values specified in table 10.3.
Table 10.3 - Tightening torque of threaded connections at assembling of brake gears
The name of a part Number on Figure 10.5 Torque, N.m
Nut lock (М30х2) 34 200 – 250

Support of brake cover plates (М42х2) 9 200 – 250
Bolt of fastening of brake disk (М30х2) 14 260 – 320
Nut of fastening of external cheeks (М27х2) 7 370 – 450
Stud of fastening of external cheeks (М27х2) 8 370 – 450
Bolts of fastening of internal cheeks (М30х2) 4, 10, 21 550 – 700
The further assembling is performed in the following sequence:
- to make assembling of a reducer of a motorized wheel and to install the motorized wheel onto a dump
truck (look the order of assembling and setting in section "Electric motorized wheel");
- to install rear wheels onto hubs (look the order of setting of wheels in section « Wheels and tires).
Fractional disassembling of brake gears of rear wheels for removal of the brake cylinders lo-
cated on internal cheeks
For removal of the brake cylinders located on the lower internal cheek it is necessary:
- to release pressure in a hydraulic system of brakes (release of pressure is made by turning out of lock-
ing needles of the brake valve);
- to unsplint and turn out nuts 7 (look figure 10.5) of fastening of the lower external cheek 3;
- to remove the lower external cheek 3 from studs 8 in assembly with cylinders 11, brake cover plates
27, supports 9, bolts 54 and springs 55;
- to turn studs 8 out;
- to unscrew bolts 4 and to lower an internal cheek 17 in assembly with cylinders 11, brake cover plates
27, supports 9, bolts 54 and springs 55 downwards in parallel with a brake disk;
- to unscrew bolts of fastening 25 of brake cylinders 11 and to remove brake cylinders for looking over.
Assembling and setting of cheeks to make in inverse sequence.
The upper internal cheek is removed analogously to lower cheek. Taking into account, that the bracket
of a parking brake 22 together with the upper internal cheek are fastened by bolts 4, parking brake cylinders
should be braked to keep the whole gear of a parking brake on a brake disk, thus wheels should stand on land.
Replacement of brake cover plates of brake gears of rear wheels and brake gears of a parking
brake
Replacement of brake cover plates is made without removal of a reducer of a electric motorized wheel, in
an axle casing.
Replacement of brake cover plates of brake gears of rear wheels and parking brake is performed in the
following sequence:
- to release pressure in a hydraulic system of brakes (release of pressure is made by turning out of lock-
ing needles of the brake valve);
- to unlock a nut of disengaging 44 (look figure 10.5) and to turn it against the stop;
10-31
Braking systems
7513-3902080 RM
- to unlock and to turn out supports 9 and bolts 54 on all cheeks of a service brake and if necessary on
cheeks of a parking brake;
- to take brake cover plates;
- to move pistons 29 of cylinders of a service brake 11 against the stop to the case 31;
- to install new brake cover plates 27, to turn in supports 9 and bolts 54 and to lock them;
- to adjust clearances between brake cover plates of a parking brake and a brake disk;
- to unscrew nuts 44 of disengaging before coincidence of nut openings to a opening of the screw and to
stop them by a splint 43.
10.4.3 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-
75131, BELAZ-75132
After disassembling to check technical conditions of service surfaces of parts by an external examination
and metering of their critical parameters. There should not be corrosion, burrs and other mechanical injuries on
service surfaces of parts.
The basic nominal and maximum permissible sizes of parts of braking systems of dump trucks BELAZ-
75131, BELAZ-75132 are given in table 10.4.
Table 10.4 - Nominal and maximum permissible sizes of basic parts of braking systems of dump
trucks BELAZ-75131, BELAZ-75132
Dimensions, mm
Number, name of part
and parameters to be checked Nominal
sible
7513 – 3501072
Disk
32 28,00 Steel 35 187 – 241 НВ
− 0,39
Thickness
7513 – 3501089
+0,035
Brake case 90 90,050 Steel 45 187 – 241 НВ
Internal diameter
7513 – 3501102
Piston
89,900
−0,036
Steel 45 241 – 285 НВ
− 0,090
damages of chrome
coating
7555 – 3501190 Asbestos code
Cover plate 40 15,0 composition
−1,0 207–17
Thickness with frame
75132 – 3507232-10
Cylinder case of parking brake
Internal diameter +0,035
90 90,050 Steel 45 40 – 46 HRCэ
Internal diameter
+0,054
105 105,100

Bush sleeve +0,027 pling with valve core
12 7512–3514026 Steel 40Х 40 – 46 НRCэ
Internal diameter 0,01 – 0,03 mm
no more
10-32
Braking systems
7513-3902080 RM
Continuation of Table 10.4

Dimensions, mm
Number, name of part
and parameters to be checked Nominal
sible
75132 – 3507281
Cylinder piston of parking brake −0,036
External diameter
90 89,900
− 0,071
−0,036 Steel 45
External diameter 105 104,900
− 0,071
There must not be

damages of chrome
coating
Valve core pling with bush
Carbonization
sleeve 7512–
Diameter of corbels 12,00 3514025
Steel 40Х h 0,7 – 0,9 mm
57 – 63 НRCэ
0,01 – 0,03 mm
no more
7512 – 3514045
+0,043
Plug 12 12,050 Steel 40Х 34 – 40 НRCэ
Internal diameter
7512 – 3514060-10
−0,016
Rod 12 11,900 Steel 40Х 45 – 50 НRCэ
− 0,059
External diameter
7545 – 3545016
Case +0,1 165,1 ТВЧ
165 Steel 45 h 1,5 – 3,0 mm
Internal diameter There must not be 50 – 60 НRCэ
damages of surface
75132 – 3577043-20
+0,025
Cylinder case of service brake 50 50,03 СЧ 20
Internal diameter
75132 – 3577044-10
Cylinder piston of service brake
49,9 241 – 285 НВ
−0,025 ТВЧ
Steel 40Х
h 1,0 – 2,5 mm
− 0,087
damages of chrome 49 – 59 НRCэ
coating
7513 – 3577060 Asbestos code
Brake cover plate 40 15,0 composition
−1,0 207-17
Thickness with frame
75132 – 3577152
Disk 32 28,00 Steel 35 145 – 187 НВ
− 0,16
Thickness
10-33
Braking systems
7513-3902080 RM
10-34
Pneumatic system
7513-3902080 RM
11 PNEUMATIC SYSTEM
The pneumatic system intended to provide engine pneumatic starter system, pneumatic gears of cabinet
of traction electric drive, radiator shutters by compressed air, to connect the appliance for tires inflation and to
feed the balloon of a pneumocushioning of the driver's seat (for dump trucks BELAZ-75131, BELAZ -75132).
11.2 Possible troubles of pneumatic system and methods of their removal

Possible troubles of pneumatic system and methods of their removal are given in Table 11.1.
Table 11.1 — Possible troubles of pneumatic system and methods of their removal
Trouble and symptom Probable cause Method of removal
The pneumatic system has a significant Pipelines or hoses are damaged Replace pipelines and hoses
leak of compressed air
Failure of a pressure regulator Repair the pressure regulator
Faulty sealing of connections of pipelines, Tighten connections, replace damaged
hoses, end fitting connection parts and sealings
Decrease of productivity of the compressor Breakage of suction or pressure valves Replace valves
Deterioration of pistons or rings Replace pistons or rings
Cylinder-head gasket is damaged or tight- Tighten gasket or tighten cylinder head
ened not tightly bolts
There is a lot of oil in condensate Piston rings, oil sealing of crankshaft,
bearings of lower crosshead of compres- Replace worn out parts
sor are worn out
Pressure regulator does not maintain
Control of regulating device is broken Make an adjustment
working air pressure
The air leak from the connecting pipe of a Diaphragm of regulating device is dam-
Replace the diaphragm
pressure regulator into an atmosphere aged
when filling up the system with air
The valve of air exhaust into atmosphere Clean and blow through or replace the
is damaged or polluted valve
Dehumidifier does not ensure automatic Internal cavity of dehumidifier is polluted Disassemble and wash the dehumidifier
removal of a condensate
Diaphragm is damaged Replace the diaphragm
11.3 Repairing of devices of pneumatic system
BEFORE REMOVAL AND REPAIRING OF DEVICES OF PNEUMATIC SYSTEM REDUCE AN AIR

PRESSURE IN SYSTEM UP TO ATMOSPHERIC. DISCHARGE OF AIR FROM SYSTEM IS MADE
THROUGH THE CONDENSATE DUMP VALVE OF AIR TANK.
11.3.1 Repairing of a dehumidifier

Disassembling of a dehumidifier.
Disassembling of a dehumidifier is performed in the following sequence:

- to disconnect air tube, to unscrew bolts of fastening and to remove a dehumidifier from a dump truck;
- to unscrew bolts 22, 25 (figure 11.1) and to disconnect the refrigerant 23 from the case 7, covers 1 and
11-1
Pneumatic system
7513-3902080 RM
to take sealing rings 24 from grooves of flanges of the refrigerant;

- to unscrew bolts 17 and to disconnect the case 7 and a cover 1 to remove a sealing ring 5;
- to take valve seat 21, the valve 20, a plate of a spring 19 and a spring 18 from the opening of the case;
- to take from a cover a stop ring 4;
- to take the piston 15 as an assembly with a valve core 16, a diaphragm 13, a diaphragm disk 12 and,
having removed a retaining ring 10, a stop ring 11 and a sealing ring 14 to disconnect them;
- to take a sealing disk 2 from a valve core 16;
- to turn out hollow screw 8 from the case 7 and to take out swirler 9;
- If necessary to take a pin 6 from a swirler opening.
Figure 11.1 – Dehumidifier:

1 – cover; 2 – sealing disk; 3, 18 - springs; 4 – stop ring; 5, 14, 24 – sealing rings; 6 – pin; 7 – case; 8 – screw; 9 – swirler; 10 – re-
taining ring; 11 – stop ring; 12 –disk; 13 – diaphragm; 15 – piston; 16 – valve core; 17, 22, 25 – bolts; 19 – spring plate; 20 – valve;
21 – valve seat; 23 – refrigerant
I, II –- outlets
11-2
Pneumatic system
7513-3902080 RM
Assembling of a dehumidifier.
Assembling of a dehumidifier should be performed in the conditions providing protection of a compo-
nents from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on parts,
and there should not be scratches and other faults on service surfaces. Before assembling clean all channels
of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white spirit and
dry them up.
Before assembling pay special attention to a condition of rubber sealing ring. At an opportunity
use a new package of general mechanical rubber goods. When mounting sealing rubber rings keep up
that rings are not twisted in grooves and are not undercut.
When assembling friction surfaces of parts to grease with a thin layer of lubrication Litol-24.
Assembling of dehumidifier to make in the following sequence:

- to install a pin 6 into an opening of a swirler 9;
- to install a swirler into the inner space of the case by a 7 pin in an opening of the case;
- to turn in a tapped hole of the case 7 hollow screw 8, preliminary having greased a surface of a thread
with a sealer "УГ-9" THAT 6-01-1326-86;
- to install a sealing disk 2 into an opening of a valve core 16;
- to install a spring 3, a piston 15, a diaphragm 13, a diaphragm disk 12, a sealing ring 14, a stop ring 11
on a valve core and having contracted a package of parts to install a retaining ring 10 into a groove of a valve
core;
- to install the package of parts collected on a valve core into the inner space of a cover 1;
- to install stop ring 4 into the inner space of a cover 1;
- to install spring 18, a plate of a spring 19, the valve 20 and the valve seat 21 into the opening of the
case 7;
- to install sealing ring 5, a cover 1 on the end of the case 7 and to fix a cover with bolts 17;
- to install sealing rings into the grooves of flanges of the refrigerant 23 and to connect the refrigerant to
the case 7, having fixed bolts them with 22 and 25;
- to install and fix a dehumidifier on a dump truck and to connect air tubes.
Test of a dehumidifier
Dehumidifier is to be tested on setting which scheme is given in figure 11.2.To check operation of the
valve 8. The valve should open at air pressure reaching 4 +2,0 МPа (the test is carried out without the refrig-
− 0,5
erant, places of connection of the refrigerant are closed by plugs 10).
For inspection of leakproofness to connect a refrigerant instead of plugs10. To open the crane 4 and to
fill in a dehumidifier with compressed air under pressure 0,6 - 0,8 МPа. Inspection is performed by a soap
emulsion. An admissible leakage is 50 sm3 per one minute.
For inspection of operation of the valve of automatic drain to enclose the crane 4, by the crane 7 through
a throttle 6 to lower an air pressure up to 0,1 МPа, thus on downtakc tube strong formation of soap bubbles
should be observed.
To reach and maintain an air pressure in a dehumidifier of 0,7 МPа, thus formation of soap bubbles on
downtakc tube should stop immediately. To lower an air pressure in a dehumidifier from 0,7 МPа to zero, thus
strong formation of soap bubbles on downtakc tube should be observed.
Figure 11.2 – Scheme of dehumidifier testing setting:

1 – pipe duct of input of compressed air; 2, 5 – manometers; 3 – a reducer of pressure; 4, 7 – cranes; 6 – throttle opening (diame-
ter of 0,4 mm); 8 – valve; 9 – settling tank; 10 – plugs
11-3
Pneumatic system
7513-3902080 RM
11.3.2 Repairing of a pressure regulator

Disassembling of a pressure regulator.
Disassembling of a pressure regulator should be performed in the following sequence:
- to disconnect air tubes, turn out elements of fastening and to remove a pressure regulator from a
dump truck;
- to turn out a fuse 8 (figure 11.3) and to remove a sealing ring 5;
- to take out a piston 3 as an assembly with a stock 4 , a guiding plate 6, a cuff 2 from the case of an
regulator 19 and to take out a spring 1. If necessary to turn out a nut 7 and to remove guiding plate, a cuff and
a piston from a stock;
- to turn out a valve body of the relief mechanism 23 and to remove a sealing ring 22;
- to take out a spring 24 and a valve 20 from the case of the regulator
- to turn out a cover 12 of safety valve and to take out a plate of a spring 9, a spring 13 and a safety
valve 15;
- to turn out the case of a safety valve 14 and to remove a sealing ring 16;
- to take out a spring 17 and a check valve 18 from the case of the regulator;
- to turn out a connecting pipe 21 from the case of the regulator;
- to turn out an adjusting screw 33 from a housing of the regulating device 30 and to turn out a housing
from the case of regulator 19. To take out a plate of a spring 31, springs 26, a disk 27, a stop ring 28 and a
diaphragm 29;
- to take out a filter 25 from an inlet opening of the case of regulator.
Figure 11.3 – Pressure regulator:

1, 13, 17, 24, 26 – springs; 2 – cuff; 3 – piston; 4 – stock; 5, 16, 22 – sealing rings; 6 – guiding plate; 7 – nut; 8 – plug; 9, 31 – plate
of spring; 10, 32 – lock-nuts; 11, 33 – adjusting screws; 12 – cover; 14 – case of safety valve; 15 – safety valve; 18 – check valve;
19 – case of regulator; 20 – valve; 21 – connecting pipe; 23 – case of valve o relief device; 25 – filter; 27 – disk; 28 – stop ring; 29 – dia-
phragm; 30 – housing of regulating device;
I, IV – spaces of relief device; II, VI, VII – channels of relief and regulating devices; III – channel connecting to receiver
(through antifreezer); V – channel for air supply from compressor (through dehydrator)
11-4
Pneumatic system
7513-3902080 RM
Assembling of a pressure regulator.

Assembling of a pressure regulator should be performed in the conditions providing protection of a com-
ponents from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on parts,
of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white spirit and
dry them up.
Before assembling all friction surfaces should be greased with a thing layer of Litol-24.
Assembling of pressure regulator to make in the following sequence:

- to install a diaphragm 29, a stop ring 28, a disk 27, springs 26, a plate of a spring 31 in an opening
of the case of the regulator 19 and to turn the housing of the regulating device 30against the stop;
- to screw an adjusting screw 33 with a lock nut 32 into a tapped hole of a housing;
- to install a check valve 18 with a spring 17 into an opening of the case of the regulator and to turn the
case of a safety valve 14, preliminary having placed a sealing ring 16;
- to place a safety valve 15, a spring 13, a plate of a spring 9 into an opening of the case of a safety
valve 14 and to turn a cover 12 against the stop;
- to screw an adjusting screw 11 with a lock nut 10 into a tapped hole of a cover;
- to place spring 24, the valve 20 on a valve body of the relief mechanism 23 and to turn a valve body
into a tapped hole of the case of an adjuster 19, preliminary having placed a sealing ring 22;
- to place a piston 3, a cuff 2, a guiding plate 6 onto a stock 4 and to fix them by nut 7;
- to install a spring 1 a package of details collected on the stock into an opening of the case of the regu-
lator 19 and to turn a fuse 8, preliminary having placed a sealing ring 5;
- to screw a connecting pipe 21 into a tapped hole of the case of the regulator 16;
- to place a filter 25 into an inlet opening of the case of the regulator.
Adjusting and checking of a pressure regulator.

Each pressure regulator should be adjusted and tested on setting which scheme is given in figure 11.4:
- with an adjusting screw 11 (figure 11.3) to provide operating of a safety valve 15 at pressure of com-
pressed air in a receiver 0,90 - 0,95 МPа (at the screw packaged against the stop 33);
- to stop the screw a lock nut 10;
- with an adjusting screw 33 to adjust pressure of switching of regulator up to 0,80 - 0,82 МPа, thus pres-
sure of switching off should be 0,65 МPа;
- after adjusting to stop the screw with a lock nut 32;
- to check a pressure regulator on leakproofness by means of a soap emulsion. Thus a discharge open-
ing of the connecting pipe 21 must be closed. The air leak is not admitted.
Figure 11.4 – Scheme of testing setting of pressure regulator:

1 – compressor; 2 – dehydrator; 3, 8 – disconnecting valves; 4, 7 – manometers; 5 – pressure regulator; 6 – receiver; 9 – throttle
opening (diameter 9 mm)
11-5
Pneumatic system
7513-3902080 RM
11.3.3 Repairing of the single protective valve

Disassembly of the single protective valve.
Disassembling of the single protective valve is made in the following sequence:
- to turn out screws 10 (figure 11.5) of fastenings of a cover 3 to the case 1, to remove a cover, to take
out a diaphragm 2, a washer 11, a piston 4, springs 5, 9 and a plate of springs 6;
- to remove a stop ring 16 and to take bush 15, a spring 13, a valve body 14 and a ring of the valve 12
out the case 1.
After disassembling parts of the valve should be degreased and washed up in hot water.
Assembling of the single protective valve.

Assembling of a single protective valve should be performed in the conditions providing protection of a
components from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on
parts, and there should not be scratches and other faults on service surfaces. Before assembling clean all
channels of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white
spirit and dry them up.
Assembling of single protective valve should be performed in the following sequence:

- to place a ring of the valve 12, a spring 13 and bush15 on a valve body 14;
- to install collected on the valve body 14 package of details into an opening of the case 1, to compress
it and to stop in the case with a stop ring 16;
- to install diaphragm 2 and a washer 11 into the case 1;
- to install a plate of a spring 6, springs 5 and 9 and a piston 4 into the inner space of a cover 3;
- to place a cover 3 on the case 1 and to fix it with screws 10 and washers;
- to turn adjusting screw 7 with a lock nut against the stop into a tapped hole of a cover 3 and to leave
the valve in such position on 12 - 14 hours.
Adjusting and checking of the single protective valve

Adjusting and checking of the single protective valve is made in the following sequence:
- To connect the valve under the scheme (figure 11.6). Cranes 2, 10, 11 should be closed;
- To open the crane 2. To adjust by-passing pressure by an adjusting screw 7 so that a receiver 8 is
started to be inflated at pressure in a receiver 4 of 0, 55 - 0,555 МPа;
Figure 11.5 – Single protective valve:

1 – case; 2 – diaphragm; 3 – cover: 4 – piston; 5, 9, 13 – springs;
6 – spring plate; 7 – adjusting screw; 8 – lock nut; 10 – screw; 11 – washer;
12 – valve ring; 14 –valve case; 15 – bush: 16 – stop ring
I, III – outlets, II – space
11-6
Pneumatic system
7513-3902080 RM
- to fill in a receiver 8 up to pressure, equal to pressure in a receiver 4. Manometers 5 and 9 should dis-
play equal values;
- to check on leakproofness, having covered places of possible escapes by a soap emulsion;
- to enclose the crane 2, to open cranes 10 and 11, to release air from receivers, again to enclose cranes 10
and 11;
- to open the crane 2, to check on adjustment once more and to correct if necessary;
- to release air from a receiver 4 through the crane 11, thus the manometer 9 should not display pres-
sure decrease.
Figure 11.6 – Scheme of testing of single

protective valve:
1 - the pipe of input of compressed air (pressure
0,7 МPа); 2, 10, 11 - cranes; 3 - a throttle (diameter of
1,1 mm); 4, 8 - receivers; 5, 9 - manometers; 6 – the
single protective valve; 7 - the adjusting screw
11.3.4 Repairing of a safety valve

Disassembling of a safety valve.
Disassembly of a safety valve is made in the following sequence:

- to turn out and to remove a nut 7 (figure 11.7);
- to turn a press-on hush 8 out of the case 3;
- to take out a stock 4 with washers 6 and a spring 5;
- to turn seatof a safety valve 1 out of a tapped hole of the case 3;
- to take the valve 2 out of the saddle.
Assembling of a safety valve.

Assembling of a safety valve should be performed in the conditions providing protection of a compo-
nents from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on parts,
of cuttings and mud, blow through by compressed air.
The valve 2 and seat of a safety valve 1 grease with a thin layer of spindle oil АУ OCT 38.01.412 – 86
before assembling.
Assembling of a safety valve is performed in the following sequence:
- to place valve 2 in seat of a safety valve 1;
- to turn the case 3 on seat of a safety valve against the stop;
- to put sequentially a washer 6, a spring 5, a washer 6 on a stock 4 and to install a stock into an internal
opening of the case up to contact with a mounting surface of the valve seat 2;
- to turn a press-on hush 8 into a tapped hole of the case 3;
- to screw in a nut 7, not pressing on a thread of the press-on hush.
Figure 11.7 – Safety valve:

1 – seat; 2 – valve; 3 – case; 4 – stock; 5 – spring; 6 – washer; 7 – nut; 8 – press-on hush
11-7
Pneumatic system
7513-3902080 RM
Adjusting and testing of a safety valve.

Each collected safety valve should be adjusted and tested on setting which scheme is given in
figure 11.8.
Pressure of opening of safety valve is of 5 (0,95 + 0,15) МPа. Adjusting is made by turning-in a press-on
hush 8 (look figure 11.7) into the case 3.
After adjustment to stop a press-on hush with a nut 7.
To check a safety valve on leakproofness, having covered places of possible escapes by a soap emul-
sion. Air leaks through the valve before its start are not admitted.
Figure 11.8 – Scheme of testing of a safety valve:

1 – pipeline of input of compressed air; 2, 6 – cranes; 3 – receiver; 4 – manometer;
5 – safety valve
11.3.5 Repairing of antifreezer

Disassembling of antifreezer.
Disassembling of the antifreezer is performed in the followingsequence:
- to disconnect air tubes, to turn out elements of fastening and to remove antifreezer from a dump
truck;
- to unscrew bolts 2 (figure 11.9) and to disconnect the upper case 11 from the lower case 7;
- to take a sealing ring 17 from a groove of the lower case 7;
Figure 11.9 - Antifreezer:

1 – measuring rod; 2 - a bolt; 3, 14, 15, 16, 17 - sealing rings; 4, 19 - plugs; 5 - washer; 6 - spring; 7 - lower case; 8 - fuse;
9 - yoke; 10 -jet ; 11 - upper case; 12 - a pin; 13 - rod; 18 – stop ring
11-8
Pneumatic system
7513-3902080 RM
- to turn a fuse 4 out of the lower case and to remove a washer 5;

- to take out a fuse 19 and to remove fuse 8 and a spring 6 from a rod 13;
- to take a stop ring 18 and a yoke 9 out of a groove of the upper case;
- to take a sealing ring 16 out of a groove of a yoke;
- to move a rod 13 to the lower position and to remove a sealing ring 15;
- to turn a measuring rod 1 out of the upper case and to remove a sealing ring 3;
- if necessary to press out a pin 12 to move a rod 13 to the lower position and to take a sealing ring 14
out of a groove
Assembling of the antifreezer.

Assembling of a antifreezer should be performed in the conditions providing protection of a components
from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on parts, and
there should not be scratches and other faults on service surfaces. Before assembling clean all channels of
cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white spirit and
dry them up.
Assembling of the antifreezer is made in the following:
- to install a sealing ring 14 into a groove of a rod 13;
- to place rod into an opening of the upper case 11;
- to press-in a pin 12 into an opening of a rod;
- to place rod a sealing ring 15 into a groove of a rod;
- to put fuse 8 onto a spring 6 and to place it on rod against the stop in a butt-end;
- to place a fuse 19 on the other side of a springs;
- to place a sealing ring 16 into a groove of a yoke 9;
- to install a yoke 9 into an opening of the upper case 11 and to lock it with a stop ring 18;
- to place a sealing ring 17 into a groove of the lower case 7;
- to combine mounting surfaces of upper 11 and lower 7 cases and to fix them with bolts 2 and washers;
- to place a sealing ring 5 on a plug 4 and to turn a plug into a tapped hole of the lower case 7;
- to install a sealing ring 3 onto a measuring rod 1 and to turn a measuring rod into a tapped hole of the
upper case 11;
- to fix the antifreezer on a dump truck and to connect air tubes.
Testing of antifreezer.
To test the antifreezer on leakproofness by an air pressure of 0,6 – 0,8 МPа, having covered the places
of possible escapes with by a soap emulsion. Escape of air is not admitted. If necessary to replace sealing
rings in the places of escapes.
11.3.6 Repairing of he pneumatic switch

To regulate the temperature condition of engine there is a pneumatic switch which is an element of drive
of jalousie attaching to the block of radiators.
Disassembling of the pneumatic switch.

Disassembling of the pneumatic switch is made in the following:
– to disconnect the air pipes, elements of jalousie drive, to unscrew the bolts of fastenings and to re-
move the pneumatic switch from the dump truck;
– to unscrew bolt 11(figure 11.10) and to remove a cover 1 from a case 3;
– to take a piston 5 out of an opening of a case 3;
– to take a stop ring 6 out of a groove of a stock 8 and to remove a piston from stock;
– to take sealing rings 2, 7, 4 and 9 out of grooves of a case 3, piston 5 and stock 8.
11-9
Pneumatic system
7513-3902080 RM
Figure 11.10 – Pneumatic switch:

1 - a cover; 2, 7, 9 - rings; 3 - case; 4 – sealing ring; 5 – piston; 6 - a
stop ring; 8 - a stock; 10 – locking washer; 11 - a bolt
Assembling of the single protective valve.

Assembling of a single protective valve should be performed in the conditions providing protection of a
components from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on
parts, and there should not be scratches and other faults on service surfaces. Before assembling clean all
channels of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white
spirit and dry them up.
Assembling of the pneumatic switch is performed in the following sequence:
- to install ring gaskets 7, 4 and 9 into grooves of the case 3, a piston 5 and a stock 8;
- to install the piston 5 onto a stock 8 and to fix a locking ring 6;
- to install the piston in assembly with a stock of an opening of the case. The piston with rubber rings
should move freely without jams in both directions;
- to place a sealing ring 2 into a groove of the case 3;
- to install a cover 1 onto a butt-end of the case, to fix it with bolts 11, having stopped them with locking
washers 10.
Testing of the pneumatic switch.

To test the pneumatic switch for leakproofness by an air pressure 0,4 МPа at a stock stroke in both
sides against the stop. Pressure drop of air is no more than 0,05 МPа within five minutes. To cover places of
possible escapes with a soap emulsion and if necessary to replace sealing rings in places of escapes.
11-10
Electrical equipment
7513-3902080 RM
12 ELECTRICAL EQUIPMENT
During a continuous duty of dump trucks in an electric equipment there can be characteristic faultiness ,
such as the electric wires isolation destruction, the electric machines sweepers attrition, the plugs and contacts
oxidation, the electric apparatuses adjustment. violation
To attend the big attention to the electric wire technical condition devices and apparatuses and duly re-
moval of faultiness for maintenance in good condition of the dump truck electric equipments . To eliminate the
faultiness in good time. Fine faultiness of the electric equipment, not eliminated it is duly, can reduce further in
serious failures which removal will demand a significant time and means.
The electric equipment repair make in the specially places . This places should be equipped for these
purposes by the qualified specialists with special gears instruments, stands and accessories application..
12.1 Technical requirements to an electrical equipment
Accumulator batteries ensure reliable operation of electrogears, have no weep of an electrolyte and
slackened landing of dowels.
The alternator works noiselessly, without a brush sparking and excessive heat and gives a current, suffi-
cient for a charge of accumulator batteries and power supply of users.
Gears of illumination are completed with rectified lamps which force of light corresponds to a technical
data of a gear. The direction of a luminous flux of headlights is adjusted according to the instruction.
All test instruments operate and testify with a suitable exactitude.
Window wipers ensure full clearing a glass, their operation is not accompanied by knock and noticeable
noise.
Electromotors of heaters do not create significant noise at operation.
Cutout switches and switches ensure reliable turning on and cutting off of the corresponding gears of an
electrical equipment
Possible failures of an electrical equipment and modes of their elimination are reduced in Table 12.1.
Table 12.1 – Possible faultiness in electric equipment and ways of their removal
The name of failure and its
The probable reason Mode of elimination
external development
Fuse F21 has fused To replace fuse
Breakage of the electric circuit To test integrity of the circuit
By pressure the button of the cutout switch
of "weight" accumulator batteries are not Cutout switches S14 and SB2 are defec- To test serviceability of cutout switches.
connected to the electrical network tive Faulty devices to replace.
Electric drive connection to batteries is
To test electric drives connection
wrong
Alternator or voltage control box is defec-
To test charging current
tive
Accumulator batteries are dischargeed A short-circuit between plates in the ac-
cumulator battery Repair or replace accumulator battery
Plates sulphation
Lowering of an electrolyte level in accumula-
Gassing Test of the voltage control box accuracy
tor batteries
Excessively a high electrolyte level Test electrolyte level
The big force of a charge current To test
The electrolyte escapes from vent holes of Test voltage control box
serviceability of a voltage control box
one or several accumulators in charging time
Plates short circuitв in one of accumulator
Repair or replace accumulator battery
batteries
12-1
7513-3902080 RM
Table continued 12.1

At the key established in the lock - cutout
Blow-out of the fuse To replace the fuse
switch test instruments do not work
At the key established in the lock - cutout
Blow-out of the fuse To replace the fuse
switch indicating lamps do not work
One of test instruments (the pressure indica- The transmitter or the index is defective To replace the faulty device
tor or temperatures) does not work Violation of integrity of the circuit To test integrity of the circuit
Electric fuse of the circuit is blow out To replace electric fuse
Accumulator batteries are discharged To charged accumulator batteries

Voltmeter arrow is motionless on zero Wire break to voltmeter To remove damage
To exchange places wires on outlet plus
Wires connect to the voltmeter incorrectly
“+” and minus “-“
Voltmeter is defective To replace device
The voltmeter shows discharge at the work- Relay-regulator is defective To replace relay-regulator
ing engine (arrow on red zone); at turning on To test power circuit and to remove
Break or insecure contact in power circuit
of users and a speed-up of the engine the trouble
arrow deflects even more to the left Alternator is defective Look dump truck service instruction
Voltmeter arrow vibrated too much at
Alternator is defective Look engine service instruction
change at engine speed rotation
Voltage on the alternator is more 28 V, lamp
Relay-regulator is defective To replace relay-regulator
s are blow out or abnormal its burning
Not connect any element (voltage control
Test devices hookup
box, alternatorstorage battery).
Circuit opening between generator storage Visual inspection or at help of the control
batteries. lamp find break and to eliminate it
Circuit opening of the generator excitation. At the the help of the control lamp or de-
vice test the hookup output terminals of
Broken wire connected outlets of the volt- the voltage control box and alternator.
age control box and alternator Find the break and eliminate it.
At the idle engine and switched off
"mass" to test of the alternator brush as-
sembly .To take out sweepers, to delete
At the medium frequency rotational speed of The brushes hanging,
a strike of the brushing dust, to test, free
the engine crank shaft the voltmeter show conveyance of sweepers to brush-
voltage of the storage batteries 24 V holders
Wipe a ring with a napkin and to test a fit
Pollution of the slip rings
of a sweeper to rings
The drive gear of the alternator is devec-
tive Is defective to test a tension of belts Test a tension of belts and if necessary
and if necessary to adjust to adjust
Abruption emitter lines of output transistors Replace transistor

Transitions a collector - emitor of output
transistors. Are punched to replace tran- Replace transistor
sistors
At connection of loading voltage of the alter- A breakdown or abruption in one of valves Dismantle the alternator and to test each
nator sharply drops of the detector block valve separately. Failed to replace
A wear of details of the bearing or its
Heightened mechanical noise at twirl of a ro- To replace the bearing
break-up
tor of the alternator
Bend the ventilator Correct the bend ventilator places
The noise of bearings accompanying with Delete old lubricant, wash out the bear-
The bearing is polluted
excessive heating ing and put in pawn new lubricant
Heightened noise (the alternator buzzs) Is
defective выпрямительный the block Re- Is defective rectifier the block Replace rectifer block
place выпрямительный the block
12-2
7513-3902080 RM

To test and if necessary to manufacture
Slackening tighten belts..
a tension of belts
At operation of the dump truck the arrow of Pollution of slip rings, a heightened wear To examine brush assemblyand to re-
the voltage meter oscillates of sweepers owing to what pressure of a move failures
spring is diminished by sweepers
At operation of the dump truck in the block of
Outage of output transistors (КТ837Х) is
indicating lamps the lamp faltering light ig-
possible. The relay part of the circuit of a Replace transistors
nites (in adjusters 21.2702), rocking arrow of
voltage control box
the voltage meter
A breakdown of transition a collector -
emitter of the output transistor owing to Replace transistor
what on exciting windings the dc voltage
Voltmeter shows high voltage, i. е arrow is in
Break tie baselines of the output transistor
yellow zone Replace transistor
of the voltage control box
Hit of ectogenic plus on clip " Ш " of the al-
To remove closure between wires
ternator
To remove the window wiper and to re- To remove the window wiper and to re-
move failure move failure
At turning on the window wiper does not
The fuse owing to jamming bars operates
work To find the reason and to remove failure
or failures of the electromotor
Wear of spiral gear of reducer To replace the spiral gear
The window wiper works on one speed To remove break and (or) to replace the
Break wires or the switch is defective
cutout switch
At shut down of the window wiper of a
To test connection, integrity of the switch
sweeper or does not stop in an extreme po- Wrong switch connection, the switch is de-
and the limit switch of the window wiper.
sition on, or irregular connection of the fective or failure of the limit switch is
Failure of elements to remove
switch stops in an inadequate place
At switched off "mass" what arrow or a gear Closure of a wire of a gear connecting clip
has deviated before failure to the right " Д " with a transmitter on "mass" of the To remove closure of a wire
dump truck
After an engine firing the arrow of a ta- Abnormally the device Is connected is
Is connected is necessary to change two
chometer displaces in the opposite direction necessary to change two any phases on
any phases on the connective panel
the connective panel
After start-up the arrow of a tachometer is
A broken wire or absence of power supply To remove break or to replace a fuse
not twirled
Absence or a blow-out of a fuse, phases
At driving of the dump truck the arrow of the To test presence of a fuse or to remove
break, breakage of the drive gear of a
speedometer stands in place . abruption
transmitter of the speedometer
The arrow of the speedometer at driving a Abruption of one of phases or outage of To remove abruption or to replace the
dump truck goes jerky the transistor transistor
The arrow of the speedometer stands on
Mixed in connection of phases transmitters
null, the countable node counts in a under- Reconnect two any phases
of the speedometer
side
Closure of a plate of a collector by a dust
which was formed in result an attrition of To remove the electromotor, to analyze,
The motor armature of a heater is twirled
the sweepers, is not twirled by insufficient test a collector, brush assembly and to
with small speed or not twirled
pressure of springs absolutely jam of remove failure
sweepers in a brush-holder
The motor armature of a heater is twirled Pollution of the bearings lubrication or a To remove, dismantle test and eliminate
with small speed, the fuse is burn out short-rotor circuit the faultiness
The fuse is absent or burn out Replace the fuse
By pressure the button signals are not pow- Wire broken Test and remove faultiness
ered up To test serviceability of the relay and if
Switching equipment faultiness
necessary to replace
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To test receipt of power supply from the
Is absent power supply from the switch of
reverser or it is necessary to replace a
At driving by a trailing side the backup alarm the reverser or from a fuse
fuse
does not work (faltering sounding))
To test serviceability and if necessary to
Connecting telay is defective
replace
The signal sounds hoarsely or publishes a Slackening strengthening of a signal, a
rattling sound torque retention loss of wires, a burning of To test and remove the faultiness
contact pieces To test and remove failure
At turning on of the switch of turning move-
Closure of wires on "mass" of the dump To test closure of wires on a lamp or on
ments in any side of a lamp of turn indicators
truck, i.e. operates the relay of a guard "mass" and to remove
and indicating lamps do not work
Is defective a circuit of connection of the
relay of turning movements and an indicat-
At turning on of turning movement of a lamp To test and remove the faultiness
ing lamp (nozzle stamping on isolation of a
of the corresponding bort side flicker, the in- wire)
dicating lamp on щитке is not present gears
Setting lamps in fast-head or tail lights of To install lamps of the corresponding
of a cabin
smaller power power
A burn-out of one of lamps To replace a lamp
At turning on of turning movements lamps of The relay of turning movements is defec-
both bort sides of a dump truck are not pow- tive. Internal break or outage any an ele- To remove the relay and to give to repair
ered up, but circuits are rectified ment of the circuit
The fuse has burn out To replace a fuse
A temperature detector are not connected
to "mass" of a dump truck (the water tube To install a "mass" dam
If the temperature of a chilled fluid has ex- is not connected to "mass")
0
ceeded 80 С, the louvers remain enclosed The electronic relay and the pilot relay is
defective Is defective Is defective to test To test and if necessary to replace out-
and if necessary to replace out-of-order of-order elements of the circuit
elements of the circuit{scheme}
12.2 Faultiness elimination of the the protection system

The majority electric circuits of dump trucks is protected by the fuses who are opening a circuit in over-
load case by current of the big force.
The location of the protection system of the electric equipment, their designation and rate values are in
manual operation on the dump trucks.
To test fuses condition first of all at the failing in the electric circuit . The fuse operation (break of the
electric circuit) testifies to presence of short circuit in the circuit. In this case establish faultiness and only after
that replace the fuse. Starting search of faultiness in the electric equipment of the dump truck, have in view of,
that almost all electric circuits gain feed from one point - "+" the ammeter (voltage meter). This point is the be-
ginning of all electric circuits and in most cases from it to begin the control.
Table 12.2 – - Fuses of system of the low-voltage equipment of dump trucks BELAZ-75131, BELAZ-75132
Ruses designation
Protected circuits
in block
Feed circuit of the lock -cuto switch, of the switch of engine emergency shut-down, voltmeter, engine protective
F 1A (BELAZ-75132)
relay on pressure
F 1A (BELAZ-75131) Feed circuit of the electronic module of the engine control
F 2Б Feed circuit of the reverse motion and reversing light signal
F 3В Feed circuit of the metering equipments
F 4Г Feed circuit the blocks of the control lamps , control lamps
F 5Д Feed circuit of the overall dimensions indicators (port side)
F 6Е Feed circuit of the overall dimensions indicators (starboard),of the fog lamp
F 7Ж Feed circuit of the lamp lower beams (port side)
F 8И Feed circuit of the lamp lower beams(starboard)
F 9К Feed circuit of the lamp high beam (port side)
F 10Л Feed circuit of the lamp high beam (starboard)
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Ruses designation
Protected circuit
in block
F 11А System feed circuit of the parking brake, stop-light lamps fuel control system from the overflow
F 12Б Feed circuit lighting of the switches
F 13В (BELAZ-75132) Feed circuit of the lighting lamps of the motor section, of the engine start relay , level sensors
F 13В (BELAZ-75131) Feed circuit of the lighting lamps of the motor section, level sensor s of the refrigerating fluid, fuel, oil
F 14Г (BELAZ-75132) Feed circuit pumping system of the under hood lamp, of the hand lamp socket
F 14Г (BELAZ-75131) Feed circuit of the lock-cutout switch, of the pumping system
F 15Д Feed circuit of the turning off system
F 16Е Feed circuit of the cab heater electric engine, body lighting lamp
F 17Ж (BELAZ-75132) Feed circuit of the time relay of the protection break , oil pumping system after engine stop
F 17Ж (BELAZ-75131) Feed circuit of the selector switch and turn switches
F 18И (BELAZ-75132) Feed circuit of the radiator blind switching off system and the engine fan
F 18И (BELAZ-75131) Feed circuit of the radiator blind switching off system and the engine fan relay switching off
F 19К (BELAZ-75132) Feed circuit of the stop engine system
Feed circuit of start system and engine stop, lock blockage, buzzer, tachometer, body lifting disconnexion sys-
F 19К (BELAZ-75131)
tem at the running engine
F 20Л Feed circuit of the windshield wipers, screen washers, plafondes, fan blower
F 21 Charging cirguit of the storage batteries
F 22 (BELAZ-75132) Feed circuit of the heating oil system in the regulator, selector switch
F 22 (BELAZ-75131) Feed circuit of the control panel starting preheaters, of the electric engine of the fuel pumping pump
F 23 (BELAZ-75132) Feed circuit of the fuel pumpimg pump
F 24 (BELAZ-75132) Feed circuit of the oil pumping pump before engine start
Table 12.3 – Protective devices of the iow –voltage installation of the dump trucks BELAZ-7514, BELAZ-75145
Ruses designation
Protected circuit
in block
F 1A (BELAZ-7514) Feed circuit of the oil heater system the returnes regulator
F 1A (BELAZ-75145) Feed circuit of the lighting lamp of the fuel tank
F 2Б (BELAZ-7514) Feed circuit of the electron relay of the protection on pressure, lock blocking relay, voltmeter, buzzer, timer
F 2Б (BELAZ-75145) Feed circuit lock blocking relay, voltmeter, buzzer, timer
F 3В Feed circuit of the lock-cutout switch, of the test instrumentes
Feed circuit of the cab fans heaters, of the fan driver blower , limit switch of traction motors blower, of hte hand lamp
F 4Г socket
F 5Д Feed circuit of the sizes indicators of the port side , of the highlight rheostat, fog lamp
F 6Е Feed circuit of the sizes indicators of the starboard
F 7Ж Feed circuit of the switch lower beam
F 8И Feed circuit of the lighting lamps of the motor section
F 9К Circuit of the lamps high beam, (port side)
F 10Л Circuit of the lamps high beam, (starboard)
F 11А Feed circuit сигнала reverse motion and rear lamp
F 12Б Feed circuit of the electronic module and control interposing relay of the engine temperature conditions
F 13В Feed circuit of the control lamps block, of the radiator blind switch
F 14Г Feed circuit of the parking brake system, stop-light, of control fuel level sensor from owerflow
F 15Д Feed circuit opf the fuel pumping system,body lifting and lowering
Feed circuit or the turns relay, of the alarm signaling switch , turns lamp indicators left and right sides, body high-
F 16Е
light lamp
F 17Ж Feed circuit of the warning signal, of the control lamp block, control lamp
F 18И (BELAZ-7514) Feed circuit of the engine protection on the pressure and oil pumping in the lubrication system after engine stop
F 18И (BELAZ-75145) Feed circuit of the fan engine switching on
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Ruses designation
Protected circuit
in block
F 19К Feed circuitof the windshield wiper, screen washer , of the cab plafond
F 20Л Feed circuit of the engine stop system
F 21, F 22 Charging circuit of the storage batteries
F 23 Feed circuit of the electric motor of the pumping pump
F 24 Feed circuit of the electric motor of the oil pumping pump
F 25 Feed circuit of the control of the pre-starting heaters
12.3 Faultiness elimination and repair of the electricity supply system

The electricity supply system includes storage batteries, the alternator, the alternator with the built-in re-
lay-regulator, voltmeter, the remote switch of "weight" and the switch of "weight" were in the cabin, an electric-
ity cable, connecting sources of the electric power with users.
The injured sections of the electric wiring are subject at repair to fractional or complete replacement,
thus the cross-section of the mounted wire should be not less admissible size or is equal to cross-section of an
injured wire..
12.3.1 Service of storage batteries

The storage batteries are established on dump trucks such as 6СТ-190A.
Technical data of the storage battery
Voltage rating, V ………………………………………………………………..……………………….. 12

0
Capacity at 10 - hour discharge and t electrolyte temperature 30 С, Amp-hr ………………….. 174
Discharge current at 10 - hour discharge, Amp …………………………………………………….... 17,4
Current magnitude of the first charging for dry-charged batteries, Amp ………………………….. 19
Volume of the electrolyte necessary for a filling of one battery up to an operating level, l ….. 12
Before to start service or jobbing of the storage battery, check up and clarify the reasons of possible
faultiness. For the control of the storage batteries condition remove them from the dump truck, delete the mud,
moisture and electrolyte from covers of jars of interelement crosspieces. To test the condition of the mon-
oblock, the covers, the mastics, the plugs and interelement crosspieces.
After survey of storage batteries to test their fitness to operation and charge degree. Fitness to operation
is defined on the voltage gauged by the accumulator tester in the each battery element.
The voltage should be in completely charged element 1,8-1,85 V (under load) and be kept resistantly to
during 5 - 6 sec. (look table 12.4).
Тable 12.4 – –-Parameters describing degree of the elements fitness of storage battery to operation
Voltage in element, V Fitness to operation degree, %
1,85 100
1,7 75
1,6 50
1,5 25
1,3 0
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The charging degree of the storage battery depending on the density of electrolyte is reduced in
table 12.5.
Table 12.5 - The charging degree of the storage battery depending on the density of electrolyte
0 3
Electrolyte density, reduced t 25 С, g/sm
Flat battery
Completely charging battery
на 25 % на 50 %
1,30 1,26 1,22
1,28 1,24 1,20
1,26 1,22 1,18
1,24 1,20 1,16
1,22 1,18 1,14
The electrolyte density is established with the help of the areometer in each element of the battery.
The control of the electrolyte level in storage battery is carried out by means of glass tube diameter 3 - 5
mm on which two labels on distance of 10 and 15 mm from the end face are put. For electrolyte level the con-
trol to turn out the fuse in battery and to insert the tube into an aperture against the stop in face shield. To en-
close by finger the free end of the tube and to lift it is electrolyte should fill in the tube up to any level between
labels. It is electrolyte level.in battery
The battery unloaded more than on 25 % in the winter and more, than on 50 % in the summer, it is nec-
essary to remove from maintenance and to lead its recharge.
Before charging the new or repaired battery and depending on climatic region the electrolyte defined
densities (table 12.6) should be filled.
Table12.6 – Dependence of the electrolyte density from the climatic region
Electrolyte density,
Climatic region (mounthly air temperature 0 3
Season to plus 25 С, g/см
in January, C
filled В конце зарядки
Very cold with temperature from minus 50 to winter 1,28 1,30

minus 30 summer 1,24 1,26
Cold from minus 30 to minuc 15 all year 1,26 1,28
Moderate from monus15 to minus 8 all year 1,24 1,26
Hot dry from minus 15 to plus 4 all year 1,22 1,24
Warm moist from 0 to plus 4 all year 1,20 1,22
Notice - the deviation of the electrolyte density on plus 0,01 гg/sm3 Is supposed.
To refill of one battery type 6СТ-190 it is required 12 l of electrolyte. Electrolyte prepares from sulfuric
battery acid and distilled water in utensils, rack against sulphuric acid - ceramic, plastic, deflate ebonite, lead.
In utensils water all over again is filled in, then at continuous stirring sulphuric acid. For deriving electrolyte of
the corresponding density it is necessary to be guided by table 12.7.
Table 12.7 – Ratio between electrolyte density, water amount and sulfuric acid in 1 l of the electrolyte
0 3 0 3
Required electrolyte density at 25 С, g/sm 25 С, г/см 1,20 1,22 1,24 1,26 1,28 1,40
3
Amount of the sulfuric acid the density 1,83 г/см , л 0,200 0,221 0,242 0,263 0,285 0,426
Water amount 0,859 0,839 0,819 0,800 0,781 0,650
The temperature of the electrolyte which is filled in the battery, should be not less plus 15 0С and no
more plus 25 0С in regions with cold and temperate climate and no more plus 30 0С in regions with the tropical
climate.
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Before refuel of electrolyte to turn out from the battery the fuse and to remove from them film closing the
vent, and to cut off a protuberance at the fuse end . If instead of film and protuberance the sealing disk under
fuse is applied, to delete it. After filling the battery by electrolyte vents should remain open.
To fill in electrolyte until the surface of electrolyte will not touch the lower end of the tube of neck. At the
tube absence to fill in electrolyte up to the level on 10 - 15 mm higher welding shield.
Later 20 mines but not later than through 2 hour after electrolyte filling to check its density. If the density
of electrolyte will decrease no more than for 0,03 g/sm3 against the density of filled electrolyte batteries can be
handed over in maintenance.
If the density of electrolyte will be reduced more than on 0,03 g/sm3 batteries are necessary to charging.
The temperature of electrolyte in battery before charging should be no more than 30 0С in cold and mod-
erate zones and no more than 35 0С in hot dry and warm wet zones. If temperature of electrolyte more speci-
fied, it needs to be cooled.
For charging the positive side of the battery is connected to the positive pole of the current source, and
negative - to negative.
The strength of charging current is established depending on the charging condition. The following
charging conditions storage batteries are applied:
charging the new or repaired storage batteries (first charging). For dry charging batteries the charging
current - 19 amp;
- next batteries charging while in service (boost charge). Charging current - 19 amp.;
- control-conditioning cycle or the warning of sulphation plates (recharge). Charging current - 19 amp.
To charge the battery it is necessary until the ample effervescence in all elements of the battery will oc-
cur, and the density of electrolyte and voltage will stay fixed within two hours. If the temperature of electrolyte
0
appears more than 45 С it is necessary to reduce charging current half or to interrupt charging for the while,
necessary for reduction of temperature up to 30 - 35 0С. Batterie voltage to inspect the voltage meter with the
scale on 30 V with scale interval of 0,2V.
In the end charging, if the density of electrolyte gauged in view of the temperature correction (table
12.8), will differ from norm to modify the electrolyte density . The distilled water is add at thus, if the electrolyte
density more norm, and the acid of the density 1,4 g/sm3 is refilled, if it less norm.
After the adjustment of the electrolyte density to continue batteries charging on 30 minutes to complete
hashing electrolyte, and then batteries to disconnect. Later 30 minutes after batteries switching-off to measure
the electrolyte level in all accumulators of the battery.
Table 12.8 temperature corrections to the electrolyte density

0 3
Electrolyte temperature at the density change, С Corrections to the areometer indication , g/sm
From minus 55 to minus 41 minus 0,05
From 40 to minus 26 minus 0,04
From minus 25 to minus 11 minus 0,03
From minus10 to minus 4 minus 0,02
From minus 3 to plus19 minus 0,01
From plus 20 to plus 30 0
Trom plus31 to plus 45 0,01
From plus 46 to plus 60 0,02
0
Notice- at the electrolyte temperature more plus 30 С the correction is added to the actual indication of the areometer, at the t
0
temperature less plus 20 С - is subtracted.
If the electrolyte level will be less norms, to add in the accumulator electrolyte the density what is speci-
fied in table 12.6. At the electrolyte level more norms the electrolyte excess to select at the rubber bulb.
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12.3.2 The storage batteries possible faultiness

The following faultiness of the storage batteries at the service are possible:
Plates sulphation. The sulfate presence in the accumulator can be defined to the following attributes:
- sharp voltage drop at the operative starter;
- at the voltage metering by accumulator tester the voltage meter arrow is not retained during 5sec. in
limits 1,8 - 1,85 V and deflects below division 1,7 V;
- at the charging the voltage is increase and began the gassing;
- presence of the white bloom on negative plates (sulphation).
The white bloom is formed on the surface of positive plates at the strong sulphation. In case of the plate
strong sulphation (if there is such opportunity) it is necessary to replace on new, otherwise such accumulator is
unsuitable to the further maintenance and is subject to replacement
Short circuit inside the accumulator which attributes are:
- early electrolyte temperature increase and the weak gas emission in the charging process ;
- significant voltage reduction at short-lived dischargings.
The short circuit removal is possible only at complete disassembly of the storage battery.
Breakage of output pines. The element with the torn pin is defined with the help of the voltage meter of
the discharge tester (at not to powered loading) serial the control of the accumulator battery elements. In the
element with the torn pin the voltage meter arrow does not deflect.
12.3.3 The repair work which is not requiring the disassembly of the storage battery
For removal of outside damages of the storage battery it is necessary to merge electrolyte and to en-
close apertures of jars fuses.
Cracks in acid-proof mastic are eliminated by heating of mastic to such condition when it fills in the
crack. It is not recommended to apply to heating mastic the blow lamp or other heating means with open flame.
At the leak of electrolyte through the slot covers dress by screw-driver, fill by mastic and smooth by the
hot blade. If electrolyte dribbles at the terminal block pins, delete mastic around of the pin and solder up its
connection with by the cover. After that the place around of the pin again fill up by mastic and smooth down by
the hot blade.
The broken off interelement crosspieces solder by the carbon. In the place of the crosspiece connection
by three-square file cut the flute on all width. Under the crosspiece put the strip of the tin which cleaning cloth
turn up up so that they densely joing to the crosspiece and have formed the tray. The crosspiece end fuse with
the help of the carbon which through the special header is connected to the positive pole of the current source.
Alternatively of the source of the electric power it is possible to use the storage battery. For complete the weld
filling add the lead. In the soldering time do not suppose formation of the electric arc between lead and the coal
rod.
Strongly injured crosspiece replace by new for what a special hob drill a ring bore around of the lead-out
dowel and remove a web.
New web dress on on lead-out dowels, notched on the ends, and then space between each dowel and a
web fill up with the melted lead.
Removal of the insignificant sulphation make in the following sequence:
- unload the storage battery by current 17,4 amp. at the
ten-hour condition up to the voltage
1,7 V in each element (Figure 12.1);
Figure 12.1 – Discharging circuit of the storage battery
- merge electrolyte and fill up with distilled water or the

weak solution of sulphuric acid (densities 1,04 - 1,06);
- charge the battery by current 3,5 - 4 amp.. If in charging
time the electrolyte temperature it will be raised up to plus 45 0С,
the charging interrupt and give the storage battery to be cooled up to normal temperature. When the electrolyte
density will reach 1,15, fuse it, then again fill up by distilled water or the weak solution of sulphuric acid and
continue charging.
The charging and the electrolyte gang to manufacture until the electrolyte density will cease to raise
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12.4 Repair and service of the alternator

On dump trucks BELAZ - 75145, 75131 alternator is delivered together with the engine. At repair and
service of the alternator it is necessary to use the documentation affixed to the engine.
On dump trucks BELAZ - 7514-10, 76132 the three-phase synchronous alternator 631.3701 (figure
12.2) with built-in rectifier blocks is installed.
Alternator technical data
Rated power, W………………………………………………………………………………. 4200

Rated voltage, V…………………………………………………………………………….... 28
Rectifier current, А……………………………………………………………………….…… 150
о -1
Armature speed at an ambient (25 + 10) С rpm no more than , min :
at load current of 80 A……………………………………………………………….. 1850
at load current of 150A………………………………………………………………. 2350
Overfrequency speed of the rotary alternator, rpm……………………………………... 8000 + 400
Exciting current, А………………………………………………………………………….… 3,5 + 0,2
Force of brush holder springs compressed to heit of 14,5 mm …………………………. 3-4
Brush model…………………………………………………………………………………... М1А
Minimum permissible brush height , mm …………………………………………………. 8
Alternator weight (without sheave),kg, no more…………………………………………. 22
Figure 12.2 – Alternator:

1 – brush holder base; 2,25 –nut of the terminal outlet, 3 – brush holder; 4, 18, 21, 26 - screw; 5 - stuffing box; holder ; 6 - stuffing
box; 7 - cover on the rings part; 8 - exciting winding; 9 - rotor halfs; 10 - stop ring; 11 - cover from drive end; 12 - bolt; 13, 22 - bearings;
14 - barrel; 15 - tab; 16, 27 - nut; 17 - sheave;19 - fan; 20 - stator; 23 - diodes block; 24 - housing; 28 - slip ring
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7513-3902080 RM
12.4.1 Alternator disassembly

Alternator disassembly to manufacture in the following sequence:
- turn off screws of strengthening of housing 24 (Figure 12.2);
- turn off nuts 2, 25, strengthenings of outputs "plus", "Ш", "0";
- turn off screws 4, strengthenings of brush-holder 3;
- to remove brush-holder 3 with sweepers;
- to remove housing 24;
- turn off screws, 26 strengthenings the grounding of a brush-holder 1 to a cover 7 to remove the
grounding of a brush-holder;
- turn off a nut 27 on the shaft on the part of slip rings, preliminary having unbent a protuberance of a
lock washer;
- turn off a nut 16 on the shaft from a drive end and to remove a sheave 17;
- to remove the fan 19 and a tab 15;
- turn off three handrail bolts 12;
- turn off three phase outputs of a stator winding from the internal block;
- to remove a cover 7 on the part of slip rings a remover, resting on a butt of the shaft of a rotor and in-
flow under coupling studs on a cover;
- turn off three phase outputs of a stator winding from the external block;
- to remove a stator 20;
- to remove a cover 11 from a drive end from the shaft of a rotor a remover or on press, a method of a
release of a rotor from a cover;
- turn off screws of strengthening of the bearing 18 in a cover from a drive end and squeeze the bearing 13
and the barrel 14;
- turn off screws of strengthening of the bearing 21 in a cover on the part of slip rings and squeeze ь the
bearing 22;
Before assembly to put in pawn in bearings the lubricant №158, Литол 24.
Assembly of the alternator to manufacture in sequence to inverse disassembly with observance of the
following demands:
- pressure on sweepers at squeeze of a spring up to 14,5 mm 3 - 4 N;
- altitude of sweepers from a spring up to the grounding of a sweeper not less than 8 mm.
12.4.2 Alternator technical state after repair

After repair of the alternator to lead control inspection of a critical parameters under the circuit, reduced
in figure 12.3, on the special stand providing a smooth variation of a rotor speed of the alternator up to
-1
5000 min . Mustered parameters should match to a technical data.
Figure 12.3 -Circuit for inspection of alternator electric performances:

G - alternator; R1, R2 - resistance of loading; S1, S2, S3 - cutout switches; А1, А2 - ammeters, V1, V2 - voltage meters; O, "+", Ш
- outputs, ИПТ - constant-current source
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12.5 Repair and service of of external and internal illumination system

To a lighting system and a light alarm treat: main headlights, dipped headlights, fog lights, side lights, tail
lights, a headlight of a trailing side, a headlight of illumination of the chassis, a headlight of a motor chamber, a
headlight of illumination of side space, side indexes of turning movements, lamps of illumination of scales of
gears, plafonds, подкапотные lamps of illumination of the cabinet of a low-voltage electrical equipment, indi-
cating lamps of turning on of a high beam, excessive heating of traction motors, wear of guards of the traction
electric drive, emergency temperature of a cooling fluid, from a flood of the fuel, two blocks of indicating lamps,
the socket connection of a droplight.
During a service and repair of system of external and internal illumination make (if necessary) substitu-
tion of failed gears of illumination and a light alarm.
12.5.1 Light headlights adjustment

Headlights with European asymmetric light distribution the lower beam give the sharp boundary between
light and dark zones of light spots on the covered part of road. Therefore it is necessary to regulate rather
carefully position of light spots to not blind the drivers of opposing transport.
Before to regulate light of headlights, it is necessary to test performances of cylinders of the suspension
bracket and an air pressure in trunks and in case of need to finish mustered parameters with required mean-
ings.
Operation to execute using special gears or the shield marked according to Figure 12.4. Parameters
meanings are reduced in Table 12.9.
Figure 12.4 - Shield sectoring circuit of the headlights light adjustment:

I-I, II-II - lines of the centers of the lower headlights; III-III - line of the centers of light spots of the lower headlights; IV-IV,
V-V - lines of the centers of the upper headlights; V1-V1 - line of the centers of light spots of the upper headlights; 0-0 - line of the center
between headlights; Н - distance from a floor up to the center of the lower headlights; Н1 - distance from a floor up to the center of the up-
per headlights; h - distance from the center of the lower headlights up to the centers of light spots; h1 - distance from the centers of the
upper headlights up to the centers of light spots; and - distance from a shaft of a dump truck up to the centers of the lower headlights;
а1 - distance from a shaft of a dump truck up to the centers of the upper headlights
Table 12.9 – Parameters values
Screen sizes
Dump truck mark Lower headlights Upper headlights
H h a H1 h1 a1
BELAZ-7514-10 1375 345 1450 1875 280 1830
BELAZ-75145 1380 345 1100 3160 473 2740
BELAZ-75131, BELAZ-75132 1460 320 630 2370 250 2750
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Operation to execute in the mentioned below sequence:

Operation of resetting of headlights light to execute, using special gears or the shield (portable or sta-
tionary).
- install an empty dump truck on a horizontal platform so that its direct-axis it was perpendicular to a
plane of the shield and coincided with axle 0-0, and the distance from the shield up to scatterers of the lower
headlights made 10 m;
-on the shield to lead two verticals I-I and II-II according to distance from a direct-axis of a dump truck up
to the centers of the lower headlights;
- lead a horizontal line at a level of altitude of the centers of headlights from a platform;
- lead second horizontal line III-III on distance h lines of the centers of headlights are lower;
- switch on a passing beam of the lower headlights and serially (one headlight to enclose a light-tight
material) screws of a horizontal and vertical adjustment to achieve, that the boundary of the covered and dark
sections coincided with line III-III, and slant restrictive lines started with crosspoints of line III-III with lines I-I
and II-II.
The upper headlights are regulated on a high beam for the same position of a dump truck concerning
the shield. The centers of light spots of the upper headlights should coincide with crosspoints of lines IV-IV and
V-V With line VI-VI.
Regulating of light of fog lights is made so that light was symmetric concerning a shaft of a dump truck
and the center of a light stain attained a ground on distance of 20 m.
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12-14
Power takeoff and cardan shaft
7513-3902080 RM
13 POWER TAKEOFF AND CARDAN SHAFT

13.1 Power takeoff
13.1.1 General information
The power takeoff is intended for actuation of pumps of united steering hydraulic system, brake systems
and dumping mechanism, the engine speed transducer at the system of automatic regulation of traction elec-
tric motor, conditioner compressor and low-voltage generator (for the truck BELAZ–7514-10).
The actuation of the takeoff is performed from the hub of traction generator fan by cardan shaft.
In view of usage of pumps «Вosch Rexroth» pulley at the hydraulic system of trucks BELAZ–75131,
BELAZ–75132 from the April 2002 the power takeoff is canceled.
The power takeoff of truck BELAZ–7514-10 and BELAZ–75145 is installed on the truck chassis frame
brackets on rubber pads 6 (figure 13.1 and 13.2). Pads are rested on brackets 3 and 4, rigid fastened to the
power takeoff case and inner side of the frame rails.
The power takeoff (figure 13.3 and 13.4) is the countershaft reducer with spur pinions. All pinions of the
power take off are in constant mesh, so the aggregates, actuating from the power takeoff under the operative
motor, permanently work.
Technical state of the power take off is determined in the operation process:
– external examination;
– orally ( operation noisiness);
– over heat .
By the external examination over oil leakage you can find out the wear-out or damage of glands, packing
rings and collars. Orally you can find out random breakdowns or weakening of parts fastening. Over heat you
can define abnormal performance of bearings or change of oil level at the reducer.
13.1.2 Repair of power takeoff

13.1.2.1 Removal of power takeoff from the truck
Realize removal of power takeoff from the truck in the following way:
– start motor, lift the platform to the extreme upper position and stop it ;
– muffle motor;
– drain the oil out off the takeoff , having unwrenched drain plug;
– shut the flap on oil tank of the united hydraulic system, for exclusion of oil leakage under the detach-
ment of suction hoses from pumps;
– detach the hoses from pumps;
– disconnect cables from the motor speed transducer and generator ( for power takeoff of the truck
BELAZ–7514-10);
– take off generator, pumps and speed transducer;
– detach the flange of cardan shaft from flange of rower takeoff;
– dissplint and unwrench the nuts of power takeoff fastening to the frame chassis brackets;
– fasten the power takeoff by suspension (figure 13.5), take out bolts and bushes, take off the power
takeoff from the truck and mount to the stand (figure 13.6) or stand (figure 13.7) for disassemblage.
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Figure 13.1 —Mounting of power takeoff of the truck BELAZ–7514-10 (view from the side of back axle,
profile А-А and Б-Б shown on the figure 13.3):
1 – plug of filter hole; 2 – pump; 3, 4 – brackets; 5 – adjustment gasket; 6 – support pad; 7 – sleeve; 8 – adjustment washer;
9 - power takeoff ; 10 – plug of drain hole; 11 – plug of locating hole
Figure 13.2 — Mounting of power takeoff to the truck BELAZ–75145 (view from back axle side,
profile А-А and Б-Б are shown on the figure13.4):
1 – plug of filter hole; 2 – pump; 3, 4 – brackets; 5 –adjustment gasket; 6 –support pad; 7 – sleeve; 8 –adjustment washer; 9 plug
of locating hole; 10 –power takeoff; 11 – plug of drain hole
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Figure13.3 —The power takeoff of the truck

BELAZ-7514-10 (see section places on the figure 13.1):
1 – case; 2, 8, 12, 18, 19, 45, 55, 59 – bearings;
3 – spline bush; 4 – coupling bush; 5 – reducing ring; 6 – gear of
pump drive; 7 – flange of pumpНШ-10Е fastening; 9, 17, 22, 24,
27, 35 – distance bushes; 10 – spline bush of pump НШ-10Е
drive; 11 – flange; 13, 42, 53 – collar; 14, 39, 43 – spacer rings;
15 – thrust washer; 16 – back cap of drive shaft; 20 – reducing
bush; 21 – countershaft; 23, 28, 38, 40, 49, 51 – caps; 25 – shaft
of generator drive; 26 – gear of alternator drive; 29, 32,
58 – keys; 30 – drive pulley; 31 - reflector; 33 – cap of counter-
shaft; 34 – gear of countershaft; 36 – gear of pump drive;
37 – shaft of pump НШ-100 drive; 41 – sleeve; 44 – drive shaft;
46 – drive gear; 47 – shaft of pump drive; 48 – spacer ring;
50 – flange-pulley; 52 – shaft of fan drive; 54, 56 – spacer
bushes; 57 – gear of fan drive; 60 – cap of fan drive shaft
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Figure 13.4 —Power take off of the truck BELAZ–75145

(place of section see on figure 13.2):
1 – case; 2 – reducing ring; 3, 11, 18, 24 – bearings;
4, 13 – spline bushes; 5 – coupling bushing; 6 – flange;
7 – back cap of driving shaft ; 8, 26 – collars; 9, 20 – thrust
washer; 10, 19 – spacer rings ; 12 – reducing flange of pump
fastening; 14 – distance bush; 15 – gear of pump drive;
16 – shaft of pump НШ-100 drive ; 17 – flange-pulley;
21 – drive shaft; 22, 25, 33 – caps; 23 –; driving gear
27 – sleeve; 28 – shaft; 29 –gear; 30 – key; 31, 32 – spacer
sleeves
Figure 13.5 — Suspension 7808-6452 for fastening

of power take off :
1 – hook; 2, 4 – chain; 3 – cross-arm; 5, 6 – ring
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13.1.2.2 Disassemblage of power takeoff
Realize disassemblage of power takeoff of the truck BELAZ–7514-10 in the following way:
– take off the case cap with lining, having unwrenched the nuts of its fastening;
– take off pumps НШ-100 ( 3 units), having unwrenched bolts of pump fastening to the case ;
– take off reducing ring 5 (see figure 13.3), spline bushes 3, coupling sleeves 4;
– take out the sealing ring from the slots of each reducing ring;
– take off locking rings from spline bushes;
– take off cap 38 with lining, having unwrenched fastening bolts, take out the distance sleeve35;
– squeeze from the side of cap 38 the shaft of pump 37drive with bearing 18 and the distance bush 17;
– crimp from shaft 37 the bearing 18 and take out the distance bush 17;
– take out of case the gear of pump 36 drive the distance sleeve 17 and bearing 18;
– dissplint and unscrew the nut on shaft 25 of alternator drive, remove washer, gasket and sealing ring;
– take out pulley 30 from the shaft, extract key 29;
– take off cap 28 with packing ring, having unwrenched bolts of its fastening ;
– take off baffler 31;
– take off cap 23 with packing ring, having unwrenched bolts of its fastening;
– squeeze from side of cap 23 the shaft 25 of alternator drive with bearing 19, distance bush 27;
– crimp from the shaft 25 the bearing 19, take off distance bush 27;
– extract from case the gear 26, distance bush 24 and bearing 19;
– take off cap33, having unwrenched the bolts of its fastening;
– take off the reducing bushes 20 with packing rings from the both sides of countershaft 21;
– squeeze the countershaft 21 with bearing 19;
– crimp from the shaft 21 the bearing 19 and take off the key 32;
– extract from the case the bearing 19, the distance bush 22 and the gear of countershaft 34;
– dissplint and unscrew bolts of thrust washer 15 fastening;
– take off thrust washer with gasket;
– take off from drive shaft 44 the flange 11;
– take off the cap 16 of drive shaft with gasket, having unwrenched bolts of its fastening ;
– squeeze from cap 16 the collars 13;
– unscrew bolts and take off the motor speed transducer;
– unscrew bolts 40 and take off the cap with gasket;
– squeeze from cap 40 the collar 42;
– squeeze from the case from the side of cap 16 the drive shaft 44 with bearing 45 and distance rings 43
and 39;
– take off from the shaft the spacer ring39;
– crimp from the shaft 44 the bearing 45 and take off spacer rings 43;
– squeeze from the case the bearing12;
– extract from the case the drive gear 46 and spacer ring 14;
– take off pump НШ-10, having unwrenched bolts of its fastening;
– take off flange 7 of pump fastening, having unwrenched bolts of its fastening , with lining;
– take off spline bush 10 of pump НШ-10 drive;
– take off cap 49, having unwrenched bolts of its fastening, with lining ;
– extract the spacer ring 48;
– squeeze the shaft 47 with distance sleeve 9 and bearing 8;
– crimp from the shaft 47 the bearing 8 and remove distance sleeve 9;
– extract from the case the gear 6 ,bearing 8 and distance sleeve 9;
– squeeze the shaft 37 of pump НШ-100 drive with bearing 2 and distance sleeve 17;
– crimp from the shaft 37 bearing 2, remove distance sleeve 17;
– extract from the case the gear of pump 36 drive, bearing 2 and distance sleeve 17;
– dissplint and unwrench the nut on shaft 52 of fan drive, remove washer;
– take off flange –pulley 50 from shaft;
– take off cap 51, having unwrenched bolts of its fastening ;
– squeeze from cap the collar 53;
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– take off from shaft 52 the distance sleeve54;

– take off cap 60 of fan drive shaft with lining, having unwrenched bolts of its fastening;
– squeeze shaft 52 with bearing 59 from the cap 51 side;
– take out from case the gear 57 of fan drive and distance sleeve 56;
– take out key 58 from the shaft 52 slot;
– take off stop ring and crimp from the shaft journal the bearing 59;
– squeeze from case the bearing 55.
Carry out the assemblage of power takeoff of the truck BELAZ–75145 according to the figure13.2 and
13.4 similarly to the power takeoff of the truck BELAZ–7514-10, discussed above.
13.1.2.3 Checking of technical state of power takeoff parts

Nominal and maximum dimensions of the main parts of power takeoff are shown at the table 13.1.
Table 13.1 — Nominal and maximum dimensions of the main parts of power takeoff of trucks
BELAZ–7514-10 and BELAZ–75145
Number, part designation and con- Dimensions, mm

Material Hardness
trolled variables nominal maximum
7512 – 4202015 IronСЧ-25
751257 – 4202012 Steel 25
Casing:
Diameter of the bearing holes of gen- +0,022
erator actuator shaft and countershaft 90
−0,013 90,04
Diameter of the bearing holes of pump

drive shaft НШ-100 +0,041
140 140,05
− 0,022
Diameter of the bearing holes of drive
+0,027
shaft 150 150,05
Diameter of the bearing holes of pump − 0,014
drive shaft НШ-10
+0,035 120,045
Diameter of the bearing holes of fan 120
drive shaft and motor speed trans-
ducer
+0,035
100 100,045
549Б – 4202026
Drive shaft:
External spline diameter 60 + 0,01 59,97 Steel 40Х НВ 321 – 375
−0,03
Spline thickness 9
− 0,09 8,8
549А – 4202020
Cement
Driving gear: −0,118 68,8 h 1,4 – 1,8
69,154 Tooth face
−0,178
Steel 20ХН3А
НRС 59 – 65
+0,06 Tooth core
Width of spline cavities 9 9,20 НRС 26
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Material Hardness
549А – 4202064-10
Pump drive shaft НШ-100 +0,025
Diameter of bearing journal 90
+ 0,003 89,99
Spline thickness −0,040 Steel 40Х НRС 37 – 42

14 13,85
− 0,075
+0 , 5 26,80
Length of the common tooth normal 26,81
+ 0 ,3
549А – 4202088
Spline bush −0,3
− 0, 5 18,60
Cement
h 0,7 – 0,9
+0,045 Steel 20Х
Width of spline cavities Tooth face
7 7,10 НRС 55 – 63
Sphere diameter 55-0,05 54,80
549А – 4202132-10
Coupling bushing +0,5
Length of the common tooth normal 19,16 285 – 321 НВ
+ 0, 3 19,35
Nitrogenize
Steel 40Х h 0,2 – 0,6
Length of the common tooth normal −0,3 Tooth face
25,8 25,10
− 0,5 HV 580
Sphere diameter 75-0,05 74,80

549А – 4202068
Cement
Gear of pump drive −0,098 h 1,4 – 1,8
Length of the common tooth normal 54,113 Tooth face
−0,158 53,80 Steel 20ХН3А
НRС 57 – 65
+0,07 Tooth core
Width of spline cavities 14 14,20 НRС 28 – 44
549А – 4202078
Cement
−0,158 53,80 Steel 20ХН3А
НRС 57 – 65
+0,06 Tooth core
75125 – 4202068-10
Cement
−0,178 84,00 Steel 20ХН3А
НRС 57 – 65
+0,07 Tooth core
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Material Hardness
75491 – 4202172
Shaft of pump drive +0,021
Diameter of bearing journal 65 Nitrogenize
+ 0,002 64,90 h 0,2 – 0,4
Tooth face
Spline thickness −0,03 Steel 40Х
12 11,80 НV 380
− 0,09 Tooth core
НRС 32 – 37
+0,288 43,10
Splines, size by rollers (roller diameter 42,621
+0,162
3,5 mm)
75491 – 4202178
Nitrogenize
Spline shaft +0,048 h 0,2 – 0,4
Spline width 3,5 Tooth face
3,40 Steel 40Х
НV 380
−0,125 Tooth core
Splines, size by rollers (roller diameter 54,218 53,80
4 mm) −0,222 НRС 32 – 37
549А – 4202106-30
Countershaft +0,017
+ 0,002 29,99 Steel 45 241 – 321 НB
Width of key slots −0,010

6 6,00
− 0,055
549А – 4202108
Cement
Pinion of countershaft −0,098 h 1,4 – 1,8
−0,158 53,40 Steel 20ХН3А
Tooth face
НRС 59 – 65
Width of key slots +0,065 Tooth core
6 6,10
+ 0,015 НRС 28 – 44
549Б – 4202128-30
Shaft of generator drive
Spline thickness 6
−0,048 5,90
Diameter of bearing journal +0,015 Steel 40Х НRС 25 – 36

30 29,99
+0,002
8 8,00
−0,065
549А – 4202134-10 Cement

Gear of generator drive h 1,1 – 1,5
−0,071 Tooth face
−0,131 23,70 НRС 59 – 65
Steel 20ХН3А Tooth core
+0,070
6 6,12 НRС 28 – 44
Width of spline cavities + 0,022 Spline face
НRС 26
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Material Hardness
7519 – 4202412
Fan drive shaft
Spline thickness 6
−0,048 5,90
Diameter of bearing journal +0,023 Steel 40Х НВ 241 – 285

45 44,99
+ 0,003
−0,020 12,0
Width of key slots 12
− 0,075
751257 – 4202412
Shaft
Diameter of gear planting 50 + 0,008 49,97
+0,018 Steel 40Х НВ 241 – 285
+0,002 44,99

12 12,0
− 0,075
75145 – 4202422
Cement
Gear −0,118 h 1,4 – 1,8
−0,178 84,35 Steel 20ХН3А
НRС 59 – 65
+0,085 Tooth core
12 12,20 НRС 28 – 44
Width of key slots + 0,025
7521 – 4202422
Cement
Gear of fan drive −0,098 h 1,4 – 1,8
−0,158 53,30 Steel 20ХН3А
НRС 59 – 65
+0,085 Tooth core
Width of key slots 12 12,20 НRС 28 – 44
+ 0,025
13.1.2.4 Assemblage of power takeoff

Realize the assemblage of power takeoff of the truck BELAZ–7514-10 in the following way:
–prepare and give the kit of parts, intended for assemblage, to the assemblage place. Clean foul places
by clear rag, flush air. Unpack bearings before direct mounting of them into the unit. In case of packing fault
detection wash the bearings in kerosene;
–mount onto the casing the brackets 3 (see figure13.1) and fasten by bolts (torque from 180 to 300
N.m.) with washers ;
–fasten the casing of power takeoff, assembled with brackets, by suspension (figure 13.5) and install
onto stand (figure 13.6) or onto stand- turner (figure 13.7).
Stand (figure 13.6) for power takeoff assemblage consists of the following main parts : driving 7 and
non-driving 5 rests, cramp 4 with hydrocylinder, carriage 3, cantilever rest 2 and hydro station 1. The body of
power takeoff is mounted onto the brackets, fastened on spindles of rests 5 and 7and tightened by bolts. The
built-up of pinions and bearings is realized with the help of hydro cramp 4 suspended on cantilever rest 2. For
ease of assembling the body of power takeoff can be rotated and fixed in any position. Rotation control is real-
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ized by means of push-button station on driving rest. Cramp control is realized by means of button station inte-
grated into the cramp handle.
Stand-turner (figure13.7) is intended for turning of power takeoff body under assemblage. The turn is re-
alized under the rotation of handle 8 of reducer 2;
– built up to the countershaft 21 (see figure 13.3) the bearing 19 up to the stop into the face of shaft
shoulders;
– mount the semicircular key 32 into the slot of countershaft 21;
– mount into the case the pinion gear of countershaft 34;
– insert the countershaft, assembled with key, into the power takeoff case cavity and having united the
pinion gear slot with key, put the gear on to the shaft against stop;
– insert bearing 19, pressed onto the countershaft, into the case cavity;
– install into the reducing sleeve20 the gasket and, having united the slots in reducing sleeve and case ,
install reducing sleeve into the case flush with case face;
– install cap of countershaft 33 and fasten by bolts with washers;
– install onto the shaft the distance sleeve 22;
– mount bearing 19 into the case opening and built up onto the countershaft 21 and into the case;
– install into the reducing sleeve 20 the gasket, having united the slots at the reducing bush and case,
mount reducing bush into the case hole flush with the case face;
– mount onto the generator drive shaft 25 the distance sleeve 24 and built up the bearing 19 flush with
shaft face;
Figure 13.6 — Stand СБ-50 for dismantling and assembling of power takeoff:
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1 – hydrostation; 2 – cantilever support; 3 – carriage; 4 – cramp with hydrocylinder; 5 – idler support; 6 – power takeoff; 7 – hom-
ing support
Figure 13.7 —Stand -turnerСБ-9 for dismantling and assembling of power takeoff:
1 – pan; 2 – reducer ; 3 – left tenon; 4 – power takeoff; 5 – right tenon; 6 – frame; 7 – tap; 8 – handle
– mount on the shaft of generator drive, assembled with bush and bearing, into the case hole of the
power takeoff and press bearing;
– mount on the cap 23 rubber ring and , having united cap holes with case holes, fasten cap by bolts
with washers;
– mount on the splines of generator drive 25 shaft the pinion gear of generator drive 26 shaft, introduc-
ing it into the engagement with gear of countershaft 34;
– mount on the shaft of generator drive the distance bush 27;
– mount bearing 19 on to the shaft of generator drive and press the bearing onto the shaft and into the
case up to stop into the distance bush 27;
– built up onto the shaft of generator drive the reflector 31up to the stop into bearing;
– mount on the cap 28 rubber ring and , having united cap holes with case holes, fasten cap by bolts
with washers;
– mount key 29 into the slot of generator drive 25 shaft and , having united the slot in the driving pulley
30with key, mount pulley on shaft up to stop;
– fasten the pulley on shaft by castellated nut with washer, previously having placed on the shaft the
rubber ring, and the lining under washer, and stop the nut on shaft by splint;
– press up to stop on to the shaft of fan 52 drive the bearing 59and fasten by stop ring , having put the
ring into the slot on shaft;
– place the key into the slot of fan drive shaft;
– place the gear of fan 57 drive shaft into the case opposite the hole under plant;
– insert the shaft of fan drive, assembled with bearing and key, into the hole of takeoff case and press
the bearing into case, having united the gear groove with the key on shaft ;
– place onto the takeoff case in series the lining and cap of fan 60 drive shaft, having united the holes,
and fasten cap by bolts with washers;
– place into the bearing 55 groove the stop ring;
– put gear 57 up to stop into the face of fan 52 drive shaft;
– place onto the fan drive shaft the spacer bush 56, bearing 55, assembled with the stop ring, and press
bearing up to the stop;
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– place onto the shaft the spacer bush 54;

– place on the takeoff case in series the lining and cap 51, previously having pressed into the cap the
collar 53, and, having united holes , fasten cap by bolts with washers;
– mount flange-pulley 50 onto the splines of fan drive shaft up to stop into the spacer bush, fasten the
flange-pulley by castellated nut with washer and stop the nut on the shaft by splint;
– press into the drive shaft 44 the bush 41 for drive of motor speed transducer;
– press into the cap 40 the collar 42;
– mount onto the drive shaft 44 four spacer rings 43 and press the bearing 45 up to stop;
– place the drive gear 46 inside case, insert the drive shaft, assembled with bearing, into the case hole,
previously having installed between gear and bearing the spacer ring 39 and ,incorporating into engagement
the driving gear with gear of fan 57drive,press bearing;
– place onto the case the lining, the cap 40 with pressed into it collar 42 and , having united the holes
,fasten cap by bolts with washers;
– put the driving gear 46 up to stop into the spacer ring 39;
– place the stop ring into the bearing groove 12;
– place onto the driving shaft 44 the spacer ring 14, the bearing 12, assembled with the stop ring, and
built up bearing onto the shaft and into the case up to stop of the locking ring into case;
– press into the cap of driving shaft 16 two collars13;
– mount onto case of takeoff the bearing, the cap of driving shaft with collars, and having united the
holes, fasten cap to case by bolts with washers;
– place on the splines of drive shaft 44 the flange 11;
– place onto the shaft face in series lining, thrust washer 15, unite holes and fasten flange by bolts with
washers;
– place onto shaft 37 of pump НШ-100 drive the distance bush 17 and press onto the shaft journal up to
stop the bearing 18;
– place inside case the gear of pump 36 drive, incorporating it into the engagement with gears 46
and 34;
– place the shaft 37 of pump НШ-100 drive, assembled with bush and bearing, into the case hole and,
pressing the bearing from side of pump mounting, put gear on shaft splines;
– place into the ring groove of reducing ring 5the rubber ring;
– mount the reducing ring into the case hole flush with case face;
– mount onto the reducing ring the technological plug and fasten it by bolts with washers;
– mount onto the shaft 37 of pump НШ-100 drive the distance bush 17, place the bearing 18 into the case
hole and press it on the shaft and into the case up to stop into the hole of distance bush;
– mount the distance sleeve 35 into the case hole, place cap 38 and , having united the holes at the cap
and case , fasten cap by bolts and washers, previously having installed under cap the lining;
– mount on the shaft 37 of pumpНШ-100 drive the distance bush 17 and press onto the shaft journal up
to stop the bearing 2;
– place inside case the gear of pump 36 drive;
– mount the shaft of pump НШ-100 drive , assembled with bush and bearing , into the case hole, and
pressing bearing, put the gear on the shaft splines;
– place into the ring groove of reducing ring 5 the rubber ring;
– put the gear of pump 36 drive on the shaft 37 splines of pump НШ-100 drive up to the stop into dis-
tance sleeve 17 face ;
– place onto the shaft 37 of pump НШ-100drive the distance sleeve 17 and , having put bearing 18 into
the case hole, press it into the body and on shaft up to stop into the face of distance sleeve;
– place into the ring slot of reducing ring 5rubber ring;
– mount on to the shaft of pump 47 drive the distance bush 9 and press onto shaft journal flush with the
shaft face the bearing 8;
– place inside the case the gear of pump 6 drive, incorporating it into engagement with gears 36 and 46;
– put the shaft of pump 47drive , assembled with bush and bearing, into the case hole, and ,pressing
the bearing, put the gear onto the shaft splines;
– place onto the case the lining, flange 7 of pump НШ-10Е fastening, and having united holes, fasten
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the flange to case by bolts with washers;

– put the gear of pump 6 drive on splines of pump 47drive shaft up to the stop into the face of distance
sleeve 9;
– mount onto the shaft of pump 47 drive the distance sleeve 9, and having put the bearing 8 into the
case hole, press it into the body and on shaft up to the stop into face of distance bush;
– place into the case hole the spacer ring 48;
– place onto the case the lining, cap 49, and having united holes, fasten the cap to case by bolts with
washers;
– screw studs into the power takeoff case, put the cap lining, the case cap by holes on studs and fasten
by bolts with washers;
– screw the drain magnetic plug into the case cap;
– screw into the case the plugs of locating and filter holes.
At the assembled power takeoff the the driving shaft should be rotated evenly, without jam from the
torque not more10 N.m.
Assemble the power takeoff of the truck BELAZ–75145 according to the figures 13.2 and 13.4, analo-
gously to the power takeoff of the truck BELAZ–7514-10 discussed above.
13.1.2.5 Running-in of power takeoff
Carry out running-in of power takeoff in the following way:

– fasten the power takeoff and put onto the stand (figure13.8).
The stand is meant for running-in of power takeoff as an assembly without load. It consists of foundation
8, plate 6, pedestal 7 with mounted on it electric motor 1of power takeoff actuator, two supporting poles 5,
serving for installation and fastening of power takeoff on the stand, plant for clarification and heat of oil , moni-
toring equipment, control equipment, located on the control board 2. Electric drive is united with breaking
power takeoff by means of cardan shaft 3. The rotation is transferred from electric drive through V-belt drive to
the tachometer gauge.
Oil filling of breaking power takeoff is realized through the hose with tap from plant for clarification and
heat of oil. Drainage of oil from case is realized into the capacity mounted inside of stand bed. The oil is trans-
ferred from the capacity to the tank of oil clarification plant;
Figure 13.8 —Running-in stand of power takeoff:

1 – electric motor; 2 – control board; 3 – cardan shaft; 4 – power takeoff; 5 – supporting pole; 6 – plate; 7 – pedestal; 8 – foundation
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– put the technological plugs into the holes for pump plant and gauge of rotational speed;
– join the cardan shaft of stand to the flange of drive shaft of power takeoff and fasten by bolts with
washers ;
– unwrench the drainage magnetic plug and wrench instead of it the drain cock of stand;
– unscrew filter plug and fill the oil ТАП-15В into the power takeoff up to the level of locating hole and
screw plug;
– switch on stand and realize the power takeoff running in. See modes of running in at the table13.3.
Table 13.3 – Running –in modes

Rotation speed of the power Rotation speed of the power
Running-in
Modes takeoff flange of the truck takeoff flange of the truck
-1 -1 time, min
BELAZ–7514-10, min BELAZ–75145, min
1 750 + 50 750 + 50
2 1000 + 50 1250 + 50 10 + 1
3 1500 + 50 1900 + 50
During the running-in control the lack of leaks along places of joints, along body parts, along threaded
and sealing joints, along drain and filling plugs, along breathers and clearance seals. Under oil leaks detection
along threaded joints it’s permitted to mount fasteners on sealant.
The noise level during the running-in should not exceed under the measurement on the distance (150 + 10)
mm:
– 98 dB on the mode 1;
– 105 dB on the mode 3.
Under that the external noise level on the place of measurement shouldn’t exceed 86 dB.
The oil temperature at the running-in shouldn’t be more 75 0С.
After the running-in drain off the oil from the power takeoff.
13.1.2.6 Mounting of pumps and speed transducers

Realize mounting of pumps and speed transducers in the following way:
– remove technological plugs;
– place into the slots of spline bush 3 (see figure 13.3) two stop rings;
– place spline bushes onto the pump НШ-100 shafts up to the stop;
– place onto the spline bushes 3 coupling bushes 4 up to the stop into the stop rings;
– place pumps onto the takeoff , introducing into engagement the teeth of coupling bush 4 with teeth of
the shaft 37 of pump НШ-100 drive, and fasten the pumps by bolts with washers;
– place into the slot of pump НШ-10 shaft the stop ring;
– place onto the pump НШ-10 shaft the spline bush 10 up to the stop into stop ring;
– place pump onto the takeoff, introducing into engagement the teeth of spline bush 10 with teeth of the
shaft 47 of pump drive and fasten the pump by bolts with washers;
– place the gauge of rotational speed, introducing into engagement the teeth of gauge shaft with teeth of
bush 41 and fasten by bolts with washers.
13.1.2.7 Mounting of power takeoff

Perform the installation of power takeoff under the order reversed to removal.
Mount the power takeoff coaxially to the hub of traction generator fan. Allowable offset of the power
takeoff shaft axles and fan hub under the tightened absorbers at the vertical plane not more 7 mm, at the hori-
zontal plane not more 10 mm.
The adjustment of coaxiality at the vertical plane is realized by washers 8 exchange (see figures 13.1 or
13.3) from above down or conversely, not violating their amount, and at the horizontal plane by regulating gas-
kets 5, mounting under the each fastening component not more than 7 gaskets.
Carry out the oil filling of the power takeoff according to the truck operation manual.
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13.2 Cardan shaft

13.2.1 General information
Actuation of power takeoff is realized by cardan shaft which consists of two cardan hinge and movable
joint: spline shaft 14 (figure 13.9), sliding yoke 9, unmovable spline yoke 16 fastened on shaft by locking rings
15, two crosses 1 and two flange-yokes 2.
Crosses 1 are mounted in the lugs of spline and sliding yokes and flange-yokes on needle bearings 5,
which are packed by face 3 and radial 4 self-tightening sealings. At the inner cavity of sliding yoke the plug 8 is
installed, which forms the cavity for holding of lubricator at the spline joint. For prevention of spline joint from
contamination the protective packing 11 serves, fastened by hoop 13.
Spline joint is lubricated through lubricator 10 mounted on sliding yoke, the lubrication of needle bear-
ings is realized through lubricators 7.
The cardan shaft is dynamically balanced by machine of balancing plates 17 for locking plates 19 in the
amount not more than 3 pieces. After balancing the pointers are stamped on spline 16 and sliding yokes 9 in order
not to change mutual parts position under repair .
Under the cardan shaft assemblage mutual yokes position is arranged by pointers stamped on them.
Besides under disassembling of cardan hinge you need to notch the flange-yoke 2 and sliding 9 or spline yoke
16 in order not to remove parts to 180 °C under the following assemblage .
Balancing violation (change of mutual parts position), weakening of shaft and needle bearings fastening,
as well as wear –out of parts causes vibration of cardan shaft and reduces its life.
Figure13.9 – Cardan shaft of the power takeoff actuator :

1 – cross; 2 – flange-yoke; 3 – face sealing of bearing; 4 – radial sealing of bearing; 5 – bearing; 6 –bearing cap; 7,
10 – lubricators; 8 – plug of sliding yoke; 9 – sliding yoke; 11 – gland; 12 – packing ring of gland; 13 – nut-hoop of gland; 14 – spline shaft;
15 – mantle rings; 16 – spline yoke; 17 – kit of balancing plates; 18 – bolt of bearing cap fastening; 19 – locking plates
13.2.2 Possible malfunctions of cardan shaft and its remedies

Possible malfunctions of cardan shaft and its remedies are shown at the table 13.4.
Table 13.4 – Possible malfunctions of cardan shaft and its remedies

Malfunction and its external manifesta-
Possible reason Remedy
tion
Cardan shaft vibration The bolts of cardan shaft cap fastening are Tighten the bolts of cardan shaft cap fas-
weakened tening
The cardan hinge parts are worn out Replace worn parts
The spline joint of cardan shaft is worn out Replace spline yoke and shaft or sliding
yoke
13-15
7513-3902080 RM
Malfunction and its external manifesta-

Possible reason Remedy
tion
Parts of cardan shaft are deformed Replace deformed parts and balance
cardan shaft
Coincidence of axes of the driving shaft of Tune the deviation from coincidence of
power takeoff and the hub of fan wheel of axes of the driving shaft of power takeoff
traction alternator is much higher than per- and the hub of fan wheel of traction al-
missible value ternator
Knocking at the cardan shaft under the Needle bearings are destroyed, the parts of Replace bearings, replace or repair the
spline joint of cardan shaft are worn out cardan shaft
motor turn hopping
Fastening of cardan shaft bolts to the flange Tighten the nuts of flange fastening bolts
of power takeoff and the hub of fan wheel
traction alternator is weakened
13.2.3 Repair of cardan shaft

13.2.3.1 Removal of cardan shaft from the truck
For removal of cardan shaft from the truck – unwrench bolts
of cardan shaft fastening to the hub of traction motor ventilation
wheel and nut of cardan shaft fastening to the flange of power
takeoff. Move at the spline joint the sliding yoke back up to the
stop and remove cardan shaft using special suspension (figure
13.10).
Figure 13.10 – Suspension 7808-6229 for removal

and mounting of cardan shaft:
1 – axe; 2 –nut; 3, 5 – rings; 4 – chain; 6 – link; 7 – left arm; 8 – right arm
13.2.3.2 Disassemblage of cardan shaft

Before disassemblage of cardan shaft it’s necessary to make sure in the presence of pointers, stamped
under balancing on spline and sliding yokes. If pointers are absent, they should be done.
Diassemblage of cardan shaft is realized as follows:
–cut off spline shaft 14 (figure 13.9) and sliding yoke 9;
–take off mantle rings 15 and cut off spline shaft 14 and spline yoke 16;
–unlock and unwrench the bolts of bearing caps 6 fastening on flange -yokes 2, sliding yoke 9 and
spline yoke 16;
–squeeze sequentially the needle bearings 5 out of flange-yokes 2, spline yoke 16 and sliding yoke 9
and take out cross 1 and take off from cross pins the face seals 3.
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13.2.3.3 Checking of technical state of cardan shaft parts

Nominal and maximum dimensions of main parts of cardan shafts of trucks BELAZ–7514-10 and BE-
LAZ–75145 are shown at the table 13.5.
Table 13.5 —Nominal and maximum dimensions of the main parts of cardan shafts
Dimensions, mm
Material Hardness
trolled variables
Nominal Maximum
540–2208049-11
Flange yoke: 50+0,012 50,05
Bearing hole diameter -0,027
Steel 40 229 — 269 НВ

External yoke width on lugs 155+0,041 155,15
-0,022
Spigot diameter 198-0,09 197,8
75482–2208048 Sliding yoke

75482–2208024 Spline yoke
549В–4250048-20 Sliding yoke
549В–4250024 Spline yoke 50+0,012 50,05
Diameter of bearing holes -0,027
External yoke width on lugs 155+0,041 155,15 Steel 40 229 — 269 НВ

-0,022
Diameter of spline slots 65+0,06 65,10
5+0,09 5,15
Width of spline slots +0,03
53205–2205030-10
Cross: Cement
Tenon diameter 33,635-0,016 33,60 h 1,8 — 2,2 mm
Steel 20ХГНТР
61 — 66 HRCэ
Size on tenon faces
143-0,04 142,9
75482–2208020-10 Spline shaft

549В–4250020-10 Spline shaft 5-0,030 4,85 241 — 285 НВ
Spline thickness -0,078
Steel 40Х
Splines ТВЧ h 2
External spline diameter 65-0,03 64,85 42 — 56 HRCэ
-0,06
13.2.3.4 Assemblage of cardan shaft

Before assemblage parts of cardan shaft should be washed and air flushed. Clean and air flush the
crosses oil ducts and wrench the lubricators into threaded openings.
DIESEL FUEL AND KEROSENE FOR PARTS WASHING ARE NOT USABLE AS THEY ARE BADLY EVAPO-
RATED OR LEAVE A LAYER ON THE PARTS SURFACE WHICH MIXED WITH LUBRICATION AND VIOLATE ITS
STRUCTURE!
Carry out the assemblage of cardan shaft in the following order:

– fill up the needle bearings for the half with lubricator № 158М (filling the lubricator, turn the bearing
13-17
7513-3902080 RM
needles so that they will be fully covered by lubricator, besides lubricate operation edges of glands);
– put on the cross pins 1 (see figure 13.9) end seals 3;
– insert into the one of flange-yoke 2 holes the needle bearing 5, introduce one cross pin 1 into the
yoke hole, where there is no bearing, and the other insert into the inserted bearing. Under inserting of needle
bearings into the yokes orient the bearings so that slot on the bearing face will on the same line with threaded
yoke holes. Such bearing orientation is required for bearing caps 6 installation;
– mount on the cross pin and insert into the flange-yoke the second hinge bearing;
– mount bearing caps 6 and mount under bolts 18 locking plates 19. Tighten and stop bolts of caps fas-
tening, having bent the whiskers of locking plates on the bolt head panes. Bolt tightening torque should be
25 – 32 N.m;
– similarly assemble with cross the second flange-yoke 2, sliding yoke 9 and spline yoke 16;
– mount the mantle rings 15 to the spline shaft 14;
– check up assembled hinges for angular rolling. Piston throw under the turn on full angle should be
smooth, without jamming;
– lubricate spline part of the joint of sliding yoke 9 and spline yoke 14 by lubricant
Литол-24 and insert the spline yoke into the sliding yoke.
Each bearing should be packed by self-tightening packing 4, mounted into the bearing hoop. Face pack-
ing hasn’t protective hoop. Spline joint is protected by packing 11.
Under the cardan shaft assemblage it’s necessary to install the hinge lubricators so that they were di-
rected to one side and positioned under the angle 30 – 60 degree to the axe of cross pins. The hinge yokes
under the rotation of them around crosses in both sides should be smoothly rotated.
13.2.3.5 Mounting of cardan shaft to the truck

Before mounting of cardan shaft check coaxiality of axes of drive shaft of power takeoff and hub of venti-
lation wheel of traction alternator. If required center.
Carry out mounting of cardan shaft to the truck in the order reversed to the taking off of cardan shaft
from the truck, using the special suspension (see figure 13.10).
Carry out tightening of cardan shaft fastening bolts by torque from 102 to 126 N.m, tighten the nut of bolt
joint by torque from 54 to 67 N.m.
After mounting to the truck lubricate the spline joint and needle bearings of cardan shaft through lubrica-
tors according to the truck operation manual.
UNBALANCE (CHANGE OF MUTUAL PARTS POSITION), BENDING OF CARDAN SHAFT, PARTS WEAR-
OUT, WEAKENING OF SHAFT AND NEEDLE BEARINGS FASTENING, WEAR-OUT OF MOVABLE SPLINE JOINT –
ARE THE REASONS OF VIBRATION, KNOCKING, REDUCING OF CARDAN SHAFT SERVICE LIFE WHICH LEADS
TO ITS DESTRUCTION.
13-18
Dumping mechanism
7513-3902080 RM
14 DUMPING MECHANISM
14.1 General
Dumping mechanism for BELAZ-7514-10, BELAZ-75145 dump trucks is of hydraulic type and is
electro-hydraulically driven, ensures raising and lowering of the body and makes it possible to stop body in
any intermediate raised or lowered position. It comprises three gear-type pumps НШ100А-4 __ 19, 20, 22 (pic-
ture 14.1) and pump НШ10В-3 __ 21, two three-stage telescopic hydraulic cylinders 7, hydraulic control dis-
tributor 1, control valve 8, hydraulic distributor 16, auxiliary hydraulic distributor 5, oil tank, solenoid valve 14
preventing spontaneous body raising on the move and oil piping system.
Dumping mechanism is actuated from the cab by electric switch available on the control board.
Picture 14.1 – Functional hydraulic diagram of dumping mechanism for BELAZ-7514-10,

BELAZ-75145 dump trucks:
1 – hydraulic control valve; 2 – lowering control pilot; 3 – raising control pilot; 4 – unit for unloading hydraulic system pump in steer-
ing; 5 – auxiliary hydraulic distribution valve; 6 – check valve; 7 – hydraulic cylinders; 8 – control valve; 9 – overflow valve; 10 - throttle;
11 – relief valve; 12 – lowering valve; 13 – braking valve; 14 – solenoid valve preventing spontaneous body raising on the move;
15 – steering hydraulic system; 16 – hydraulic distribution valve; 17 – spool valve for raising; 18 – spool valve for lowering; 19, 20,
22 - НШ100А-4 pumps; 21 -НШ10В-3 pump; 23 – filter;
I – for steering hydraulic mechanism; II – for pneumatic hydraulic accumulators
Dumping mechanism in BELAZ-75131, BELAZ-75132 dump trucks ensures body raising and
lowering, makes it possible to stop body in any intermediate raised or lowered position. Mechanism is
equipped with hydraulic drive of progressive type with electro-hydraulic actuation. It comprises two three-stage
telescopic hydraulic cylinders Ц1 and Ц2 (picture 14.2 а), control board ПУ, control unit БУ, oil pumps Н1- Н3,
oil tank and interconnecting oil piping.
Dumping mechanism is actuated from the cab by electric switch on the control board.
14-1
Dumping mechanism
7513-3902080 RM
Picture 14.2 а – Functional hydraulic diagram of dumping mechanism in BELAZ-75131,

BELAZ-75132 dump trucks:
БУ – control unit; КП1, КП4 – relief valves; КР – reduction valve; Н1, Н3 – pumps; ПУ – control board; Р1, Р2 – hydraulic distribu-
tion valves; Р3, Р4 – solenoid hydraulic distribution control valves; Ф1 – filter; Ц1, Ц2 – hydraulic cylinders;
I – delivery piping into steering hydraulic system
14-2
Dumping mechanism
7513-3902080 RM
Picture 14.2 b – Functional hydraulic diagram of dumping mechanism in BELAZ-75131-50 dump truck:
А1 – control board; А2 – control unit; А3 – drain filter; Р1-Р4 – distributors; КП1-КП3 – relief valves; К1 – valve; КР1 – reduction
gear; Ц1, Ц2 – hydraulic cylinders;
Ф1-Ф3 – filters; ДР – throttle; Н1, Н2 – pumps;
I – hydraulic line of the steering system II – hydraulic line from pneumatic hydraulic accumulators
14-3
Dumping mechanism
7513-3902080 RM
14.2 Possible faults of the dumping mechanism
14.2.1 Major faults of the dumping mechanism in BELAZ-7514-10, BELAZ-75145 dump

trucks, their causes and remedy
One is to be guided by table 14.1 for trouble shooting and faults remedy in the dumping mechanism.
Table 14.1 __ Major faults of the dumping mechanism; their causes and remedy
Fault and its cause Trouble shooting Remedy
Body fails to rise If the switch is positioned at “raise” and steering hydraulic sys-
tem fails to function (“zero effect of steering”), and the body
fails to rise then control valve for the dumping mechanism is to
be examined, and if the steering wheel obeys, i.e. steering hy-
draulic system functions, then hydraulic distribution valves of
the dumping mechanism are to be inspected
Insufficient operating liquid content in the To add operating liquid up to
Level is to be checked through eyelets
oil tank the marking
Solenoid hydraulic distribution spool Operating liquid flows in the drain line of the hydraulic distribu- To eliminate chocking or to re-
valve УИС (device preventing spontane- tion valve УИС place hydraulic distribution
ous body raising) chocked up in opened valve
position
Power supply from switch to solenoid
Steering functions with the body raising procedure activated.
hydraulic distribution spool valve is inter- To restore power supply circuit
Power supply circuit is to be checked for intactness
rupted
Raising spool of solenoid spool hydraulic Operating liquid in the piping from solenoid spool hydraulic dis- To cleanse out or to replace
distribution valve chocked up tribution valve to face chamber of raising spool of spool hy- solenoid spool hydraulic distri-
draulic distribution valve features no pressure bution valve
Raising spool of hydraulic distribution Piping leading to face chamber of the raising spool is to be dis- To cleanse out or to replace
spool valve chocked up connected and spool travel is to be checked by torque of hydraulic distribution spool
(400±50) Nm. Spool stroke makes up (18±0,5) mm. valve
Excessive pressure of operating liquid in Piping is to be disconnected from face chamber of the lowering
face chamber of the lowering valve spool. Raising procedure is to be initiated. If the body is being To clean up or to cleanse out
raised, this implies that hydraulic drain line leading from face hydraulic drain line
chamber of the spool valve to the oil tank is clogged up
Lowering valve chocked up Piping is to be disconnected from face chamber of the lowering To cleanse out or replace con-
valve and valve stroke is to be checked by torque of (60±10) trol valve of the dumping
Nm. Valve stroke makes up 1,5 — 2 mm. mechanism
Supporting valve at the drain spot does
Operating liquid pressure is to be measured in the hydraulic To replace the supporting
not ensure operating liquid pressure of
line of the steering system. It shouldn’t be less than 0,7 MPа valve
0,7 — 1 MPa
Overflow control valve in dumping Operating liquid features low pressure in delivery hydraulic line To cleanse out or to replace
mechanism chocked up in opened posi- leading from control valve to head end of the hydraulic cylin- control valve of the dumping
tion ders mechanism
Operating liquid is not supplied into suc- Shutter in the oil tank is closed, transportation plugs in the To open the shutter and to re-
tion pipe-line pumps haven’t been removed move the plug
Body lifts slowly
Low capacity of pumping Lifting is being effected slowly but body is held in neutral posi-
tion. Body spontaneously lowers down at the speed of To replace pumps
(600±50) mm/h
Excessive leakage of operating liquid
Body spontaneously lowers down from neutral position at the To replace control valve of the
from control valve of the dumping
speed of (600±50) mm/h dumping mechanism
mechanism
Spool valve of the auxiliary hydraulic dis- Piping leading to the face end of the spool of additional hydrau-
To cleanse out or to replace
tribution valve chocked up lic distribution valve is to be disconnected and spool valve
auxiliary hydraulic distribution
stroke is to be checked by torque of (400±50) Nm. Spool
valve
stroke makes up (18±0,5) mm
14-4
Dumping mechanism
7513-3902080 RM

Fault and its features Possible cause Remedy
Overflow valves of the hydraulic cylin- Head ends of hydraulic cylinders are to be checked for leakage
ders allow leakage into rod ends by making dead in turns every hydraulic cylinder.
3
Leakage should not exceed 50 sm /min if operating liquid in
the head ends of the hydraulic cylinders is being pressurized
by the weight of empty body. In these circumstances high
pressure hoses leading to rod ends of the hydraulic cylinders To replace valve or cylinder of
are to be disconnected from the piping leading to control valve the dumping mechanism
of the dumping mechanism. Then the engine is to be started
and the body is to be raised by one stage of the hydraulic cyl-
inders. Switch is to be positioned at “neutral” and leakage from
rod end of every hydraulic cylinder is to be measured. To raise
body by more than one stage of the hydraulic cylinders is for-
bidden
Body rises with jerks
Insufficient content of operating liquid in To pour operating liquid up to
Operating liquid content in the tank is to be measured
the tank the marking
Air ingress at the junction spots of parts Hydraulic system is to be visually examined. Operating liquid To tighten junction spots or to
and assemblies of the hydraulic system foams in the tank replace defective O-rings
Body lowers down spontaneously from
neutral position
Check valves (balls) are leaky or missing Balls and caulk edges are to be checked To caulk balls to their seatings
Overflow control valve of the dumping To cleanse out or to replace
Body spontaneously lowers down from neutral position at the
mechanism is leaky control valve of the dumping
speed of (600±50) mm/h
mechanism
Overflow valves of the hydraulic cylin- Head ends of the hydraulic cylinders are to be checked for
ders are leaky leakage into the rod ends by making dead in turn every hy-
3
draulic cylinder. Leakage should not exceed 50 sm /min when
opperating liquid in the head ends of the hydraulic cylinders is
being pressurized by the weight of empty body. In these cir-
cumstances high pressure hoses leading to rod ends of the To replace valve or defective
hydraulic cylinders are to be disconnected from the piping cylinder of the dumping device
leading to control valve of the dumping mechanism. Then the
engine is to be started and the body is to be raised by one
stage of the hydraulic cylinders. Switch is to be positioned at
“neutral” and leakage from rod end of every hydraulic cylinder
is to be measured. To raise body by more than one stage of
the hydraulic cylinders is forbidden
Excessive pressure in the face end of Piping leading to the face end of the raising spool valve is to be To cleanse out or to replace
the lowering valve disconnected and spool valve travel is to be checked by torque hydraulic distribution spool
of (400±50) Nm. Spool valve stroke makes up (18±0,5) mm valve
Body fails to lower down
Power supply circuit leading from switch
to solenoid hydraulic distribution spool Power supply circuit is to be checked for intactness To restore power supply circuit
valve is broken
Lowering spool of the solenoid hydraulic Operating liquid features no pressure in the piping leading from To cleanse out or to replace so-
distribution spool valve choked up solenoid hydraulic distribution valve to the face end of the lower- lenoid hydraulic distribution
ing spool of the hydraulic distribution spool valve spool valve
Lowering spool of the hydraulic distribu- Piping leading to the face end of the lowering spool is to be
To cleanse out or to replace
tion spool valve choked up disconnected and lowering spool travel is to be checked by
hydraulic distribution spool
applying effort (400±50) N/m. Spool stroke makes up (18±0,5)
valve
mm
Lowering valve choked up Piping leading from the face end of the lowering valve is to be
To remedy choking up or to
disconnected and valve travel is to checked by applying effort
replace lowering valve
(70±5) N/m. Valve stroke makes up 1,5 — 2 mm
14-5
Dumping mechanism
7513-3902080 RM
14.2.2 Major faults of the dumping mechanism in BELAZ-75131, BELAZ-75132 dump

trucks, their causes and remedy
One is to be guided by table 14.2 for trouble shooting and faults remedy in the dumping mechanism.
Table 14.2 __ Major faults in the dumping mechanism, their causes and remedy
Faults and its features Possible cause Remedy

Body fails to rise Insufficient operating liquid content in the oil tank To check level and if necessary to add some more
operating liquid , to fill in the pump barrel with op-
erating liquid
Operating liquid is not supplied into the suction pipe- To open oil tank shutter, to fill in the pump barrel
line with operating liquid
Supply circuit of the solenoid of the hydraulic distri- To restore supply circuit
bution control valve is broken
Raising pilot of hydraulic distribution control valve To cleanse out hydraulic distribution valve of the
chocked up steering system
Raising spool of the hydraulic distribution valve To cleanse out hydraulic distribution valve
chocked up
Pilot of the hydraulic distribution valve responsible To check spool travel manually, if necessary to
for floating position chocked up (see picture 14.12 disassemble and cleanse out
pos 20)
КП1, КП2 relief valves or К1, К2 overflow valves are To disassemble valves and to examine operating
leaky (picture 14.2b) surfaces. To test valves for leakage (chapter
14.6.2.5)
Body raises slowly Low pumping capacity (slow raising), but the body is To replace pumps
maintained in neutral position
Excessive leakage of operating liquid through control To eliminate leakage or to replace control valve
valve (body spontaneously lowers down from neutral
position)
Overflow valves of the hydraulic cylinders are leaky To remedy leakage
КП1, КП2 relief valves or К1, К2 overflow valves are To disassemble valves and to examine their oper-
leaky (picture 14.2 b) ating surfaces. To test valves for leakage (chapter
14.6.2.5)
Body raises with jerks Insufficient operating liquid content in the tank To measure the content and if necessary to add
operating liquid
Air ingress in the suction hydraulic line of the pumps To tighten junctions or to replace O-rings
(operating liquid foams in the tank)
Body spontaneously Check valves of the hydraulic cylinders are leaky To caulk valve balls
lowers down from neu-
tral position Overflow valve is leaky To cleanse out or to replace control valve
Overflow valves of the hydraulic cylinders are leaky To eliminate leakage in the overflow valves
Excessive pressure in the face end of the lowering To clean up hydraulic drain line
valve
К1, К2 overflow valves are leaky (picture 14.2 b) To disassemble valves and to examine operating
surface of seating and valve. If necessary to grind-
in valve or to replace it
Pilot of the hydraulic distribution valve responsible To check spool travel manually. If necessary to
for floating position chocked up (picture 14.12 disassemble and to cleanse out
pos.20)
14-6
Dumping mechanism
7513-3902080 RM

Body fails to lower Supply circuit of the solenoid of the hydraulic distri- To restore supply circuit
down bution control valve is broken
Lowering pilot of the hydraulic distribution control To cleanse out hydraulic distribution control valve
valve chocked up
Lowering spool of the hydraulic distribution valve To cleanse out hydraulic distribution valve
chocked up
Lowering valve of the control valve chocked up To cleanse out control valve
Overheating of operat- Pressure in the charging line of the variable flow To adjust pressure by adjusting screw of the pres-
ing liquid (t>70 °C) pump exceeds 18 MPa sure sensitive switch
КП2 relief valve is leaky (picture 14.2 b) To replace valve
14.3 Dismounting of the dumping mechanism assemblies from dump truck

14.3.1 Dismounting of the dumping mechanism assemblies
In the process of dismounting of the dumping mechanism assemblies it is necessary
- to ensure safe locking of the body (to check that body rests solidly on the frame or to lock the
body in raised position by steel cables);
- to ensure null pressure in pneumatic hydraulic accumulators;
- to close shutters in the oil tank to prevent waste of operating liquid from the hydraulic tank in the proc-
ess of assemblies dismounting
- to mark piping, high-pressure hoses and their junction places on the hydraulic equipment;
- to disconnect piping and high-pressure hoses from hydraulic equipment and to ensure operating liquid
collection into special vessels;
- to untighten fastening screws and to dismount hydraulic equipment from frame brackets using if nec-
essary hoisting devices;
- in the process of repairs irrelevant objects or dirt should by no means get into piping and hydraulic
equipment.
14.3.2 Dismounting of the dumping mechanism cylinder
Cylinder of the dumping mechanism is to be removed from the dump truck observing the following succes-
sion:
- to place anti-backtracking supports under wheels of the front and axes of the dump truck;
Picture 14.3 — Dismounting of the dumping mechanism cylinders:

1 – technical clamp; 2, 15 –spherical bearing; 3 – locking ring; 4, 12 – cover; 5, 11, 14 – screw; 6, 17 – lubricator; 7, 16 – gland;
8 – spacer bushing; 9 – pin; 10 – hydraulic cylinder; 13 – hold-down cover
14-7
Dumping mechanism
7513-3902080 RM
- to disconnect oil piping from lower support of the cylinders;

- to lift body by crane thus body floor being in horizontal position. To place technological stands between
frame and lifted body;
- to place technological clamp 1 (picture 14.3) for fixing cylinder to the frame (is delivered with new dump
truck);
- to untighten screws 5 and to take pin 9 out;
- to untighten screws 11 and to remove cover.12;
- to uncotter , to untighten screws 14 and to remove hold-down cover 13;
- to place gripping hand of the appliance for cylinder removal (see picture 14.4) on the cylinder and to
secure it tightly ;
- to remove technological clamp for fixing cylinder to frame and to remove cylinder.
Picture 14.4 — Appliance for removal and mounting of the dumping mechanism cylinders:
1 – loader fork; 2 – cross-member; 3 – bracket; 4 – axis; 5 –dumping mechanism cylinder, bracket; 6 – ball support; 7 – support
bracket; 8 –longitudinal bracket; 9 – pin; 10 – nut; 11 – handle; 12 – jaws; 13 – insert; 14 – chain; 15 – grab
14.4 Dismantling of dumping mechanism assemblies
14.4.1 Dismantling of dumping mechanism assemblies from BELAZ-7514-10, BELAZ-75145

dump trucks
14.4.1.1 Dismantling of the dumping mechanism cylinder
Dismantling of the dumping mechanism cylinder is effected at СБ-61 stand (picture 14.5).
It is forbidden at the stand:
- to set and to reforward piping and rod as well as to place rings if turnaround table of the stand and outer pip-
ing are unclamped;
- to work or to shift parts in the operating stroke area of pneumatic cylinders in motion;
- to work at the stand if the stand is subject to swinging.
14-8
Dumping mechanism
7513-3902080 RM
Picture 14.5 – СБ-61 stand for assembly of the dumping mechanism:

1 – turnaround table; 2 – bed; 3 – table fixing appliance; 4 – pneumatic cylinder; 5 – handle; 6 – pusher’
Disassembly of dumping mechanism cylinder is to be effected in the following succession:

- to place and to secure dumping mechanism cylinder on СБ-61 stand;
- to bend up pipe wall 11 out of the slots on the cylinder cover (see picture 14.6, view А);
- to turn cover 10 out of pipe 11
- to move rod 9 with piston out of cylinder by 70 — 100 mm and to bend up retainer ring 1;
- to turn cylinder head 23 out of rod shank ;
- to extract cylinder inner pipe 7 out of piston bore;
- to bend up pipe wall 18 out of the cuts on the restricting nut 3;
- to unscrew restricting nut 3 out of pipe 18;
- to approximate stand cylinder to dumping mechanism cylinder from piston side;
- to remove rod with piston 9 and bushing 6 out of cylinder housing;
- to replace pusher and to remove pipe 18 out of pipe 17;
- to replace pusher and to remove pipe 17 out of pipe 11;
- to unscrew valve seat 14 out of rod with piston 9;
- to remove ball 15 and pusher 16.
Removal of head bearings 23 and cylinder cover 10 is to be effected in the following succession:
- to remove glands 7, 16 of the cylinder head and cover;
- to remove retainer rings 3;
- to squeeze out spherical bearings 2 and15 (see picture 14.3) using arbour.
14-9
Dumping mechanism
7513-3902080 RM
Picture 14.6 – Dumping mechanism cylinder:

1 – retainer ring; 2, 5, 8, 12, 22, 25, 30, 31 – O-ring; 3 – restricting nut; 4, 27, 34 – safety ring; 6 – bushing; 7 – cylinder inner pipe ;
9 – rod with piston; 10 – cylinder cover; 11 – outer pipe; 13 – retainer ring; 14 – valve seat; 15 – ball; 16 – pusher; 17, 18 – cylinder pipe;
19, 20, 24, 28, 33 – guide ring; 21, 29, 32, – protective washer; 23 – cylinder head; 26 – protective ring
14-10
Dumping mechanism
7513-3902080 RM
14.4.1.2 Disassembly of hydraulic distribution valve in the dumping mechanism

Disassembly of hydraulic distribution valve is to be effected in the following succession
- to untighten srews 2 with spring lock washers out of housing 4 (see picture 14.7), to remove cover 3 and to
take springs 1 and 12 out;
- to untighten screws 9 with spring lock washers and to remove cover 6;
- to remove barrel 11 and spools 5, 10 out of the housing.
Picture 14.7 – Hydraulic distribution valve:

1, 12 – spring; 2, 9 – screw; 3, 6 – cover; 4 – housing; 5 – raising spool; , 10 – lowering spool; 11 – spring barrel
I – drain chamber; II, III, V – control chambers; IV – rod end; VI, VII – steering chambers; VIII, XI – piston spaces; IX, X – pressure
chambers;
14.4.1.3 Disassembly of solenoid distribution valve in the dumping mechanism

Disassembly of solenoid distribution valve is to be effected in the following succession:
- to untighten screws 14 (see picture 14.8), to remove solenoids 10 and pushers 11;
- to untighten screws 13 and to remove flanges 9 from solenoids;
- to untighten screws 5 and to remove covers 4;
- to remove springs 7, thrust washers 16, rings 8 and spools 3 out of sleeve 2;
- if necessary to squeeze out sleeves 2.
14-11
Dumping mechanism
7513-3902080 RM
Picture 14.8 – Solenoid hydraulic distribution spool valve:

1 – housing; 2 – sleeve; 3 – spool; 4 – cover; 5, 13, 14 – screw; 6, 15 –sealing; 7 – spring; 8 – ring; 9 – flange; 10 – solenoid;
11 – pusher; 12 – anchor; 16 – thrust washer
Y1, Y2 – control chambers; С – drain chamber; Д – pressure chamber
А, Б – spools; В, Г – solenoids
14.4.1.4 Disassembly of control valve in the dumping mechanism

Disassembly of control valve is to be effected in the following succession:
- to untighten screws 8 complete with spring lock washers and to disconnect housings 6 and 26;
- to untighten screws 3 complete with spring lock washers, to remove cover 4 and restrictive bushing 1
with springs 2;
- to untighten screws 10 complete with spring lock washers, to remove cover 11 and valve 7 out of hous-
ing;
- to uncotter and unscrew cap 16, to loosen nut 14, to untighten adjusting screw 15 and to remove
spring 17, valve seat 18, ball 19;
- to untighten screws 20 and to remove cover 13;
- to remove spring 24 and overflow valve 25 out of housing 26;
- to untighten arresting device 32, to remove spring 31 and servovalve 30.
14-12
Dumping mechanism
7513-3902080 RM
Picture 14.9 – Control valve:

1 – restricting bushing; 2, 17, 24, 31 – spring; 3, 8, 10, 20 –screw; 4, 11, 13 – cover; 5, 9, 12, 21, 22, 28, 29 –O-ring; 6 – housing;
7 – valve; 14 – nut; 15 – adjusting screw; 16 – cap; 18 – valve seat; 19 – ball; 23 – protective ring; 25 – overflow valve; 26 – valve body;
27 – insert; 30 – lowering servovalve; 32 – arresting device
I – drain chamber; II – rod end; III – piston chamber; IV – control chamber; V – overflow valve chamber behind throttle; VI – pres-
sure chamber
14.4.1.5 Disassembly of auxiliary hydraulic distribution valve in the dumping mechanism

Disassembly of auxiliary hydraulic distribution valve is to be effected in the following succession:
- to unwrench screws 5 with spring lock washers, to remove cover 1, O-ring 4 and to remove spring 7;
- to unwrench screws 5 with spring lock washers; to remove cover 3 and O-ring 4;
- to remove spool 6 out of body 2
Picture 14.10 – Auxiliary hydraulic distribution valve:

1, 3 – covers; 2 – body; 4 – O-ring; 5 – screw; 6 – spool; 7 – spring;
I, III, V – drain chambers; II, IV – pressure chambers; VI – control chamber; VII, VIII – piston chambers
14-13
Dumping mechanism
7513-3902080 RM
14.4.1.6 Disassembly of solenoid distribution valve of body raise interlock in the dumping
mechanism
Disassembly of solenoid distribution valve of body raise interlock is to be effected in the similar way to
disassembly of solenoid distribution control valve.
Picture 14.11 – Solenoid hydraulic distribution spool valve:

1 – housing; 2 – sleeve; 3 – spool; 4 – cover; 5, 13, 14 – screw; 6, 15 – sealing; 7 – spring; 8 – ring; 9 – flange; 10 – solenoid;
11 – pusher;12 – anchor; 16 – thrust washer
C – drain chamber; Д – pressure chamber
14.4.2 Dismantling of dumping mechanism assemblies from BELAZ-75131, BELAZ

75132 dump tucks
14.4.2.1 Disassembly of dumping mechanism cylinder
Disassembly of dumping mechanism cylinder in BELAZ-75131, BELAZ-75132 dump trucks is to be ef-
fected in the similar way to disassembly of dumping mechanism cylinder in BELAZ-7514-10, BELAZ-75145
dump trucks.
14.4.2.2 Disassembly of dumping mechanism control unit

Disassembly of control unit in the dumping mechanism is to be effected in the following succession:
- to untighten screws 21 (picture 14.12) and to disconnect hydraulic distribution valves 19 and 20;
- to untighten screws 18 and to remove covers 4 and 15;
- to remove spring cover 3 and spring 6;
- to untighten screw 1 out of spring cover and to remove spring plug 5;
- using spring plug 5 to remove sleeve cover 14 and spool 8 with washer 7;
- to turn over spring plug and to remove sleeve 9;
- to unscrew plugs 11 and nipple 16 out of housing 10.
14-14
Dumping mechanism
7513-3902080 RM
Picture 14.12 – Control unit:

1, 18 — screws; 2 — nut; 3 — spring cover; 4, 15 — covers; 5 — spring cover; 6 — spring; 7 — spring thrust; 8 — pilot spool
valve; 9 — sleeve; 10 — housing; 11 — cork; 12, 13 — rings; 14 — sleeve cover; 16 — nipple; 17, 22 — washers; 19, 20 — hydraulic dis-
tribution valves; 21 — screw
14.4.2.3 Disassembly of hydraulic distribution valve in the dumping mechanism

Disassembly of hydraulic distribution valve in the dumping mechanism is to be effected in the
following succession:
- to untighten screws 28 and to remove cover 29 from housing (picture 14.13);
- to untighten screws 16 and to remove pilot valves 4 and 15;
- to untighten screws 3 and to remove pilot valve 4 with crossover plate 2;
- to untighten screws 5 and to remove safety valves 6;
- to untighten screws 31 and to remove overflow valves 30;
- to untighten screws 10, to remove covers 9 and plugs 14 out of stack of housings 11.
- to untighten screws 18 and to disconnect housings 11 unit;
- to untighten screws 13 and to remove covers 19;
- to turn shanks 21 and 26 out of spool;
- to remove springs 20 and 27; springs 22 and 25 out of thrust housing;
- to remove spool 24 out of housing;
- to disassemble the second section of distribution valve the same way.
14-15
Dumping mechanism
7513-3902080 RM
Picture 14.13 – Hydraulic distribution valve:

1, 8, 12, 17, 23 – O-ring; 2 – crossover plate; 3, 10, 16, 18, 28, 31 – screw; 4, 15 – pilot valve; 5, 13 – screw; 6 – relief valve;
7 – protective washing; 9, 19, 29 – covers; 11 – housings block; 14 – plug; 20, 27 – spring support; 21, 26 –shank; 22, 25 – spring;
24 – spool, 30 – overflow valve;
14-16
Dumping mechanism
7513-3902080 RM
14.4.2.4 Disassembly of relief valve in hydraulic distribution valve of the dumping mechanism
Disassembly of relief valve in hydraulic distribution valve of the dumping device is to be effected in the
following succession:
- to unscrew cover 7 (picture 14.14);
- to remove spring 5 and valve 4 out of housing 1.
Picture 14.14 – Relief valve:

1 — housing; 2 — seat; 3 — protective ring; 4 — valve;
5 — spring; 6 — O-rings; 7 — cover
14.4.2.5 Disassembly of auxiliary valve in hydraulic distributor of the dumping mechanism

Disassembly of auxiliary valve in hydraulic distributor (dumping mechanism) is to be effected in the fol-
lowing succession:
- to untighten screws 11 (picture 14.15) and to remove spring cover 10;
- to remove in the following succession piston 9. spring 8, washer 7. adjusting valve 6 out of housing 15;
- to untighten screws 19 and to remove cover 18;
- to remove plug 16, valve spindle 4 and seat 3 out of housing 15.
Picture 14.15 – Auxiliary valve:

1, 5, 17 — O-rings; 2 — protective ring; 3 — seat;
4 — valve spindle; 6 — adjusting valve; 7 — washer;
8 — valve spring; 9 piston; 10 — spring cover; 11, 12,
19 — screws; 13 — washer; 14 — nut; 15 — housing;
16 — plug; 18 — cover
14-17
Dumping mechanism
7513-3902080 RM
14.5. Checking up of parts technical conditions
14.5.1 Checking up of technical condition of dumping mechanism parts in

BELAZ-7514-10, BELAZ-75145 dump trucks
Design and tolerance limit dimensions of major parts in dumping mechanism are stated in table 14.3.
Table 14.3 — Design and tolerance limit dimensions of major parts in dumping mechanism
Part number, part denomination and Dimensions, mm

Material Hardness
controlled specifications design tolerance
Cylinder:
7519-8603183 ДПРНМ band
7519-8603184 2x165НД
7519-8603185 Бр ОЦС
7519-8603186 4-4-2,5
7519-8603188
549-8603130 cylinder pipe
30 micromicron 12 micromicron 45 steel HRC 47 — 54
thickness of chrome coating
549-8603134-10 cylinder pipe

30 micromicron 12 micromicron 40Х steel HRC 47 — 54
549-8603164-10
Cylinder rod 30 micromicron 12 micromicron 40Х steel HRC 47 — 54
Hydraulic distribution valve:
clearance between spool and bore in
housing 0,009 0,035
7520-8607254
Valve: 32-0,009 31,965 40Х steel HRC 56 — 62
belt housing -0,020
549Б-8607240
Housing:
opening diameter
60+0,03 60,05 45 steel HRC≥46,5
549Б-8607232-10
Overflow valve 32+0,060 32,06 20 steel HRC 56 — 62
belt diameter +0,025
549Б-8607235
Lowering servovalve: 10-0,13 9,965 20Х steel HRC 57 — 63
belt diameter -0,27
549А-8606198
Pusher: 5-0,04 4,8 35 steel HB 241 — 285
outer diameter -0,12
549Б-8606198
Pilot: 10-0,005 9,97 20Х steel HRC 57 — 63
belt diameter -0,015
14-18
Dumping mechanism
7513-3902080 RM
14.5.1 Checking up of technical condition of dumping mechanism parts in BELAZ -

75131, BELAZ-75132 dump trucks
Design and tolerance limit dimensions of major parts in dumping mechanism are stated in table 14.4.
Table 14.4 — Design and tolerance limit dimensions of major parts in dumping mechanism
Part number, part denomination and Dimensions, mm

Material Hardness
controlled specifications design tolerance
Cylinder:
ДПРНМ band
7519-8603183
2x165НД
7519-8603184
Бр ОЦС
7519-8603185
4-4-2,5
7519-8603186
7519-8603188
549-8603130 pipe
30 micromicron 12 micromicron 45 steel HRC 47 — 54
549-8603134-10 pipe
30 micromicron 12 micromicron 40Х steel HRC 47 — 54
549-8603164-10
Cylinder rod 30 micromicron 12 micromicron 40Х steel HRC 47...54
5132-8606423 Clearance in match-
Sleeve: 10+0,015 ing Cementing
sleeve-spool 20Х steel h 0,7 — 0,9 mm
inner diameter
0,01 — 0,02 57 — 63 HRCэ
not more
Spool: ing Cementing
belt diameter 10,00 spool - sleeve 20Х steel h 0,7 — 0,9 mm
0,01 — 0,02 57 — 63 HRCэ
not more
ing
Housing:
sleeve-spool ВЧ 50 cast iron 150 — 190 НВ
spool opening 25+0,027 0,005 — 0,020
not more
Spool: ing Cementing
belt diameter 25,00 sleeve-spool 20Х steel h 0,7 — 1,0 mm
0,005 — 0,020 56 — 61 HRCэ
not more
78211-4617122
Valve: Operating surface of the valve must be 40Х steel 43,5 — 49,5 HRCэ
scratch- and damage-free
14-19
Dumping mechanism
7513-3902080 RM
14.6 Assembly of dumping mechanism units

Assembly of dumping mechanism units is to be effected at specially conditioned sites using special pur-
pose tools, extractors, appliances, assembly and trial stands. Assembly sites should prevent dirt and dust in-
gression on the parts to be assembled.
Assembly parts should show no evidence of rust, cinder, abrasives and other mechanical fouling. They
are to be thoroughly washed in diesel fuel and blown out by compressed air. It is not recommended to wipe
parts before assembly with scouring cloth to avoid channel clogging up and spool jamming. Oil channels are to
be cleaned up and blown out by compressed air.
In the assembly process a new set of general mechanical rubber goods is to be used (O-rings,
glands, gaskets). Before assembly all O-rings are to be cleansed in oil of A make.
Assembling sequence for every unit is considered thus, giving a chance to disassemble this unit respec-
tively for repair purposes. If unit was disassembled partially, assembly sequence can differ.
In the assembly procedure mating faces of the parts are to be lubricated with oil of A make or with oil
running in the hydraulic system of dumping mechanism.
After repaired assembly has been mounted in the dump truck, functioning of dumping mechanism is to
be supervised, it should satisfy the following requirements:
- raising arrangement system must ensure smooth jerk- and jamming free raising and lowering of body;
- body interlocking in any intermediate position;
- oil leakage at junctions of oil piping and joint planes of the assemblies is not allowed.
14.6.1 Assembly of dumping mechanism units in BELAZ-7514-10, BELAZ-75145 dump

trucks
14. 6.1.1 Assembly of dumping mechanism cylinders
Assembly of dumping mechanism cylinders is to be effected in the following succession:
- to insert protective washer 21 into annular groove on bushing 6 (see picture 14.6);
- to place O-ring 5 by pressing protective washer 6 to the wall from collar side;
- to place safety ring 4 into outer groove on bushing;
- to place O-rings 22 into outer groove on bushing;
- to place cylinder rod with piston 9 upwards on stand;
- to place pushers 16 into piston bore, at the same time pushers should travel free in the seat without
jerks;
- to place and then to caulk balls 15 to their seats; caulked edge should be continuous and smooth;
- to place and to draw up valve cages 14 into threaded bore on piston. To center-punch cages in two an-
tipode sites opposite the notch. Faces of cages and piston are to be aligned in one plane;
- to place guide ring 24 (view B) into lower annular groove on rod piston;
- to place successively protective ring 26, O-ring 25, protective ring 26 into middle annular groove on
piston;
- to place guide ring 24 into upper annular groove on rod piston;
- to place O-ring 8 into inner groove on piston;
- to fasten outer pipe 11 to prismatic supports of the stand, matching bores on pipe with location pin and
pipe end with face thrust of the stand;
- to place guide ring 19 into annular groove on pipe;
- to place successively protective washer 32, O-ring 31, protective washer 32 into annular groove on
pipe (view C);
- to place safety ring 34 into annular groove on pipe;
- to place pipe 17 into outer pipe 11, to approximate stand cylinder to the pusher and to forward pipe 17
up to the thrust at the stand;
- to place guide ring 20 into annular groove on pipe 17;
- to place successively protective washer 29, O-ring 30, protective washer 29 into annular groove on
pipe (view C);
14-20
Dumping mechanism
7513-3902080 RM
- to place safety ring 27 into annular groove on pipe;

- to insert pipe 18 into pipe 17, to approximate stand cylinder, to replace pusher and to forward pipe 18
up to the thrust at the stand;
- to place restricting ring 13 into groove on pipe 18;
- to fasten semi-assembled rod and to place into pipe 18 applying piston 9 up to the thrust;
- to place semi-assembled bushing 6 on rod and into pipe 18 opening;
- to place and to draw up restricting nut 3 (with torque of 0.55 – 0,7 kNm) into pipe 18;
- to bend pipe wall into two slots on the nut as shown in view A;
- to place cylinder tube 7 into piston bore up to the collar stop;
- to place retainer ring 1 onto the shank of right-hand cylinder head 23;
- to place O-ring 2 into annular groove on head 23;
- to place O-ring 8 into annular groove bore on head 23;
- to place and to screw in cylinder head with torque of 0,55 – 0,7 kNm into shank bore;
- to bend retainer ring 1 onto two rod grooves;
- to place O-ring 12 into annular groove on cylinder 10;
- to place and to screw in cover 10 into outer pipe 11 with torque of 0,8 — 1 kNm;
- to bend pipe wall into two slots as shown in View A.
Testing of dumping mechanism cylinders
To supply operating liquid into chamber I from pumping installation capacitated 120 – 140 l/min and
pressure value at relief valve not exceeding 3 MPa. Chamber II is to be connected to drainage. To separate
hydraulic cylinder in full and to wash it out for three minutes.
Folding of hydraulic cylinder should be consequential beginning from the stage of smaller diameter.
Jamming of sections is not allowed. Pressure in piston chamber of hydraulic cylinder at the moment of its fold-
+0,5
ing should not exceed 0,3 MPa.
Checking for leakage is to be done by supplying operating liquid under pressure of 15+1 MPa simultane-
ously into chambers I and II of hydraulic cylinder. Proving time should be 3 minutes. Moisture on outer faces is
not allowed.
Leakage from piston chamber into rod end should not exceed 0,4 l/min assumed that pressure in rod
end makes up (15±1) MPa. Checking is to be done when both-way action stage is not in advanced position
(pos. 9). Positioning of other stages can be disregarded.
14. 6.1.2 Assembly of hydraulic distribution valve (dumping mechanism)

Assembly of hydraulic distribution valve is to be effected in the following succession:
- to press spring barrel 11 into housing 4 (see picture 14.7);
- to place spools 5 and 10 into housing;
- to place O-rings 7 and 8 into housing 4 grooves;
- to place cover 6, to set and to draw up screws 9 complete with spring lock washers;
- to place O-rings 7 and 8 into housing groove;
- to place springs 1 and 2, cover 3 into housing, to place and to draw up screws 2 complete with spring
lock washers
After assembly of hydraulic distribution valve has been completed, spool traveling is to be checked
through bore in the cover. Spool should travel from one utmost position into the other without jerks and driven
by spring should come back into original position.
Testing of hydraulic distribution valve.
Chambers IX and X are to be connected to high-pressure pumping plants featuring capacity of
120 – 140 l/min. Chambers I, IV, VI, VII, VIII, XI are to be connected to drainage and chambers II, III – to
sources generating control pressure of (0,5±0,3) MPa. Chamber V is to be plugged.
Operating liquid is to be supplied into chambers IX and X, whole its flow going through chambers VI and
VII to drainage. When operating liquid is supplied into chamber II of control pressure, raising spool should
travel from one utmost position into the other and whole flow of operating liquid should go through chambers
VIII and XI to drainage. When pressure is released in chamber II, raising spool driven by spring should come
back into original position and whole operating liquid flow should go through chambers VI and VII to drainage.
When operating liquid is supplied to chamber IX, control pressure is to be gained in chamber III. At the
same time lowering spool should travel from one utmost position into the other and whole operation liquid
stream should flow into drainage through chambers IV and VII. If pressure is being released in chamber III,
14-21
Dumping mechanism
7513-3902080 RM
lowering spool driven by spring should come back to original position and whole operating liquid stream should
flow into drainage through chamber VII.
At least five switch-overs are to be performed.
Chamber IV is to be plugged. If operating liquid is being supplied into chamber X from pressure generat-
ing source featuring capacity of 120 l/min, and control pressure is being created in chamber III, operating liquid
pressure in chamber IX should amount to (2,5±0,5) MPa.
Chambers IX and X are to be connected to high-pressure pumping plant. Z, B, VI, VII, VIII, XI chambers
are to be plugged and I, II and III chambers are to be attached to gauging tank.
14.6.1.3 Assembly of solenoid control distribution valve (dumping mechanism)

Assembly of solenoid hydraulic distribution valve is to be effected in the following succession:
- to force sleeves 2 (see picture 14.8) with seals into housing 1 and to place rings 8;
- to place flanges 9 with O-rings on solenoids 10;
- to start and to draw up screws 13;
- to place O-rings 15 into flange grooves;
- to place pushers 11 and solenoids 10 with flanges 9 on housing;
- to start and to tighten screws 14;
- to place spool 3 into sleeve (spool-and-sleeve should match dimensionally)
- to place thrust washers 16, springs 7 and covers 4 with O-rings 6 on spool;
- to bolt and to draw up screws 5;
Testing of solenoid distribution valve.
Chamber Y1 is to be connected to high-pressure pumping plant featuring capacity of (15±3) l/min. Cham-
bers Y2, Д and С are to be connected to drainage system.
When solenoid В is activated and simultaneously operating liquid is supplied into chamber Y1, spool А
should travel from one utmost position into the other and all operating liquid must flow into drainage through
chamber Д. When solenoid В is deactivated, spool driven by spring must come back into original position and
all operating liquid must flow into drainage through chamber C.
Chamber Y2 is to be connected to high-pressure pumping plant featuring capacity of (15±3) l/min.
Chambers Y1, Д and С are to be connected to drainage system.
When solenoid Г is activated and simultaneously operating liquid is supplied into chamber Y2, spool Б
should travel from one utmost position into the other and all operating liquid must flow into drainage through
chamber Д. When solenoid Г is deactivated, spool Б driven by spring should come back into original position
and all operating liquid must flow into drainage through chamber С.
At least five switch-over are to be performed.
14.6.1.4 Assembly of control valve in the dumping mechanism

Assembly of control valve is to be effected in the following succession:
Before assembly valves 7, 25, 30 and ball 19 are to be ground-in and caulked to their cages.
- to place ground-in servo-valve 30, spring 31 onto housing 6 (see picture 14.9), to screw in and to
tighten arresting device 32 with gasket;
- to place O-ring 5 into annular groove on housing;
- to place O-ring 9, cover 11 into outer groove on housing and to tighten with screws 10;
- to place valve 7, springs 2, restricting bushing 1 into housing;
- to place O-ring 29, cover 4 and to tighten with screws 3;
- to place overflow valve 25 and spring 24 into housing 26;
- to place O-rings 21, 22 and protective ring 23 into annular grooves on cover 13;
- to place cover 13 into housing 26 and to tighten with screws 20;
- to place caulked ball 19, valve cage 18, spring 17 and adjusting screw 15 into cover 13. Screw is to be
bolted and drawn up in the housing
- to place gaskets on adjusting screw, to screw in nut 14 and cap 16;
- to place O-rings 12 and 28 into grooves on housing 6;
- to place housing 6 onto housing 26, to bolt and to draw up screws 8.
After assembly of control valve has been completed, valve travel is to be checked through bores in the
housings. They should travel from one utmost position into the other without jerks and come back into original
position driven by springs.
14-22
Dumping mechanism
7513-3902080 RM
Testing of control valve.

Chamber VI is to be connected to high-pressure pumping plant featuring not less than 16 MPa, cham-
bers III, V and II are to be plugged, chambers I and IV are to be connected to drainage.
To supply operating liquid at discharge rate of not less than 100 l/min into chamber VI and using adjust-
ing screw 15 to set safety valve at pressure value of (14±0,5) MPa. Adjusting screw is to be secured by check
nut 14.
Chamber VI I to be connected to pumping plant featuring capacity of 240 — 280 l/min, chamber I is to
be connected to drainage, chamber IV is to be connected to source generating control pressure not less than
0,5 MPa, and chambers II and V are to be made dead.
When operating liquid is supplied into chamber VI under pressure of (0,8±0,15) MPa and simultaneously
control pressure is gained in chamber IV, overflow valve 25 should open and all operating liquid from chamber
VI should flow into drainage through chamber I. When pressure in chamber IV is released, overflow valve
driven by spring must close, at the same time operating liquid pressure in chamber VI should set at the value
of (0,8±1,15) MPa.
Not less than five switch-overs are to be effected.
14.6.1.5 Assembly of auxiliary hydraulic distribution valve (dumping mechanism)

Assembly of auxiliary hydraulic distribution valve is to be effected in the following succession:
- to place O-ring 4 into groove on housing 2 (see picture 14.10);
- to place cover 3, to bolt and to draw up screws 5 complete with spring lock washers;
- to place spool 6 and spring 7 into housing;
- to place O-ring 4 into groove on housing;
- to place cover 1, to bolt and to draw up screws 5 complete with spring lock washers;
After assembly spool travel is to be checked through bore in the cover. Spool should travel from one ut-
most position into the other without any jerks and come back into original position driven by spring.
Testing of auxiliary hydraulic distribution valve.
Chambers II and IV are to be connected to pumping plants featuring capacity 120 — 140 l/min. Cham-
bers I, III, V, VII, VIII are to be connected to drainage, and chamber VI is to be connected to control pressure
source not less than 0,5 MPa.
Operating liquid is to be supplied into chambers II and IV, it should entirely flow into drainage through
chambers III and V. when control pressure is gained in chamber VI, spool should travel from one utmost posi-
tion into the other and all operating liquid must flow into drainage through chambers VII and VIII.
When pressure in chamber VI is released, spool should come back into original position driven by spring
and all operating liquid must flow into drainage through chambers III and V.
14.6.1.6 Assembly of solenoid distribution valve of body raise interlock (dumping mechanism)
Assembly of solenoid distribution valve of body raise interlock is to be effected in the similar way to as-
sembly of solenoid distribution control valve.
Testing of solenoid distribution valve for body raise interlock.
When solenoid is activated and simultaneously operating liquid is supplied into chamber Д, operating
liquid must flow into drainage through chamber С.
14.6.2 Assembly of dumping mechanism units in BELAZ-75131, BELAZ-75132 dump
trucks
14.6.2.1 Assembly of dumping mechanism cylinders
Assembly of dumping mechanism cylinders in BELAZ-75131, BELAZ-75132 dump trucks is to be ef-
fected in the similar way to assembly of dumping mechanism cylinders in BELAZ-7514-10, BELAZ-75145
dump trucks.
14.6.2.2 Assembly of dumping mechanism control unit

Assembly of control unit is to be effected in the following succession:
- to place rings 12 (see picture 14.12) onto sleeve 9;
- to place sleeve 9 into housing 10 from the side of bore, marked by letter Р, previously lubricating
14-23
Dumping mechanism
7513-3902080 RM
rubber rings, (sleeve face must match face plane of housing);

- to place rubber ring 13 into sleeve cover 14;
- to place sleeve cover into sleeve opening, holding sleeve from opposite side;
- to place cover 15, drawing up screws 18 complete with washers 17;
- to place rubber ring 13 into groove on spring plug 5;
- to place rubber ring 12 into groove on spring cover 3;
- to place spring plug with ring into bore on spring cover 3 up to the full stop;
- to draw up screw 1 with nut 2 in threaded bore on spring cover;
- to place spool 8 with spring stop 7 into sleeve 9 bore
CAUTION: THROTTLE BORES OF SPOOL ARE TO BE SITED FROM SLEEVE 14 COVER SIDE.
- to place spring 6;
- to place semi-assembled spring cover into bore on housing 10 and to secure using cover 4 with screws
18 complete with washers 17;
- to place hydraulic distribution valves 19, 20 on housing 10 and to secure with screws 21 complete with
washers 22;
- to place cocks 11 and nipple 16.
Testing of dumping mechanism control unit is to be effected in the following succession
- to create pressure 4 — 20 MPa in channel Р (picture 14.16), drainage is to be carried off from chamber
Т1 into tank and by connecting manometer with measuring limit of 10 MPa to chamber М, when solenoids are
deactivated, reduction pressure is to be set at (3±2) MPa using screw 1 (see picture15.6);
- channels X, Y, Z must be open for leakage evaluation and measuring: 0 — 100 sm³/min pressure in
chamber Р (10±1) MPa;
- by connecting manometers to chambers X and Y, one is to check distribution valve 20 performance,
activating its magnets by turns and waiting for the moment when
pressure value reaches (3±0,2) MPa in chambers X and Y;
- performance of distribution valve 20 is to be checked
when pressure value of 16 — 20 MPa is supplied (through throttle
1,5 mm in diameter) to chambers А and В;
- magnet activation should lead to pressure reduction in
chambers down to 0 – 0,5 MPa. Drainages Т and Т2 at this mo-
ment should be connected to tank and pressure Р should not be
used.
Picture 14.16 — Setting up of control unit:

Т1, Т2 — drain chambers; X, Y — control chambers; А, В —relief valves
control chambers
14.6.2.3 Assembly of hydraulic distributor relief valve

Assembly of hydraulic distributor relief valve is to be effected in the following succession:
- to place protective ring 3 into annular grooves on valve 4 (see picture 14.14), previously greasing it by
Litol-24 lubricant;
- to place valve into body 1. Valve should travel in the body without any jerks;
- to place spring 5;
- to place ring 6 into groove on cover 7 and to place cover into valve body.
14.6.2.4 Assembly of auxiliary valve (hydraulic distributor)

Assembly of auxiliary valve (hydraulic distributor) is to be effected in the following succession:
- to place rubber rings 1 and 2 previously greased with Litol-24 lubricant into annular grooves on seat 3
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Dumping mechanism
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(see picture 14.15);

- to place two rubber rings 5 into annular groove on valve spindle 4;
- to place spindle into valve seat (before placing of rubber ring, spindle should travel in valve seat with-
out any jerks);
- to place seat with spindle into valve body 15;
- to place rubber ring 17 into annular groove on plug 16;
- to place plug into body;
- to place cover 18 and to secure it using screws 19 with spring lock washers 13;
- to place adjusting valve 6 complete with washer 7 and spring 8;
- to place rubber ring 1 into annular groove on piston 9;
- to place piston into housing;
- to place cover 10 and to secure it with screws 11 complete with spring lock washers 13;
- to place adjusting screw 12 complete with nut 14 into cover.
14.6.2.5 Assembly of hydraulic distribution valve

Assembly of hydraulic distribution valve is to be effected in the following succession:
- to assemble housing block 11 (see picture 14.3), by placing O-rings 12 and to tighten with screws 18
with torque of 100 — 115 Nm;
- to place plugs 14 into bores on body, protective washers 7 and rings 8 being previously placed into an-
nular grooves on plugs;
- to place covers 9 on body and to draw up screws 10 complete with spring lock washers;
- to place spool 24 into body 11, previously greased with И-20А oil, and to check spool travel in 4 posi-
tions every 90 degrees. Spool should travel driven by its own weight smoothly and jerk-free. Spool should fea-
ture the same serial number as housing block;
- to place successively spring support 20, spring 22, spring support 20 onto spool face;
- to insert shank 21 into openings on spring support and to screw it in into face bore of spool 24.
Threaded area of shank is to be previously covered with УГ-9 proofing compound;
- to place successively spring support 27, spring 25, spring support 27 onto spool face;
- to insert shank 26 into openings on spring supports and to screw it in into face bore of spool 24.
Threaded area of shank is to be previously covered with УГ-9 proofing compound;
- to place rings 23 previously greased with Litol-24 lubricant into annular groove on covers 19;
- to connect covers 19 to housing block 31 and to secure with screws 13 complete with spring lock
washers with torque of 55 — 85 Nm;
- to assemble the second section of hydraulic distributor similarly;
- to place O-rings 8 into annular grooves on relief valves 6;
- to secure valves 6 to body with screws 5 complete with spring lock washers and to tighten with screws with
torque of 38 — 45 Nm;
- to place O-rings 1 into annular grooves on additional valves 4 and 15;
- to connect auxiliary valves 4, 15 and valves 6 with screws 6 complete with spring lock washers;
- to place O-ring 1 into annular grooves on crossover plate 2;
- to bolt together auxiliary valve 4, crossover plate 2 and safety valve 6 with screws 3 complete with
spring lock washers;
- to place O-rings 8 into annular grooves on overflow valves 30;
- to bolt valves 30 to semi-assembled unit with screws 31 complete with spring lock washers and to tighten
with screws with torque of 38 — 45 Nm;
- to bolt cover 29 to semi-assembled unit with screws 28 with spring lock washers.
Testing of hydraulic distributor (dumping mechanism) is to be effected in the following succession:
To supply operating liquid by turns into chambers А1, А2, В1, В2 under pressure of (16±0,5) MPa, leak-
3
age from single chamber should not exceed 100 sm during (60±5) sec.
After checking of inner impermeability has been completed, safety valves are to be adjusted for pressure
at discharge rate not less than 100 l/min using adjusting screws Г:
- chamber Р1 — (20±0,5) MPa;
- chamber Р2 — (16±0,5) MPa;
- chamber В2 — (8±0,5) MPa.
Operating liquid is to supplied into chamber P1 at discharge rate not less than 100 l/min and under pres-
sure of (16±0,5) MPa, leakage from chambers Т1, Т2 should not exceed 100 sm3 within (60±5) sec. To obtain
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pressure (2,5±0,5) MPa in turns in chambers Y1 and X1, drainage must be provided through chambers В1 and
А1 accordingly. Break-loose pressure on spool should not exceed 0,65 MPa. Operating liquid is to be supplied
into chamber P2 at discharge rate not less than 100 l/min, drainage is to be done from chambers Т1, Т2. To
obtain control pressure (2,5±0,5) MPa in turns in chambers Y2, X2, drainage from chambers Т1, Т2 should
stop and should be provided through chambers В2 and А2 accordingly. Break-loose pressure on spool should
not exceed 0,65 MPa.
14.7 Mounting of dumping mechanism assemblies into dump truck
14.7.1 Mounting of dumping mechanism assemblies into dump truck

In the process of mounting of dumping mechanism assemblies it is required:
- to ensure safe body interlocking (to check that body rests solidly on dump truck frame or to interlock
body in raised position using steel cables);
- to check null pressure in pneumatic hydraulic accumulators;
- to mount hydraulic equipment on frame brackets using if necessary hoisting devices;
- to connect piping and high-pressure hoses to hydraulic equipment;
- to draw up fastening screws.
During assembly procedure of the hydraulic system there should be no irrelevant objects, dirt and so on.
14.7.2 Mounting of dumping mechanism cylinders into dump truck

Before mounting dumping mechanism cylinders into dump truck, articulated spherical bearings of head
23 (see picture 14.6) and cylinder cover 10 are to be mounted in the following succession:
- to place one retainer ring 3 (see picture 14.3) into cylinder head and cover and to force articulated
spherical bearings 2 and 15 into retainer rings up to the full stop;
- to place one more retainer ring having secured articulated bearings into cylinder head and cover;
- to grease spherical surfaces of bearings with Litol-24 lubricant and to pack it into gland spaces;
- to press glands 7 and 16 (two pieces) into cylinder head and cover accordingly.
Mounting of dumping mechanism cylinders into dump truck is to be effected in the following succession:
- to place anti-backtracking supports under wheels of front and rear axes of dump truck;
- to lift body by crane thus body floor being in horizontal position. To place technological stands between
frame and lifted body;
- to place spacer bushings 8 into cylinder cover;
- to place appliance for removal and mounting of cylinders (see picture 14.4) onto cylinder and to secure
it safely;
- to place cylinder onto lower frame support;
- to place hold-down cover 13 of cylinder head and to secure it with screws 14;
- to match cylinder cover with body ears;
- to place pin 9 complete with spacer bushings 8, cover 4 and to draw up screws 5 (spacer bushings
should travel symmetrically);
- to screw in lubricators 6 and 17 into cylinder cover and head;
- to grease articulated spherical bearings with Litol-24 lubricant through lubricators until lubricant shows
up from underneath glands;
- to place cover 12 of cylinder head;
- to connect oil piping to lower cylinder supports.
Assembly of dumping mechanism cylinders in BELAZ -75131, BELAZ-75132 dump trucks is to be ef-
fected in the similar way to assembly of dumping mechanism cylinder in BELAZ -7514-10, BELAZ-75145 dump
trucks.
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Cab, cab equipment and empennage
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15 CAB, CAB EQUIPMENT AND EMPENNAGE

Cab - two-seater, all-metal, two-door, with thermo-noise insulation and soft lining, is mounted from the
left on brackets and fastened by bolts (figures 15.1, 15.2)through rubber absorbers, which reduce the vibration
of the truck under moving.
Cab of the truck BELAZ-75131, BELAZ-75132 meets requirements of safety system ROPS. At the cab
there are operator’s pneumo-sprung seat (BELAZ-75131, BELAZ-75132) or torsion (BELAZ-7514-10,
BELAZ-75145)and fold-back seat, instrument panel, heater with two fans, electric screen washer, two-brush
windshield wiper. The cab is also equipped with two sun visors, floodlamp lighting, hanger, pocket for docu-
mentation. The place for medicine chest and fan of air blowing is provided.
The locks and drop windows are mounted into the door (with stop devices from the inner door side). The
doors are equipped with outer and inner handles. The air-tightness of door and windows is provided by rubber
seals.
The sandwich soft lining, coated with perforated vinyl leather, is used on the ceiling, sidewalls and
backwalls.
Glazing of cabin is provided good visibility from the operator place. Windscreen is plane triple (two pol-
ished glasses with transparent plastic film between them), back and side screens are toughened and safety.
Figure 15.1 – Mounting of cab and empennage of trucks BELAZ -75131, BELAZ-75132:
1 – left wing; 2 – front bonnet; 3 –rear bonnet; 4 –right wing; 5 –left rear wing; 6 – bolt of cab fastening; 7, 11 –plates; 8 – pad of
cab fastening; 9 – bracket; 10 –bolt
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Empennage grounds of the truck are made of special steel sheet (with effect «antislip») in thickness of 3
to 4 mm.
During the operation on the parts of empennage and cabin as a result of weather or mechanical impact
the following defects can be emerged :damage of antirust coating, cracks, breaks, dents, bends, weakening of
threaded joints, breakage of rubber pads of cab fastening.
Zones of empennage or cab where the coloration is damaged or there is a corrosion, it’s necessary to
clean and paint opportunely for preserving them from the further corrosion trouble.
Figure 15.2 –Mounting of cab and empennage of trucks BELAZ-7514-10, BELAZ-75145:

1 – front left wing; 2 – front bonnet; 3 – rear bonnet; 4 – front right wing; 5 – additional right wing; 6 – support beam; 7 – additional
left wing; 8 – bolt; 9 – pad of cab fastening; 10 - plate
Cabs and empennages of trucks BELAZ -7514-10, BELAZ-75145 are differ in form, operator seat and
screens.
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15.1 Taking off of cabs, empennage and its repair

For damage repair the parts of empennage and cab should be taken off from the truck. Before such op-
erations lift up and stop the bed by means of stop cable, as shown at the figure 15.3.
Figure 15.3 –Bed stopping:

1 – rope for platform fastening; 2 – pintle; 3 – washer; 4 – splint; 5 – bolt
The empennage is taken off by means of any pull adaptations, which are appropriate in load capacity
and meet safety requirements. Left and right wing are removed by
turns as an assembly with brackets. At that it’ s necessary previously
to cut off the bolts with nuts, by which the empennage is fastened to
the frame.
The diagram of cabin fastening is shown at the figures 15.4
and 15.5.
Before cab removal it’ s necessary to do the following:

-disconnect electric wiring, which goes from units and assem-
blies to the cab;
-discharge pneumohydraulic accumulators;
-discharge air tanks;
-disconnect the drive of fuel supply control;
-disconnect the hoses of supply to the hydro steering, previ-
ously having made marking on clamps, fastened on both ends of cut-
off point (if marking is absent);
Figure 15.4 –Diagram of cab fastening under the removal from trucks
BELAZ-75131, BELAZ-75132:
1 – truck cab; 2 – ring-bolt; 3 – pull adaption (with 4 hooks)
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Figure15.5 – Diagram of cab fastening under the removal from trucks BELAZ-7514-10, BELAZ-75145:
1 – truck cab; 2 – pull adaption
- disconnect the pipes to the drive valves of service and parking brakes, previously having made mark-
ing on clamps, fastened on both ends of cutoff point (if marking is absent);
- disconnect the hoses of cab heater from the heat exchanger;
- disconnect the air pipe-line from the square of pneumo-cushioned seat powering (for trucks BELAZ-
75131, BELAZ-75132);
- disconnect the hoses of conditioner (if it’s installed);
- cut off bolts (see figures 15.1 and 15.2) with nuts, by which the cab is fastened to the beams of rest;
- for joining of pull adaptation (for trucks BELAZ-75131, BELAZ-75132) screw into the holes, located on
the cab roof, four ring-bolts (ring-bolts are put into kit of spare
parts);
-remove cab and place it onto the special stand.
Repair of cab and empennage. Dents and bends on

the cab parts are cleared by method of driver and straightening
of damaged surface by means of special tool kit (figure 15.6).
Figure 15.6 –Set of tools for dent flattening:

1-6 – hammers; 7,8 – mauls; 9-16 – mandrels; 17-19 – props
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The example of dent flattening is shown at the figure 15.7.
The most surface imperfections, which can’t be straightened by

straightening, are flattened by filling of them by tin solder, heat-resistant
mastic made on the base of epoxy resin,or plastic. Applied for such
goals material should have good adhesiveness with metal. Before apply-
ing of the material blanch the flattening surface by hog or abrasive cloth.
Cracks, breaches, breaks on the parts of cab and empennage are
cleared by gas or gas-electrical welding. Welding section should be
thoroughly cleaned out from contamination and paint by means of metal
brush (hog) and solvent flushing. Depending on the thickness of weld-
ing metal select the number of torch head, diameter of welding wire and
Figure 15.7 –Dent flattening: torch angle . In case of need by means of wet asbestos board prevent
а – tapping; b – straightening; the insulating spacers of cab from fire and metal spray.
1 – prop; 2 – hammer; 3 – panel Plain welding of cracks at the sheet metal don’t provide high-
strength joint, therefore in most cases the welding of additional boosters
from the inner side of parts is need .
Warps in doors and window opening of cabin should be eliminated by means of special stretching and
contracting devices with mechanical or hydraulic drive. Rests of adaptations should have big joggles according
to the form of parts upon which they rest during the work. The violation of stated requirements can cause local
deformation of parts at the places of adaptation stop.
The door of cab after repayment should be free opened and closed and have uniform gap along the whole
aperture outline. For compacting of door aperture place the new rubber compactors. After the repayment clean
the welded section from contamination and cinder, degrease and paint.
Under the truck mounting onto the truck change the worn-out
pads for new ones.
Replacement of cab screens. Immovable cab screens
(windshield, side and rear) are mounted into the rubber compactors
1 (figure 15.8) and fastened by rubber cam bushings 2.
Figure 15.8 –Mounting of immovable cab screens:

а – mounting of windshield, b – mounting of rear window
1, 11 – window; 2, 10 –clamp; 3 – screw; 4, 7 – bushing; 5, 12 –compactor; 6, 8 –
nut; 9 – stud
For removal of cab windshield unscrew nuts 6, extract screw 3 and take off clamps 2, take out cam
bushing 4 and , pushing by hand onto the screen top, squeeze it out (this operation would be better realized
the two together in order to prevent the glass drop at the moment of its outcome from aperture).
The mounting of windscreen should be realized in the following way:

- lay the compactor along the whole outline of the window door aperture in order to the butts are located
under clamps;
- mount outside the cabin the glass into the lower compactor slot and , little by little bringing the sealing
edge beyond the glass border, put the glass into place .
The mounting of the windshield is better the two together: the one inserts the glass into the compactor
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7513-3902080 RM
and press it tightly to the window aperture, the other brings the sealing edge beyond the glass border;
- insert the cam bush by means of mandrel (figure 15.9) into the compactor slot along the whole length;
-mount clamps.
Figure 15.9 – Mounting of cam bushing with the help of mandrel:

а – mounting of locking bush; b - mandrel
Removal and mounting of rear screen and immovable side screen of the cab should be realized simi-
larly.
15.2 Repair of cab equipment

15.2.1 Repair of cab equipment of trucks BELAZ-75131, BELAZ-75132
Change(removal) of movable door window is realized in the following way :

-take off door, having unscrewed bolts 3 (figure 15.10) which fasten it to the loop, and put it onto the
lazy board for avoiding of lacquer coating damage and comfort of further operations performance, (all opera-
tions can be made without door removal);
Figure 15.10 – Cab:

1 – left rear cab panel; 2 - left cab door; 3 – screw of loop fastening to the door; 4 – loop
15-6
15-7
Figure 15.11 – Cab door:

1 – door; 2- drop window; 3 –side door window; 4 –inner door handle; 5 – door lining; 6, 10, 17, 19, 21, 46 – washers; 7 – glass limiter; 8 – buffer of bonnet; 9,
16, 20, 27, 36, 45 – screws; 11 – bracket of window raiser; 12, 32 – gaskets; 13 – edging; 14, 15, 39, 40 – compactors; 18, 28 – dutchman; 22 – handle coating; 23 – han-
dle of window raiser; 24 – window raiser; 25 – handle rosette; 26, 42 – nuts; 29 – bolt; 30 – external handle; 31 – packing cork; 33 –lining holder; 34 – door packing;
35 – locking dutchman; 37 – handle of lock drive; 38 –lock drive; 41 – clamp; 43 – packing bush; 44 –stud; 47 – door lock; 48 – lower link
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- take off dutchman 20 (figure 15.11), having unscrewed screws 16;

- take off two handles 4, having unscrewed screws21;
- take off handles of castle and window raiser drives, having take out stopper 25;
- take off dutchman 29 and 33, having unwrenched screws 28 and 16;
- take off lining 5, having cut holder 39;
- take off glass limiter 9, having unwrenched bolts 8;
- take off the bracket of window raiser 13, having unscrewed four screws 8;
- release the arms of window raiser of the glass(window) 2 crank and crank 32;
- take out the glass ready-assembled with crank from the door through the lower door slit ;
-replace the glass, having mounted and swaged it, as shown on the figure 15.12 for the glass of left
door(for window of right door – mirror montage), at that necessary to glue the new lining from raw rubber. The
fit of glass into the casing should be tight;
Figure15.12 –Drop window of the left door:

1 – casing of drop window; 2 – drop window of door; 3 - lining of drop window
- realize the assemblage of door in the reverse order .

Before assemblage lubricate all attrition faces by lubricator “Литол-24” (фиол 2).
The replacement of door lock is realized in the following way :

- take off the handle of lock 36 drive (figure 15.11);
- take off dutchman 33;
- take off drive 35, having unscrewed screws 34;
- take off lock 45, having unscrewed screws 43;
- cut off the lock 35 drive from the lock link;
- replace lock and mount it at the reverse order.
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Replacement or repair of window raiser is realized in the following way:

- perform the operations stipulated under the change (taking off) of movable door window;
- take off the window raiser 23 (see figure 15.11), having unscrewed nuts 27;
- replace (repair ) window raiser and mount it in the reverse order.
Before assemblage lubricate all attrition faces by lubricator “Литол 24” (фиол 2). Check up and tune
the window raiser in accordance with figure 15.13.
Figure15.13 – Window raiser :

1 – arm; 2 – body of window raiser; 3 – backing-up roll; 4 – volute spring; 5 – body of brake mechanism; 6 – control roller;
7 – roller; 8 – roller; 9 – pinion of window raiser; 10 – spring of window raiser; 11 - rivet
The brake mechanism is checked up by the single lifting of load with mass 10+0,5 kg, at that the clear
fixation of load in any point of motion, as under the lifting so under the sinking, should be provided. Smooth-
ness of motion is controlled under the load of mass 6+0,5 kg. The load move should be uniform , without jerk-
ing, jamming, gnash and clicks. Effort on the handle of window raiser (на плече 85+2 мм) under the lifting of
load with mass 6+0,5 kg should be not more 20 N.
Replacement of the volute spring of window raiser is realized in the following way:
- take off handle 24 (see figure 15.11) of window raiser;
- take off dutchman 29;
- take off spring 4 (figure15.13),having released it from capture;
- replace spring and mount it in the reverse order.
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Operator seat – pneumo-cushioned, with the devices of seat height control, lengthwise movement, turn-
ing and back fixation (figure 15.14).
Figure 15.14 – Operator seat:

1 – handle of the mechanism of seat lengthwise movement; 2, 4 – handle of fixative of seat height regulation; 3 – seat rest with
pneumoequipment; 5 – cover of regulation mechanisms; 6 – handle of turning mechanism and seat back fixation; 7 – seat pad; 8 – seat
back; 9 – threaded hole of lap belt fastening
The lengthwise movement of seat is realized by means of handle 1. The handle should be turned left,
put the seat to the necessary position and release handle.
The regulation of turn and fixation of seat back 8 is realized by handle 6. Under the handle turn to the
upper position the back is put to the front position.
The seat pad is regulated and fixed on height and slope by the handles 2 and 4 . Under the turning of
handle up the pad takes the extreme upper position. Byturn turning of handles is provided the slop of seat pad.
Seat shell has two threaded holes 9 of size 7/16" for fastening of lap belt. The fastening bolts are in-
cluded into the kit of lap belt
For checking of serviceability of pneumatic cushioning system it’s required under the operative motor to
bring out the seat from the nominal static position by pushing or lifting it up. After the loading stop the seat
should be returned to the original position (size 150 mm), at that after the lifting up the noise of air outlet from
pneumodistributor should be heard.
The arrangement of pneumatic cush-
ioning system is shown at the figures 15.15
and 15.16.
The mechanism of pneumatic cush-
ioning is powered from the pneumosystem
receiver, mounted at the seat 3 rest (fig-
ure15.14). It consists of pneumoballon 6
(see figure15.15),pneumo distributor 3,
shock absorber4, upper 1 and lower 2
arms and buffer 5.
Figure 15.15 – Seat rest with pneumo equipment:

1 – upper arm; 2 – lower arm; 3 – air distributor;
4 – shock-absorber; 5 – buffer; 6 – pneumoballoon
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Under the operative motor the air from the pneumosystem receiver intakes to the canal I (figure 15.16)
of air distributor. Under the loading on the seat the upper and lower arms (figure15.15) are turned. At that the
arm 10 is turned(figure 15.16). The zone of insensitivity of air distributor is 4-120. Under the lifting of the seat
down the pivoted element 4 opens the valve 8,
joining canal I with canal II (receiver of pneumo-
system with pneumoballoon).The swap of bal-
loon is carried out. Nominal static size of air bal-
loon 150 mm. Under achievement of such posi-
tion the arm 10, turning pivoted element 4,
closes valve 8, stopping the air supply to the
balloon. Under the shifting of operator seat up
the pivoted element of air distributor opens the
second valve, joining canal II with canal III. The
air from the pneumoballon passes to atmos-
phere. So the effect of pneumo-cushioning is
achieved. Buffer 5 (figure 15.15) limits the mini-
mal height position of seat, the shock absorber 4
reduces the fluctuations, emerging under the
seat shifting up and down.
Under the non-operative system it’s re-
quired to dismantle it. For that cut off the pipe of
air supply to the air distributor from receiver,
take off the rest with pneumoequipment from the
truck, check the state of pipes of air supply be-
tween pneumoapparatuses, the state of pneu-
moballon (hermeticity).Having dismantled the air
distributor, check the state of rubber washer 11
Figure 15.16 – Air distributor:
on the valve 8 (figure15.14). In case of washer
1 – knee; 2 – slide; 3 – collar; 4 – rotary element; 5 – cap;
damage it should be changed. The washer 6 – lining; 7 – body; 8 – valve; 9 – stop; 10 – arm; 11 – rubber washer
should be pasted into its cage on valve. Under I – canal communicating to receiver; II – canal of air supply to
the falling out of washer from the cage – the pneumoballoon; III – canal communicating to atmosphere(figures in
system is not operative. After the trouble- brackets are marked on body)
shooting and assemblage of the system, check
up repeatedly its serviceability.
Cab heater - fluid, as a heat carrier the motor cooling fluid is used. The hot fluid passes from the ther-
mostat head through the plug stopcock and rubberized fabric hose into the heat exchanger and flows out of it
into the inlet pipe of motor. The cold air, delivered by two fans, passing through the heated exchanger, is
heated and enters the cabin. The amount of supplied into the cabin external air is regulated by shutter. The
shutter can be mounted so that only the external air, or the part of external air together with cab air, or only the
inner air will be entered the cab.
The hot air from the heater is supplied onto the windshield by the one fan, and by the other – to the zone
of operator feet and to the left and right side door windows.
The fans of the heater are connected into the network through two switches according to the double-
mode circuit for separate engagement into the work and control of their productiveness and hence of air tem-
perature at the cab.
Stopcock of the heater connect, mounted on the discharge pipe, gives the opportunity to reduce the
amount of hot liquid, entried into the heat exchanger, or fully overlap the entry on summer period. On the run-
down pipe the stopcock is not mounted.
Under the connect of aluminium heat exchanger to the cooling system the pressure and rundown pipe
lines can be connected to any exchanger pipe junction.
For air purification, supplied into the cab through heat exchanger, the paper filter, which should be peri-
odically cleaned from dust and dirt, is mounted outside on the front cab side wall.
The repair of heater is realized by replacement of worn components: radiator, electric motors, rotor and
rubberized fabric hoses.
For change of electric motor (figure 15.17) it’s required:
- unscrew bolts 8 and extract from heater cage 7 the electric motor 14 with the fan rotor 9;
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7513-3902080 RM
- unscrew the screw of rotor fastening (it’s not shown at the figure) and take off the rotor from the motor ;
- unscrew nuts 15 and take off from the motor the disk 11.
Under the mounting of motor the fan rotor should be rotated without jamming.
Figure15.17 – Cab heater :

1, 12 – nut; 2 – washer; 3, 13 – spring washer; 4, 8 – bolt; 5 – air intake; 6 – radiator; 7 – heater cage; 9 – fan rotor; 10, 15 – gas-
ket; 11 – disk; 14 – electric motor;
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For replacement of radiator it’s required:

- overlap the heater valve and wait for the drainage of cooling liquid.
- cut off the hoses of cooling liquid supply;
- unscrew nut 9 (figure 15.18), extract splint 4 and take off the cable of shutters control drive (for trucks
BELAZ-7514 the cable is absent);
- unscrew nuts 7 and take off the lower cage of the heater;
- unscrew nuts 6 of heat exchanger fixative and take off radiator.
For replacement of air filter it’s required:
- unscrew bolts 11 (figure 15.18) and take off grating of cab casing14;
- unscrew nuts 13, take off clamps 12 and extract filter 15.
Figure 15.18 –Mounting of cab heater of trucks BELAZ-75131, BELAZ-75132

1 – air flue; 2 – electric motor of the heater; 3 – cab heater; 4 – splint; 5, 6, 7, 9, 10, 13 – nut; 8 – cable of heater shutter;
11 – screw; 12 –holder; 14 – grating of cab casing
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Figure15.19 –Mounting of cab heater of trucks

BELAZ-7514-10, BELAZ-75145
1 – filter; 2 – air intake; 3 – heater cage; 4 – arm of heater shutter;
5 – electric motor; 6 – nozzle of windshield blower; 7 – gasket
Windshield washer – consists of polyethylene pot for fluid and pump with electric motor, mounted at
this pot. The pump is joined by hoses with two jets.
Under switching of pump the fluid passes through hoses into jets and splits by them on screen. At the pot
cap there is a hole which provides the pressure equalization in it under the pump operation. The direction of fluid
jet is regulated by turn of the ball at the plastic jet in order to the flush is directed into the upper zone of section,
describing by the brush of windshield wiper.
Figure 15.20 – Removal and montage of windshield washer:

1 – electric wind shield washer; 2 – protective bush; 3 – tee; 4 - jet
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For avoidance of filter and jets clogging, it’s necessary to flood the pot only by filtered fluid and clean pe-
riodically the jets. As the operational fluid for windshield washer it’s required to use special antifreezing fluids
mixed with water in proportion according to application instructions of this fluid.
Removal and montage of the windshield washer is shown at the figure 15.20.
The repair of windshield washer is realized by replacement of worn components: pump with electromo-
tor, pot, jets and hoses.
Windshield wiper –consists of electric motor, links, and arms with brushes, fastened on the front cab
board. Removal and montage of arms and brushes of windshield wiper are shown at the figure 15.21.
Figure 15.21 –Removal and montage of arm and brush of windshield wiper:
1 – brush; 2 – drive of wiper; 3 – arm; 4 – nut; 5 – link
The repair of windshield wiper is realized by replacement of worn components: electric drive(or electric
drive as assembly with electric engine), brush, arm (or arm as assembly with brush).
For change of arm with brush unscrew nut 4 and take of it from the axe cone. Place the new arm with
brush and fasten it by nut.
For change of electric drive take off the link from axe of the drive, having unwrenched nut and taken off it
axe cone, unscrew 3 bolts, fastening the drive to bracket and cut off cord assemblies. Replace the drive and
assemble it in reverse order.
Conditioner. On customer demand the truck is equipped by block chladone system of air conditioning
with location of compressor on engine, air cooling block (evaporator)at the cab behind the operator seat, con-
denser block on the back cab side wall. The conditioner units are joined between them by elastic pipes of
chladone-resistant rubber.
Charging of conditioner, its putting into operation, repair are realized in accordance with operation man-
ual for this conditioner by specialists of the conditioner firm-supplier or their regional representatives.
After the performing of all working concerning repair or change of faulty parts, place the cab and em-
pennage. The montage is realized in reverse order.
15-15
7513-3902080 RM
15.2.2 Repair of cab equipment of trucks BELAZ-7514-10, BELAZ-75145
Replacement (removal) of movable and immovable door windows is realized in the following way:
Figure 15.22 – Cab:

1 – cab; 2 – loop; 3 – screw of loop fastening to the cabin;
4 - screw of loop fastening to the door; 5 – left cab door
- take off door, having unwrenched bolts 4 (figure 15.22), fastening it to the loop and put it onto lazy
board for avoidance of lacquer coating damage and confort of further operations performing (all operations can
be performed without door removal);
Figure 15.23 – Cab door:

1 – fixative of movable window; 2 – door compactor; 3 – handle bush; 4 – external door handle; 5 - handle of lock drive; 6, 7, 13,
20 – screw; 8 – drive of door lock; 9 – link of lock drive; 10 – stud of handle fastening; 11 – compactor of immovable window; 12 – frame of
movable window; 14 – holder of door window frame; 15 – immovable window; 16 – movable window; 17 – window compactor; 18 – door;
19 – lock; 21 – inner door handle; 22 – door lining; 23 – lining holder
15-16
7513-3902080 RM
- take off the inner door handle 21 and handle of lock drive 5, having unwrenched bolts 6 (figure 15.23);
- take off lining 23 holders and dutchman 22;
- take off the holder of door window frame 14, having unwrenched screws 13;
- take off movable window 16 with frame 12 and packing 17;
- take off immovable window with packing 11;
- replace windows;
- assemble the door in reverse order.
After assemblage the movable window should smoothly without jam opens and closes, and compactors
of door windows are abutted without gaps to the windows .
Replace the lock drive and door lock in the following way :
- take off door handle21 and handle of lock drive 5, having unwrenched screws 6;
- take off the lining 23 holders and dutchman 22 (figure 15.23);
- unscrew screw 20 and take off lock 19;
- unscrew the stud of handle 10fastening and take off external handle 4;
- unscrew screws 7 and take off the door lock drive 8 with link 9;
-replace the lock and install it in reverse order.
Operator’s seat – cushioned, with devices of height seat control, lengthwise movement, turning and
back fixation (figure 15.24).
Figure 15.24 – Operator’s seat:

1 – corrugated sheath; 2 – handle of toughness regulation; 3 – seat pad; 4 – handle of seat horizontal regulation; 5 – seat back;
6 – handle of seat back slope regulation ; 7 – spring; 8 – adjustable stop
15-17
7513-3902080 RM
The seat is regulated:

- by operator mass with the help of handle 2;
- by height ± 40 mm. For change of seat height adjustment it’s necessary, having seized the operation seat by
both hands, to lift it up, at that the latch of adjustable stop 8 is fixed and gives the opportunity for adjustable
stop to take extreme lower position. After that sink the seat to extreme lower position, and then, again lifting
the seat up, put it to the handy position;
- by horizontal with the help of handle 4 (± 75 mm);
- by slope angle of seat back by means of handle 6 (2, 5° – 20°).
Replacement of cab heater, windshield wiper and windshield washer is realized analogously as on the
trucks BELAZ-75131, BELAZ-75132.
15-18
Frame and body
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16 FRAME AND BODY
Frames used on dump trucks and bodies of a welded construction are characterized by tall longevity at
operation in the close conditions of maintenance.
For security long and a fault-free operation of the basic bearing components of a construction of a dump
truck observe service regulations. Do not suppose overload of the dump truck. While in service a dump truck
periodically inspect availability index of product of a frame and a body.
Imperfections detected at checks (cracks, holes, dog-legs) frames and bodies in due time eliminate.
The frame manufactured of high-strength low-alloy steel 10ХСНД with the following mechanical proper-
0
ties: a ultimate strength σВ = 540 МPа, a yield stress σТ = 400 МPа, impact strength at a minus 70 С not less
2
аН = 30 N.m/sm .
The body manufactured of high-strength, antiwear alloyed steel 18ХГНМФР with the following mechani-
cal properties: a ultimate strength σВ = 1100 МPа, a yield stress σТ = 1000 МPа, impact strength at a minus
40 0С not less аН = 30 N.m/sm2.
Both steel quality are characterized by good weld ability any kinds of a welding.
For deriving a qualitative welded connection at repair quality of used electrodes and preparation of a
surface to a welding has the important value. With this purpose apply electrodes such as Э-46А or Э50А. Ap-
plication of these electrodes allows to provide a necessary ultimate strength of a weld seam (a ultimate
strength should be not lower σВ = 420 МPа).
Electrodes should be stored in a dry heated location with temperature not below plus 16 0С and a rela-
tive humidity of air no more than 60 %. Directly ahead of use electrodes should be calcinated on a condition
specified on packaging.
Before calcination to test rods of electrodes on absence of a rust by collapse of a coverage on 1 –2 elec-
trodes of each brand. Presence of a rust is not supposed.
To transport the calcinated electrodes to a work station and to store them in carefully closed container,
guarding against moistening and pollution.
16.1 Technical condition inspection of frame (body) and defects imperfections

definition
Before inspection of availability index of product of a frame (body) it is necessary to wash up a dump
truck water or the ferry under a high pressure, to install on well covered body. It will facilitate visual inspection
and searching of faults. For searching faults use improvised means – a portable flashlight, the putty knife, a
wire brush, a gas burner, etc.
Many cracks are easy for noticing on pure metal, sometimes it is possible to resort and to the help of
colouring agent. It is possible to take advantage for searching cracks of a method of insignificant heating (up to
300 0С) a prospective section with the help of a gas burner. Thus the crack will extend. The given method will
allow to define also, whether the prospective imperfection a crack or a small scratch is.
At visual inspection pay special attention to a condition of brackets and their welding places as they are
the most loaded and most responsible sections of a construction. Check up a condition of weld seams. Cracks
usually appear in the places were under an operation of stretching efforts. The location of such sections is
shown in figures 16.1, 16.2, 16.3 and 16.4. Cracks, as a rule, are augmented, if the dump truck continues to
remain in-process. Therefore, the most preferable is repair on initial stage of a cracking. If nevertheless after
detection of a crack the dump truck cannot be delivered on repair, it is necessary to apply a method of «stop-
ping wimbling» which will consist in the following: define finite points of a crack and drill there bores. It will re-
duce magnitude of effort by a waste of a crack and temporarily will stop its increase
16.2 Preparation of frame (body) for repair

Preparation of a frame (body) for repair consists in preparation of a surface to a welding. For this pur-
pose it is necessary:
16-1
Frame and body
7513-3902080 RM
Figure 16.1 – Location of the most loaded sections of a frame of dump trucks BELAZ-75131, BELAZ-75132
(are shown by arrows):
1 – first cross bar; 2 – second cross bar; 3, 7 – spars; 4 – fourth cross bar; 5 – rear cross bar; 6 – third cross bar
Figure 16.2 – Location of the most loaded sections of a frame of dump trucks BELAZ-7514-10, BELAZ-75145
(are shown by arrows):
1 – first cross bar; 2 – second cross bar; 3, 7 – spars; 4 – fourth cross bar; 5 – rear cross bar; 6 – third cross bar
16-2
Frame and body
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Figure 16.3 – Location of the most loaded sections of a body of dump trucks BELAZ-75131, BELAZ-75132
(are shown by arrows)
16-3
Frame and body
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Figure 16.4 – Location of the most loaded sections of a body of dump trucks BELAZ-7514-10, BELAZ-75145
(are shown by arrows)
16-4
Frame and body
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– precisely to define an occurrence of cracks. At a development of cracks on parent metal in both ends
bore viaholes in diameter of 6 – 8 mm;
– to prepare a crack under a welding for what to delete from a zone of a crack metal with simultaneous
shaping a facet, having provided an angle of disclosing of 30 – 45 grades, obtunding of crimps of 0 – 2 mm,
and a spacing between crimps of 2 – 6 mm. Removal of metal to manufacture on all length of a crack , using
for this purpose arc-air cutting (melting-down of parent metal by a coal electrode and a blowing its jet of com-
pressed air). Application of oxygen cutting is possible, however it is less efficient and has wider heat-affected
zone. With the help polishing machine to manufacture a square-wave stripping of crimps, to clear of slag and
sparks places of a welding. At presence on sections of repair of colour and lubrication to burn their paring knife
and to smooth out a metal sweeper or polishing machine.
Operation of clearing of a surface from pollution is obligatory, otherwise it is impossible to receive the
qualitative welded connection safely working in conditions of reversal loads.
16.3 Frame (body) repair

ATTENTION: BEFORE THE BEGINNING OF WELDING OPERATIONS IT IS NECESSARY TO DISCONNECT
THE ACCUMULATOR BATTERY.
Welding up of the most responsible sections prepared for this operation on a frame and a body is nec-
essary for executing with preheating and consequent heat treatment (tempering). Before the beginning of a
welding a section preheat a gas burner up to temperature 150 – 200 0С, and after a welding preheat up to tem-
perature 600 – 650 0С and then slowly chill.
Preheating and consequent heat treatment prevent undesirable structural transformations into metal,
considerably sink residual stresses at a welding and by that eliminate formation of crazes in a welding weld
and an adjoining zone. With same purpose the welding should be manufactured at above-zero temperature in
conditions of a guard of a place of a welding from deposits and drafts.
16.3.1 Downhand welding

Welding up of the prepared sections to manufacture in some passes. At a welding the first pass it is
necessary to pay special attention to that the radical of a weld well foundered as faulty fusion sinks quality of
repair. At a welding of a root pass it is necessary to use electrodes in diameter of 3 – 4 mm.
Welding methods of a root pass:
– in a case, when a spacing no more than 3 mm – foundered completely the radical of a weld (Fig.16.5);
– in a case, when a spacing more than 3 but less 6 mm – a gap of the radical fuse two passes (Fig. 16.6);
– in a case when a spacing more 6 mm – to manufacture a welding on a lining (Fig. 16.7).
At a welding (welding up) of the cut cracks it is forbidden to include electrodes, a wire, an armature, etc.
as it is shown in figure 16.8.
Figure 16.5 Figure 16.6
16-5
Frame and body
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Methods of driving of an electrode.

– at a welding of a root pass to shade slide an electrode on width of a spacing of the radical;
– after the second stratum driving of an electrode is made on width of
the previous axle;
– the penultimate stratum direct up to a level on 1-2 mm is lower than a
surface of parent metal (Fig.16.9).
Axles of last stratum of a weld should have smooth mating as among
themselves, and with a surface of parent metal.
At veed cutting crimps and spacings up to 6 mm a welding of the first
and second stratum to manufacture the methods which have been mentioned
above.
Figure 16.9
ATTENTION:
1 AT THE INCREASED WIDTH OF THE ELECTRODE OSCILLATION THE AXLE OF THE CONCAVE CAMBER
THAT RESULT IN THE INSUFFICIENT FUSION OF THE RADICAL IS GAINED.
2 AT SMALL WIDTH OF THE ELECTRODE OSCILLATION THE AXLE OF THE CONVEX CAMBER THAT RE-
SULTS IN THE INCOMPLETE FUSION AT THE GASKET OF THE FOLLOWING STRATUM ON BOTH EDGES OF THE
AXLE IS GAINED.
Graphic representations of the specified welds are reduced in Figures 16.10 and 16.11.
16.3.2 Welding in vertical position
The welding of joints in a verticality is made from below up. The

welding of a root pass is analogous to item 16.3.1. Thus it is necessary
to do steps of a lateral vibrations as small as possible to provide a weld
penetration on edges of the previous axle of a weld (figure 16.12).
Figure16.12
16.3.3 Welding in horizontal position

Welding of a root pass to manufacture analogously to item 16.3.1 and figure 16.13.
At a spacing more than 6 mm to cook two "checkpoint", starting to superimpose first the lower axle.
From the second stratum it is preferable to cook a method of a "through passage" weld. The order of suturation
is shown in figure 16.14.
16-6
Frame and body
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16.3.4 Welding in overhead position

The graphic representation of execution of the specified welds is reduced in Figure 16.15.
Figure 16.15
16.4 Welding quality control and defects elimination

In welded connections the following visible imperfections are not supposed:
– cracks of all aspects and directions;
– faulty fusion and lack of fusion;
– groups of pores and slag inclusions;
– separate pores and turnings on in diameter more than 1 mm in an amount more than 4 imperfections
on a section of a weld in length of 400 mm at distance between imperfections less than 50 mm;
– not made craters;
– snatching on parent metal;
– undercuts of parent metal depth more than 0,5 mm.
Defects of weld seams render the big agency on toughness of joints. On detection of imperfections of
welds the visual method is informative enough. On its grounding it is possible to manufacture their reparation.
To reduce a stress concentration, weld seams should be treated polishing machine having deleted thus
irregularities of a surface of an axle of a weld. Rolls and irregularity of the shape of a weld correct on all length
of a weld (look Figure 16.16).
Figure 16.16
At removal of defective places it is necessary to observe

defined rules:
– the length of a deleted section should be equated to length of a defective section plus of 10 – 20 mm
from each side, and the width of cutting of sample should be such that the width of a weld after welding up did
not exceed double width of a weld after welding up;
– the shape and sizes prepared under welding up excerpts should ensure an opportunity of a reliable fu-
sion in any place;
– the surface of each sample should have smooth outlines without sharp protuberances, acute deepen-
ings and agnails.
Craters of welds are necessary for making. Burn-through in welds are preliminary necessary for smooth-
ing out, and then to make.
To reduce a stress concentration by fusion lines with parent metal at polishing machine it is necessary to
remove undercuts depth up to 0,5 mm with a gradient junction to parent metal. At undercuts with depth more than
0,5 mm to manufacture a building-up welding a welding of filar weld on all length of an imperfection and repeat-
edly to treat polishing machine up to a gradient junction to parent metal. An abrasive wheel it is necessary to
have at a square-wave stripping across a weld (look Figure 16.17).
16-7
Frame and body
7513-3902080 RM
Figure16.17
At welding up of a defective section blanking of adjoining sections of parent metal should be provided.
After welding up of cracks and reparations of imperfections from slag and metal sparks should be
smoothed out as heat-affected zone.
For a reinforcement of repair places if necessary, it is recommended to weld on additional mouldings and
ribs. Thus, for prevention of the further collapse it is necessary to be guided by the following rules:
– terminations of ribs are necessary for issuing a gradient junction to the basic part (Figure 16.18). Tran-
sition sections are expedient for treating at polishing machine;
Figure16.18
– mouldings on spars and cross bars of frame and body should have a waste in the shape «dovetail » or
not rectilinear shape, instead of are cut off across. The welding across a staging and side members of spars
(Figure 16.19) is not supposed;
Figure16.19
– the moulding should fit to a reinforced detail densely. The welding welds should be smooth
("stretched"), without interruptions, are treated at polishing machine with a gradient junction to the basic part.
After repair and heat-affected zone it is necessary to paint weld seams colour.
16-8
Frame and body
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16.5 Body removal and setting

In most cases repair of a body is executed without its removal from a dump truck.
If for holding repair it is necessary to remove a body to perform these operations in the following se-
quence:
– install under wheel of a front axle and a rear bridge of a dump truck the thrust blocks;
– disconnect mud shields of rear whees;
– disconnect from the connective panel the wires going on a body;
– disconnect ejectors;
– disconnect cylinders of the tumbler from a body, for what it is necessary to turn out bolts 5 with protective
hollow disks (Figure 16.20) to extract distance sleeves 7 and to beat out fingers 6.
After a unhooking, cylinders to fix the special loose straps used in transit of dump trucks, with the pur-
pose of exclusion of a fault of cylinders;
– disconnect a body from a frame for what it is necessary to turn out bolts 8, to remove covers 9 with lock
plates and to beat out fingers 10. Fingers to back out in an external direction from a shaft of a dump truck;
– remove a body. For removal and settings of a body are used special pull accommodating (Figures
16.21, 16.22) and two additional expansion for maneuvering in transit and setting of a body.
Body removal of dump trucks BELAZ-7514-10, BELAZ-75145 is made analogously.
Figure 16.20 – Body removal – setting:

1 – body; 2 – cylinder of the tumbler; 3, 12 – adjusting plates; 4 – contact plate; 5, 8, 14 – bolts; 6, 10 – fingers; 7 – distance sleeve;
9 – cover; 11 – adjusting hollow disks; 13 – absorber
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Frame and body
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ATTENTION: AT THE BODY REMOVAL AND SETTING IT IS FORBIDDEN TO BE ON THE CHASSIS

OR UNDER THE CHASSIS OF A DUMP TRUCK, BETWEEN WHEEL AND THE LIFTED BODY!
Figure 16.21 – Body removal and setting scheme of the dump trucks BELAZ-75131, BELAZ-75132
Figure 16.22 – Body removal and setting scheme of the dump trucks BELAZ -7514-10, BELAZ-75145
The mass of frames and bodies of dump trucks is specified in Table 16.1.
Table 16.1 – Frames and bodies mass of dump trucks
Name БелАЗ-7514-10, БелАЗ-75145 BELAZ-75131, BELAZ-75132

Frame, kg 9370 12860
Body, kg 18100 19400
16-10
Frame and body
7513-3902080 RM
Setting of a body on a dump truck to manufacture in the following sequence:

– before setting of a body on a dump truck to grease fingers 10 (look Figure 16.20) with lubricant Литол-24;
– fasten a body, as shown in figures 16.21, 16.22 and to combine bores of brackets of a body with bores
of brackets of a frame;
– install from lateral aspects fingers 10. Between bearing parts and raggles of brackets of a body prelimi-
nary establish adjusting hollow disks 11 to remove axial clearances in hinges. Spacings should be no more than
2 mm. The spacing is defined in a zone of the least distance between surfaces. After setting fingers to combine
their lock plates with sawcuts of clampers and to fix by means of covers 9 and bolts 8 with lockwashers;
– test and if necessary to provide the greatest possible alignment of nipples of outlet pipes with bores in
the lower sheets of body gas-collecting at the expense of ovality bores of brackets of strengthening of nipples;
– enclose between spars of a frame and a body technological linings and sink on them a body;
– fill in cavities of bearings of the upper heads of cylinders of the tumbler lubricant Литол-24 and to in-
stall distance sleeves 7. To combine bores of heads of cylinders with bores of eyelets of brackets, to install fin-
gers 6 upper bearing parts of cylinders;
– install covers 9 with lock plates and to fix bolts 5;
– test and if necessary, with the help of adjusting shims 12 to provide a uniform fit of absorbers 13 to a
seating of spars of a frame. Layer pads of the full shape go into into a package and components of 1/2 and 1/3
lengths and 1/2 width for elimination wedge-shaped spacings. The spacing between the absorber and a frame
should not exceed 1 mm. In separate places the wedge-shaped spacing up to 3 mm is supposed. A minimum
size of contraction of a shock-absorber – 37 mm;
– lift a body and to remove safety linings. To remove pull accommodating and the expansion. To grease
hinges of end support bearings of a body and the upper bearing parts of cylinders of the tumbler;
+1
– test presence of a spacing of 0 mm between guiding bodies and contact plates 4. If necessary to adjust
a spacing by means of adjusting plates 3 (cross-section B-B);
– install stones eliminator, having connected them with brackets by means of fingers and splints;
– install mud shields of rear wheel, having attached them to a body by means of bolts, nuts, flat and re-
taining washer;
– connect with the additional panel the wires going on a body.
16-11
Frame and body
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16-12
Fire-fighting System
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17 FIRE-FIGHTING SYSTEM
17.1 General and safety requirements

Fire-fighting system is of combined type, manually actuated, intended for extinguishing fires of А, В, С
grades and electric equipment under up to 1000 V. On customer’s order fire-fighting system with automatic ac-
tuation of powder line can be mounted in the dump truck.
Fire-fighting system consists of two non-interconnected lines – of powder type I (fig. 17.1) and of solu-
tion type II, which can be initiated both simultaneously and individually. Powder line is intended for fire extin-
guishing in engine compartment, fuel and oil tanks. Solution line is intended for fire extinguishing in the places,
which are out of powder line service area, and places subject to recurring of fire.
17.1.1 Powder line

Powder line consists of powder tank 1 with diaphragm guard 6 and filling neck 3, gas-cylinder 9 with
connected reduction gear 8, gas pipe-line 7, powder pipe-line 4 and spray circuit 5.
Powder tank 1 contains automatic loosener, constantly loosening powder using natural vibration of the
dump truck.
Diaphragm guard 6 prevents powder tank from atmospheric moisture ingress.
When valve on gas cylinder 9 is opened, gas is supplied through reducing gear 8 and gas pipe-line 7
into powder tank 1 where it fluffs up the powder. Gas and powder mixture being under pressure of 1,2 MPa
break up diaphragm guard 6 and is thrown through powder pipe-line 4 and spray circuit 5 into engine com-
partment, onto fuel tank and combined hydraulic system tank and extinguishes fire.
Tank fuelling with powder is effected through filling neck on tank body. To avoid clogging up of powder
line channels, powder is not supposed to have lumps exceeding 2 mm.
17.1.2 Solution line

Solution line consists of solution tank 18 with intake 17, gas cylinder 10 with connected reduction gear 11,
gas pipe-line 12, hoses 13 and 16, drum 14 and locking device 15.
When valve on gas cylinder 10 is opened, gas is supplied through reduction gear 11 and gas pipe-line
12 into solution tank 18. Pressure value of 1,2 MPa is gained over extinguishing solution, what forces solution
out of tank through intake 17 and hose 13 to drum 14 and along hose 16 to locking device 15. By pressing on
locking device lever, solution is sprayed out into given direction up to the distance of 10 m.
17.1.3 Safety requirements

Dump truck operators and personnel servicing system equipment, are to be guided by “Regulations
for arrangement and safe operation of vessels under pressure”, “Safety requirements when operating cus-
tomer’s electric equipment under voltage of up to 1000 V”.
In the process of repairs, assembly and maintenance of fire-fighting equipment it is necessary to take
the following precautions:
– strikes against gas cylinder and valve as well as cylinder falling are not allowed;
– cylinders with compressed gas should not be subject to direct heating by heat sources;
– after filling–in of cylinder with valve operative outlet is to be plugged. Plug can be removed only when
mounting cylinder in the dump truck directly before connecting hose to operative outlet;
– storage and transportation conditions of cylinders should comply with requirements for arrangement
and safe operation of vessels under pressure.
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Fig. 17.1 — Combined fire-fighting system:

1 – powder tank; 2 – screw; 3 – filling neck; 4 – powder line; 5 – spraying circuit; 6 – diaphragm guard; 7, 12 – gas pipe-line;
8, 11 – reduction gears; 9, 10 – gas cylinders; 13, 16 – hoses; 14 – drum; 15 – locking device; 17 – intake; 18 – solution tank;
I – powder line; II – solution line
17.2 Technical condition of fire-fighting system and trouble shooting

Technical intactness of fire-fighting system and its constant availability in case of fire risk ensure safe
operation of the dump truck.
Technical condition of the system is determined by proper and timely maintenance in compliance with
system operation directions and dump truck operation manual.
Technical condition of the system is to be determined every shift by visual examination. In the process
of inspection system assemblies, threaded joints, seals on cylinders and reduction gears are to be checked
up. If dents, cracks, damage to threaded joints, tanks and reduction gears have been spotted, they are sub-
ject to repairs.
Hoses featuring swellings or cracking are to be checked for leakage by gaining pressure of 1,2 MPa for
three minutes and if necessary they are to be replaced. Damaged pipe-lines, which open flow area has less-
ened in the result of deformation, are subject to replacement. If leakage has been spotted in solution line units,
it requires remedy.
Once in three months it is required to cleanse out solution tank intake, to fluff up powder in tank by supplying
air or nitrogen under pressure of 0,5 – 1,2 MPa, to blow out powder line and piping.
Every six months it is required to check pressure in gas cylinders and should such necessity arise to
charge them.
Gas cylinder charging is to be effected in the following succession:
– to disconnect reduction gears 8 or 11 (see fig. 17.1) from cylinders 9 or 10;
– to connect cylinder through gas pipe-line 4 (fig. 17.2) to T-joint 3, and T-joint to transport cylinder 1;
– to connect gauging device 5 to T-joint 3;
– to open valves on transporting 1 and charged 2 cylinders;
– when pressure value is reached (checking by pressure gauge of gauging device 5) in compliance with
table 17.2, for correspondent ambient temperature, to close valves on transporting and charged cylinders. By
pressing button to let residual gas out of gauging device. To disconnect gas pipe-line 4 from T-joint 3. To plug-
in operative outlet and to seal the cylinder.
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Fig. 17.2 — Charging scheme of fire-fighting system cylinder from

transporting cylinder:
1 – transporting cylinder; 2 – small capacity cylinder; 3 – T-joint;
4 – gas pipe-line; 5 – gauging device
To check solution consistency in solution tank once a year.

Gas cylinders and tanks are subject to compulsory scheduled technical survey by special control board
and should undergo hydraulic testing.
Data about system faults, assembly repairs, component system replacement, maintenance, technical
condition monitoring and technical survey are to be filled into the logbook for fire-fighting system delivered with
dump truck.
17.3 Possible faults in fire-fighting system and their remedy

To determine possible faults in the fire-fighting system and their remedy one is to be guided by table 17.1.
Table 17.1 — Possible faults in the fire-fighting system, their causes and remedy
Fault and its features Possible cause Remedy

To check gas pressure in cylinder, if nec-
No gas in cylinder
essary to charge or to replace cylinder
Extinguishing substance is not sprayed out Frozen solution To replace solution
To do servicing of whole line: to blow out
Clogging up of line channels
powder line and piping
17.4 Repairs in fire-fighting system

Repairs of cylinders, tanks and reduction gears are to be done at specialized plants having a license for
such kind of job.
Defective hoses and pipe-lines are to be removed and replaced by new ones.
17.4.1 Disassembly of fire-fighting system
17.4.1.1 Disassembly of powder line
Disassembly of powder line is to be effected in the following succession:
– to disconnect reduction gear 8 (see fig. 17.1) from cylinder 9;
– to disconnect gas pipe-line 7 from reduction gear 8 and powder tank 1;
– to disconnect powder cable 4 from tank and spraying circuit 5 and to remove it;
– to untighten screws fixing gas cylinder bracket and to remove bracket with cylinder;
– to untighten screws fixing powder tank and to remove tank;
– to disconnect hose in spraying circuit from pipe-line;
– to disconnect bolting of pipe-lines and hoses and to remove them.
17-3
7513-3902080 RM
17.4.1.2 Disassembly of solution line

Disassembly of solution line is to be effected in the following succession:
– to disconnect reduction gear 11 (see fig. 17.1) from gas cylinder 10;
– to disconnect gas pipe-line 12 from reduction gear 11 and tank 18 and to remove it;
– to disconnect hose 13 from tank and drum 14 and to remove it;
– to untighten screws fixing gas cylinder bracket and to remove bracket with cylinder;
– to untighten screws fixing solution tank and to remove tank;
– to remove split pin 3 (fig. 17.3) out of opening on drum 5 axis and to remove washer 7;
– to remove drum 14 (see fig. 17.1) with hose 16 and locking device 5 from shaft 5 (see fig. 17.3);
– to disconnect hose 16 from drum and locking device.
Repairs of solution line drum.
Major defect of the drum is collar wear out, what in the result leads to leakage in operating solution line.
Replacement of drum collars is to be effected in the following succession:
– to remove split pin 3 (fig. 17.3) out of drum 5 shaft and to remove washer 7;
– to remove drum 9 from drum 5 shaft;
– to force out brass bushings 8 from either side of the drum;
– to remove collars 6 from grooves on either side of the drum;
– to place new collars into grooves on the drum;
– to force in brass bushings;
– to grease drum shaft with Litol-24 lubricant and to place drum 9 onto it;
– to place washer 7 onto drum shaft and to lock with split pin 3.
Collars are to be checked for leakage by hydraulic pressure of 1,2 MPa within three minutes. Leakage is
not allowed.
Fig. 17.3 — Solution line drum:

1, 2 – cramps for fixing locking device; 3 – split pin; 4 – handle; 5 – drum shaft; 6 – collar; 7 – washer; 8 – bushing; 9 – drum
17-4
7513-3902080 RM
Repairs of solution line locking device.

Major defect of locking device is wearing out of rubber spherical valve cup, O-rings what leads to leak-
age in operating solution line.
Replacement of valve and O-rings of locking device is to be effected in the following succession:
– to disconnect hose 16 (see fig. 17.1) from locking device 15;
– to bore out dowel 10 (fig. 17.4) of upper lever;
– to remove upper lever 2;
– to untighten outlet 9;
– to remove valve 6 out of housing 3;
– to replace valve and O-ring 4;
– to grease valve spindle with Litol-24 lubricant, to put spring 5 on spindle and to place valve back into
opening on housing;
– to replace O-ring 8 and to screw in outlet 9 up to the full stop against housing 3;
– to place upper lever 2;
– to place new dowel 10 and to center punch it.
After assembly locking device is to be checked up for leakage by supplying hydraulic pressure of
1,2 MPa into chamber I within three minutes. Leakage is not allowed.
Fig. 17.4 — Locking device:

1 – handle; 2 –lever; 3 – housing; 4, 8 – rings; 5 – spring; 6 – valve; 7 –valve cup; 9 – outlet; 10 – dowel;
I – chamber
17.4.2 Assembly of fire-fighting system

Before assembly of the system:
– to check system units by visual examination for damage, gas cylinders and reduction gears for seals;
– to check hoses and pipe-lines passability, if necessary to blow them out by compressed air;
– to check gas pressure (air or nitrogen) in gas cylinders. Pressure should comply with the data stated in
table 17.2. If necessary pressure is to be raised up to necessary value;
Table 17.2 — Operating pressure in cylinders subject to ambient temperature

Operating pressure in cylinders, Operating pressure in cylinders,
Ambient temperature, MPa Ambient tempera- MPa
0 0
С ture, С
minimum Maximum minimum maximum
55 below zero 9 10 0 11 12,7
50 below zero 9,5 11 10 11,3 13,1
40 below zero 9,7 11,3 20 11,7 13,5
30 below zero 10 11,6 30 12,1 14
20 below zero 10,3 11,9 40 12,5 14,5
10 below zero 10,6 12,3 50 13 15
17-5
7513-3902080 RM
– to check powder line tank for availability of extinguishing powder. If necessary to fill in tank with pow-
der through filling neck. Powder should in no case feature lumps exceeding 2 mm to avoid clogging up of pow-
der line channels;
– to check solution line tank for availability of calcium chloride solution. To check solution consistency
which should comply with consistency stated in table 17.3. If necessary to fill in tank with solution through any
opening in the tank. Solution should feature no mechanical particles exceeding 2 mm.
Table 17.3 – Freezing point of calcium chloride solution
Mass concentration of so- 0 Content of calcium chloride in 100g of

0 3 Freezing point, С
lution (at 15 С), g/sm water, g
1,13 10 below zero 17,5
1,19 20 below zero 27,5
1,24 30 below zero 34
1,285 55 below zero 42,7
17.4.2.1 Assembly of powder line

Assembly of powder line is to be effected in the following succession:
– to secure powder tank 1 (see fig.17.1) in dump truck;
– to fix gas cylinder 9 with bracket in dump truck;
– to connect reduction gear 8 to gas cylinder;
– to connect gas pipe-line 7 to reduction gear and tank and to secure it;
– to mount pipe-lines for spraying circuit. Bores for powder spillage are to be directed onto protected
surfaces;
– to connect pipe-lines between themselves by hose and to fasten it;
– to place diaphragm guard at the output of powder tank, to connect tank and pipe-line of spraying cir-
cuit 5 by powder cable 4 and to fasten it.
17.4.2.2 Assembly of solution line

Assembly of solution line is to be effected in the following succession:
– to mount solution tank 18 into dump truck;
– to mount gas cylinder 10 with bracket into dump truck;
– to connect reduction gear 11 to gas cylinder;
– to connect gas pipe-line 12 to reduction gear and tank and to fasten it;
– to connect hose 16 of solution line to drum and locking device, to wind hose onto drum;
– to grease drum 5 shaft (see fig. 17.3) with Litol-24 lubricant and to place drum onto it;
– to place washer 7 onto drum shaft and to lock it with split pin 3;
– to connect hose 13 (see fig. 17.1) to tank and drum and to fasten it.
17-6
Running in of Dump Trucks after Repairs
7513-3902080 RM
18 RUNNING IN OF DUMP TRUCKS AFTER REPAIRS
In the initial period after repairing dump truck, surfaces of repaired assemblies coming into friction need
time for grinding-in and lubrication modes should get to standard. Good grinding-in of part faces ensures reli-
ability and handsome life service of assemblies and systems.
After mid-life repair one is to run in loaded dump truck for not less than 50 km.
Following restrictions are being imposed for the running-in period:
– maximum traveling speed is not to exceed 35 km/h;
– dump truck is to be operated on roads with hard pavement;
– dump truck payload is to make up 75% from rated load.
Before running in of dump truck after repairs are over it is required:
– to check by external examination operating condition of dump truck, paying special attention to tighten-
ing of all outer threaded joints (fastening of diesel alternator, wheels, suspension parts and assemblies, steer-
ing, braking systems, U-joint shaft, power take-off box and electric plants);
– to check oil level in the engine, in oil tank for combined hydraulic system, in motor wheel reduction
gears, power take-off box, to check fuel availability in the fuel tank, coolant availability in the engine cooling
system, availability of viscous lubrication on friction units;
– to check intactness and functioning of supervision gauges, pilot lights, lighting system, warning lights,
acoustic warning system;
– to check adjustment of fuel supply drive. Drive adjustment should allow maximum and minimum rota-
tion speed of engine in idling mode (ventilator is off). Checking-up is to be effected in recommended engine
operating temperature modes;
– to check intactness of power supply system for low-voltage installations. Hand in voltage indicator if
-1
engine rotation speed makes up 800 min and higher, should reside in green area (26 – 28,5 V). If indicator
hand is in red or yellow areas while engine is running, this points to malfunctioning of power supply system;
– to check on the spot steering system operation by turning steerable wheels both ways from one out-
ermost position into the other;
– traveling at speed of up to 5 km/h to do two turns from one outmost position into the other. Hydraulic
system should ensure smooth, jerk and vibration free turning of steerable wheels. Minimum turning radius ac-
cording to the track of front outer wheel should comply with data stated in technical specification;
– to do not less than three series of vehicle pull ups applying electro-dynamic, service brakes and mov-
ing backwards in the following succession:
– traveling at speed of 35 – 40 km/h to decelerate dump truck up to speed of 10 km/h applying electro-
dynamic brake;
– to pull up dump truck applying service brake;
– to engage reversing and to move backwards for not less than 20 m;
– to bring dump truck to full stop;
– to accelerate dump truck up to speed of 35 – 40 km/h after full stop;
– to check functioning of service brake system by braking up empty dump truck going straightforward
from initial speed of 20 – 25 km/h. Service brake system should ensure simultaneous braking of all wheels
without skidding effect. Checking-up of steering system, service and electro-dynamic brake systems on the
move is performed on even horizontal area featuring hard dry paving without any dents and slopes. Area di-
mensions should ensure safety of the whole procedure;
– to check performance of parking brake system. Parking brake system should ensure dump truck im-
mobility at grade of 16%;
– to check performance of dumping mechanism by raising empty body twice or thrice and by interlocking
it in raised position once. Unloading mechanism should ensure smooth jerk- and jamming free raising and low-
ering of body and its locking in any intermediate position. At the end of body raising a pilot lamp should turn
ON thus warning about emergency level of oil in steering tank. Spontaneous body lowering at speed of
0,01 m/min is allowed when switch is positioned at “neutral”;
– to check all hydraulic systems for leakage. Spraying-out or leaking of lubricant, oil, fuel, braking fluid,
coolant or gas out of any unit, assembly or through joints is not allowed. Oily spots and single drops not sub-
ject to dripping down at gland seals on reduction gears, on upper sealing of suspension cylinder sealing and
on breathers are not a defective feature.
18-1
Running in of Dump Trucks after Repairs
7513-3902080 RM
During running-in period of dump truck after completion of repairs it is recommended:

– to pay special attention to repaired assemblies and systems, to stop dump truck at regular intervals af-
ter every 10 – 20 km and to check temperature and tightening of outer threaded joints of repaired assemblies
and systems;
– to observe temperature mode not permitting overheating of engine, power take-off box, motor wheel
reducing gears, traction alternator and electric motors.
Temperature at motor wheel reduction gears, seating place of traction alternator bearings, traction elec-
tric motors, power take-off box, front wheel hubs, braking drums and plates should not exceed 60 0С (one can
hold his hand for a long time touching supervised units). Should any deviation in units performance arise, one
is to stop operating dump truck at once and to remedy deviation.
In traction mode voltage measured by voltmeters PV1 and PV2, located on supervision board in the cab,
should vary from 0 to 1000 V depending on load, and current measured by ammeter should range from 0 to
1200 А. In electric braking mode starting from speed of (30 + 5) km/h current measured by ammeter should
range from 300 to 650 А for dump trucks with payload capacity 120 T, and from 300 to 800 А for dump trucks
with payload capacity 130 T. The less is the speed, the less are the braking currents. When traveling straight-
forward in any operating mode difference in readings on voltmeters should not exceed 60 V.
Engine temperature mode, oil pressure in lubricating systems, rotation speed of engine crankshaft,
compressed air pressure in pneumatic system receivers, oil pressure in pneumatic hydraulic accumulators
should comply with data recommended in dump truck operation manual.
ALL FAULTS SPOOTED IN RUNNING-UP PROCESS OF DUMP TRUCK ARE TO BE ELIMINATED.
After running-in has been completed, one is to accomplish routine maintenance in compliance with
chapter “Maintenance” in the corresponding operation manuals.
18-2
Operation materials
7513-3902080 RM
19 OPERATION MATERIALS
At maintenance of dump trucks to apply only recommended brands of operation materials which quality
should prove to be true the deed.
19.1 Lubricant
The lubrication diagram of dump trucks BELAZ-75131, BELAZ-75132 is reduced in Figure 19.1, the list
of used greases in Table 19.1, a lubrication diagram of dump trucks BELAZ-7514-10,
BELAZ-75145 It is reduced in Figure 19.2, the list of used greases in Table 19.2, the list of equivalent
brands of oils in Table 19.3.
Doubling greases (substitutes) are authorized to be applied only at absence of the basic brands.
At transition to other brands of greases former should be deleted completely. Commixing of different
brands of greases is not supposed.
Before a filling of oil in capacity to clear fuses of a dust and muds. A filling of aggregates to manufacture
from oil-dispensing columns. A used oil to merge from warmed-upaggregates. After an oil drain to clear mag-
nets of drain plugs.
At each disassembly штекерных joints of their pad it is recommended to grease only with lubricant
Литол-24 as at smearing by other lubrications it is not ensured required current distributor. Lubricant is plotted
by a thin stratum on a metal part of the plug pads.
Figure 19.1 - Lubrication diagram of dump trucks BELAZ-75131, BELAZ-75132
19-1
Operation materials
7513-3902080 RM
Table 19.1 List of lubricant used of dump trucks BELAZ-75131, BELAZ-75132
amount lubri-
cation point
positions in
figure 19.1
Name of lubrication Amount of

Temperature of Directions for to execution
points and places of a Name of lubricant lubricant on
ambient of operations
filling dump truck
Crank case According to the engine

8ДМ-21АМС According to the engine maintenance manual 1 202 l
maintenance
15 Crank case According to the engine
КТА50С According to the engine maintenance 1 195 l
maintenance
о
Oil tank of steering control Above minus 10 С Hydraulic oil МГЕ-46В A level of a hydraulic fluid in
dumping mechanism and Above minus 55оС Hydraulic oil ВМГЗ a forecastle should not
braking systems о above midpoint upper eye at
Above minus 60 С Hydraulic oil ВМГЗ-С
discharged pneumohydraulic
4 о
Above minus 30 С Substitute:Hydraulic oil 1 340 l
accumulators and midpoints
“А” lower eye are not lower at
charged (after an engine fir-
ing)
о
Suspension rodcylinder Above minus 50 С Damping fluid ЛУКОЙЛ- The order of a filling look in
АЖ the head « Running gear
о
Above minus 40 С Substitude: 82 l (head cyl- (suspender) »
8 Жидкость аморти- 4 inder15l, rear
заторная МГП-12 cylinder 26 l
о
Above minus 50 С Substitude:
Damping fluid ГРЖ-12
о
Electric motor wheels Above minus 30 С Mobilube To install wheels so that the
redusers GX 85W/90A fuse of a locating hole has
(Mobil) been located below. The oil
10 о 2 72 l level should be up to the
Above minus 55 С Mobilube
SHC 75W/90LS lower crimp of a thread of a
(Mobil) bore
о
Driver seat shock-absorber Above minus 50 С Dampimg fluid ЛУКОЙЛ- Replace oil at the shock-
АЖ absorber repair
__ о
Above minus 40 С Substitude: 1 0,12 l
Dampimg fluid МГП-12
о
Cuffs of a crankcase of Above minus 40 С Lubricant Литол-24 To grease through greasers
electric motor wheels re- о
Above minus 50 С Lubricant Лита (on two each reducer) lubri-
dusers о cant in everyone between
__ Above minus 40 С Substitude: 4 0,6 kg cuffs cavity, thus to turn out a
Фиол-2 fuse in hollow bolt
о
Ftont wheels of hubs bear- Above minus 40 С Lubricant Литол-24 The order of a filling look in
ings о
Above minus 50 С Lubricant Лита the head « Running gear
1 о
2 7 kg (front axle)
Фиол-2
о
Suspension cylinder of Above minus 40 С Lubricant Литол-24 To grease through greasers
__ spherical bearings 8 1,12 kg up to an exit of lubrication
о
Above minus 50 С Lubricant Лита from pressure-relief valves
о
The central hinges of a Above minus 40 С Lubricant Литол-24 To grease through greasers
suspender of a front axle о
Above minus 50 С Lubricant Лита up to an exit of fresh lubrica-
__ 2 0,3 kg
and a rear axle tion from under compres-
sions
Hinges joint of cardan shaft Lubricant №158М To grease through greasers
of the drive gear of pumps up to an exit of fresh lubrica-
12 2 0,08 kg
of an integrated hydraulic tion from under sealings
system
о
Sline joint of cardan shaft Above minus 40 С Lubricant Литол-24 To grease through a greaser
of the drive gear of pumps up to an exit of lubrication
of an integrated hydraulic о from a bore in stub
11 Above minus 50 С Lubricant Лита 1 0,03 kg
system
о
Above minus 40 С Substitude: Фиол-2
19-2
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.1

Temperature of Amount of lubricant on
ambient dump truck
filling dump truck
Steering cardan shaft Lubricant №158М To grease at the repair

__ 2 0,04 kg
hinges
Hinges of transversal rods Above minus 40оС Lubricant Литол-24 To grease through greasers
__ of a suspender of a front о 4 0,48 kg up to an exit of lubrication
axle and a rear axle Above minus 50 С Lubricant Лита from under sealings
о
Steering link higes Above minus 40 С Lubricant Литол-24 To grease through greasers
о up to an exit of lubrication
3 Above minus 50 С Lubricant Лита 2 0,1 kg from under sealants
о
Hydraulic cylinder higes of Above minus 40оС Lubricant Литол-24 To grease through greasers
steering о up to an exit of fresh lubrica-
__ Above minus 50 С Lubricant Лита 4 0,2 kg tion from under sealant
о
о
Pivot barrels of front axle Above minus 40 С Lubricant Литол-24 To grease through greasers
up to a floturning of lubrica-
2 о 4 1,2 kg tion from pressure-relief
Above minus 50 С Lubricant Лита valves
о
Cylinder bearings of dump- Above minus 40оС Lubricant Литол-24 To grease through greasers
ing mechanism о up to an exit of lubrication
5 Above minus 50 С Lubricant Лита 4 0,22 kg from spacings
о
о
Rear bearings axle of Above minus 40 С Lubricant Литол-24 To grease through greasers
body о up to an exit of clearance
о
Bearings of the electromo- Lubricant Литол-24 To grease through lubricator
__ tor of the cooling fan of 2 0,03 kg
brake setting
Pull pads and connective Lubricant Литол-24 To grease metal surfaces with
panels of wires of a low- a thin stratum at everyone re-
__ voltage electrical equip- 20 0,04 kg pair
ment
о
Storage batteries of clamps Above minus 40 С Lubricant Литол-24 To grease with a thin stratum
о at setting batteries
о
Traction generator bear- Lubricant Литол-24 To put the fresh lubricant at
13 1
ings СГД 89/38-8 repair
13 2
ings СГД2 89/38-8 repair
13 1
ings ГСН-500 repair
electric motor bearings ЭК- Lubricant Литол-24 To put the fresh lubricant at
9 4 1,8 kg
420 repair
9 4 2,8 kg
420ЭД-136 repair
9 4 10 kg
420ТЭД-6 repair
Low-voltage generator Lubricant №158М To put the fresh lubricant at
__ 2 0,011 kg
bearings Substitude: Литол-24 repair
о
Running and braking Above minus 40 С Lubricant Литол-24 To put the fresh lubricant at
__ comptroller о
Above minus 50 С Lubricant Лита 4 0,04 kg repair
о
о
Steering column shafts Above minus 40 С Lubricant Литол-24 To put the fresh lubricant at
__ bearings о
Above minus 50 С Lubricant Лита 2 0,02 kg repair
о
19-3
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.1

ambient dump truck
filling dump truck
о
Cock of the cab heater Above minus 40 С Lubricant Литол-24 To grease preliminary having
о cleaned (autumn)
__ Above minus 50 С Lubricant Лита 1 0,002 kg
о
о
Lock of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
о
Hinges axle of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
о
Lock drive of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
о
Racetracks of the gear of Above minus 40 С Lubricant Литол-24 To grease at repair
conveyance of the driver- о
seat
о
о
Pneumatic starter bearings Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
Figure 19.2 – Lubricant scheme of dump trucks BELAZ-7514-10, BELAZ-75145
19-4
Operation materials
7513-3902080 RM
Table 19.2 – List of dump trucks lubricant BELAZ-7514-10, BELAZ-75145
amount lubri-
cation point
positions in
figure 19.2

ambient dump truck
filling dump truck
Crank case According of the engine

According of the engine maintenance 1 202 l
8ДМ-21АМС maintenance
1
Crank case According of the engine
КТА-38С According of the engine maintenance 1 156 l
maintenance
о
The oil-tank of steering Above minus 10 С Hydraulic oil МГЕ-46В A level of a hydraulic fluid in
dumping and working brak- о a forecastle should not
Above minus 55 С Hydraulic oil ВМГЗ
ing system above midpoint upper eye, at
о
Above minus 60 С ВМГЗ-С discharged pneumohydraulic
13 1 385 l
о accumulators and midpoints
Above minus 30 С Substitude: Hydraulic oil
lower eye,are not lower at
“А”
charged (after an engine
starting)
о
Electric motor wheels re- Above minus 30 С Transmission oil ТСп-15К To install wheels so that the
ducer о fuse of a locating hole has
Above minus 55 С Transmission oil ТСз-9гип
been located below. The oil
7 о 2 60 l
Above minus 25 С Substitude: Transmission level should be up to the
oil lower crimp of a thread of a
ТАП-15В bore
о
Power takeoff Above minus 30 С Transmission oil ТСп-15К 12 l for dump The oil level should be up to
о truck the lower crimp of a thread
Above minus 55 С Transmission oil ТСз-9гип
BELAZ-7514-10 of a locating hole
12 о 1
Above minus 25 С Substitude: Transmission 18 l for dump
oil truck BELAZ-
ТАП-15В 75145
о
Cylinder suspension Above minus 50 С Dampimg fluid ЛУКОЙЛ- The order of a filling look in
АЖ the head « Running gear
о 82 l(front cyl- (suspender)
9 4 inder 15l, rear
damping fluid МГП-12
cylinder 26 l
о
damping fluid ГРЖ-12
о
Drive seat shock-absorber Above minus 50 С Dampimg fluid ЛУКОЙЛ- To replace oil at the shock
АЖ absorber repair
__ о
1 0,12 л
Dampimg fluid МГП-12
о
Casing cuffs of the electric Above minus 40 С Lubricant Литол-24 To grease through greasers
motor wheel reducer о (on two each reducer) lubri-
Above minus 50 С Lubricant Лита cant in everyone between
__ о 4 0,6 kg cuff cavity, thus to turn out a
fuse in hollow bolt
о
Rear wheels hubs bear- Above minus 40 С Lubricant Литол-24 The order of a filling look in
ings о the head « Running gear
3 Above minus 50 С Lubricant Лита 2 7 kg
(front axle) »
о
о
Spherical bearings of sus- Above minus 40 С Lubricant Литол-24 To grease through greasers
__ pension cylinder о 8 1,12 kg up to an exit of lubrication
Above minus 50 С Lubricant Лита
from pressure-relief valves
19-5
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.2

ambient dump truck
filling dump truck
о
The hinge of an eyelet of Above minus 40 С Lubricant Литол-24 To grease through a greaser
6 the central bar of a rear о 1 0,15 kg up to an exit of fresh lubrica-
suspension tion from under sealings
Hinges of cardan shaft of Lubricant №158М To grease through greasers up
5 the drive gear box of a 2 0,08 kg to an exit of lubrication from
power takeoff under compression
о
Slotted joint of cardan shaft Above minus 40 С Lubricant Литол-24 To grease through greasers up
of the drive gear box of a о to an exit of lubrication from
power takeoff stub hole
о
Hinges of a transversal rod Above minus 40оС Lubricant Литол-24 To grease through a greaser
10 of a suspender of a rear о 2 0,24 kg up to an exit of fresh lubrica-
axle Above minus 50 С Lubricant Лита tion from under sealings
о
Steering link hinges Above minus 40 С Lubricant Литол-24 To grease through greasers up
о to an exit of lubrication from
4 Above minus 50 С Lubricant Лита 2 0,1 kg under compression
о
Steering hydraulic cylinder Above minus 40оС Lubricant Литол-24 To grease through greasers up
of steering о to an exit of lubrication from
2 Above minus 50 С Lubricant Лита 4 0,2 kg under compression
о
о
Barrels of spindle pins Above minus 40 С Lubricant Литол-24 To grease through greasers
15 о
4 1,2 kg up to a floturning of lubrica-
Above minus 50 С Lubricant Лита tion from pressure-relief
valves
о
Bearing parts of cylinders Above minus 40 С Lubricant Литол-24 To grease through greasers
of dumping mechanism о up to an exit of lubrication
о
Shafts of end support bear- Above minus 40оС Lubricant Литол-24 To grease through greasers
ings of body о up to an exit of lubrication
о
Bearings of the electromo- Lubricant Литол-24 To grease through greasers
__ tor of the cooling fan of 2 0,03 kg
brake setting
Pull pads and connective Lubricant Литол-24 To grease metal surfaces with
panels of wires of a low- a thin stratum at everyone re-
__ voltage electrical equip- 20 0,04 kg pair
ment
о
Clips of accumulator bat- Above minus 40 С Lubricant Литол-24 To grease with a thin stratum
teries о at setting batteries
о
Traction alternator bear- Lubricant Литол-24 At repair to put in pawn I skin
14 1
ings СГД 89/38-8 lubricant
14 2
ings СГД2 89/38-8 lubricant
14 1
ings ГСН-500 lubricant
о
Traction engine bearings Above minus 40 С Lubricant Литол-24 At repair to put in pawn I skin
ДК 722Д о lubricant
__ Above minus 50 С Lubricant Лита 4 1 kg
о
о
Running and breack con- Above minus 40 С Lubricant Литол-24 At repair to put in pawn I skin
trollers bearings lubricant
__ 0,04 kg Lubricant Лита 4
о
19-6
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.2

ambient dump truck
filling dump truck
Low-voltage alternator Lubricant №158М At repair to put in pawn I skin

__ 2 0,011 kg
bearings Substitude: Литол-24 lubricant
о
Bearings of steering col- Above minus 40 С Lubricant Литол-24 At repair to put in pawn I skin
umn shaft о lubricant
о
о
Cock of the cab heater Above minus 40 С Lubricant Литол-24 To grease preliminary having
о cleaned (autumn)
о
о
Lock of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
о
Hinges axle of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
__ 6 0,09 kg
о
Фиол-2
Lock drive of cab door Выше Lubricant Литол-24 To grease at repair
о
минус 40 С
о
Выше Substitude:Фиол-2
о
минус 40 С
Racetracks of the gear of Выше Lubricant Литол-24 To grease at repair
о
conveyance of the driver- минус 40 С
__ seat о 2 0,006 kg
о
о
Pneumatic starter bearings Above minus 40 С Lubricant Литол-24 To grease at repair
о
о
о
Electric motor bearings of Above minus 40 С Lubricant Литол-24 To grease at repair
the fuel feed pump о
о
о
Shafts of pads of working Above minus 40 С Lubricant Литол-24 To grease at repair
brake gears о
8 0,16 kg
__ Above minus 50 С Lubricant Лита
о
о
Adjusting bars of parking Above minus 40 С Lubricant Литол-24 To grease through greasers
brake gears о
up to an exit of lubrication
__ Above minus 50 С Lubricant Лита 2 0,02 kg from spacings
о
о
Shafts of expansion cams Above minus 40 С Lubricant Литол-24 To grease at repair
of parking brake gears о
о
19-7
Operation materials
7513-3902080 RM
Table 19.3 – List of the equivalent lubricant

Equivalent oil mark
Temperature
Oil mark Standard nummer or TУ
interval Classification ,
Oil mark Firm
specification
о
МГЕ-46В ТУ 38.001347-83 Above minus 10 С Telluss 46 Shell ISO-6074-HM-46
Мobil DTE Oil 26 Мobil
Energol HLP 46 ВР
о
ВМГЗ ТУ 38.101479-85 Above minus 55 С Telluss T15 Shell ISO-6074-HV-15
Мobil DTE Oil 11М Мobil
Batran HV 15 ВР
о
ВМГЗ-C ТУ 38.101479-85 Above minus 60 С Telluss T15 Shell ISO-6074-HV-15
Мobil DTE Oil 11М Мobil
Batran HV 15 ВР
о
Oil “А” ТУ 38.1011282-89 Above minus 30 С Donax ТМ Shell АТF
Мobil ATF-200 Мobil
Autran GM-МР ВР
о
ТАП-15В ГОСТ 23652-79 Above minus 25 С Dentax G 80W-90 Shell API: GL-4
Spirax GX 80W, 80W-90 Shell MIL-L-2105
Mobilube GX 85W/90A Мobil
Energear EP 90 ВР
о
ТСп-15к ГОСТ 23652-79 Above minus 30 С Dentax G 80W-90 Shell API: GL-4
Spirax GX 80W, 80W-90 Shell MIL-L-2105
Mobilube GX 85W/90A Мobil
Energear EP 90 ВР
о
ТСз-9 гип ТУ 38.1011238-89 Above minus 55 С Spirax GSX 75W80 Shell API: GL-4, GL-5
Mobilube SHC 75W/90LS Мobil MIL-L-46167
Energear EP 80W/90 ВР
о
ЛУКОЙЛ-АЖ ТУ 0253-025-00148599-2001 Above minus 50 С
о
МГП-12 ТУ 0253-052-00148843-98 Above minus 40 С
о
ГРЖ-12 ТУ 0253-048-05767924-96 Above minus 50 С
о
N158 M ТУ38.301-40-25-94 Above minus 30 С Alvania RL 1 Shel
Energrease LS-EP2 BP
о
Литол-24 ГОСТ 21150-87 Above minus 40 С Alvania EP 2 Shell MIL-G-18709A
Retinax EP 2 Shell MIL-G-10924C
Mobilux EP 3, EP 2 Мobil
Energrease LS3 ВР
о
Фиол-2 ТУ 38 УССР 201188-79 Above minus 40 С Alvania RL 2 Shell MIL-G-18709A
Mobilux EP 2 Мobil
Energrease LS2 ВР
ЖРО ТУ 32ЦТ 520-83 MULTIGRADE Alvania RL 3 Shell MIL-G-10924C
Mobilux EP 3 Мobil
Energrease LS3 ВР
о
Лита ТУ 38.101808-90 Above minus 50 С AeroShell Grease 6 Shell
Mobilux EP 2 Мobil
19.2 Fuel
Fuel is applied to the engine in accordance with GOST 305-82 following marks:
- Л-40 (summer) - at temperature of ambient air 0 0С and is higher;
- 3-35 (winter) - at temperature of ambient air the minus 20 0С and is higher;
- 3-45 (winter) - at temperature of ambient air the minus 35 0С and is higher;
- A (arctic) - at temperature a minus 50 0С also it above agrees recommendations of a maintenance
manual of the engine.
19-8
Operation materials
7513-3902080 RM
19.3 Сooling fluid

It is recommended multigrade to apply to an integral cooling system of engines special antifreezingcool-
ing fluids ("Antifreeze - А40М", "Antifreeze - А65М" on THAT 6-02-751-86 and other high-performance cooling
fluids) it agrees maintenance manuals of the engine.
A T T E N T I O N : COOLING FLUIDS ARE POISONOUS!
19.4 Spirit engineering

Spirit engineering (GOST 17299-78) is applied to a refueling and for washing details of electric ma-
chines and apparatuses.
A T T E N T I O N : SPIRIT ENGINEERING IS MADE OF NOT FOOD VEGETATIVE RAW MATERIAL, ON EF-

FECT ON THE HUMAN BODY TREATS TO SUBSTANCES OF 4-TH CLASS-ROOM OF DANGER!
19.5 Nitrogen
Nitrogen gaseous engineering (GOST 9293-74) is applied for cylinders charging of a suspender and
pneumohydraulic accumulators of a working braking system and steering. Gaseous engineering nitrogen is de-
livered in steel seamless cylinders under pressure (15 + 0,5) МPа. Bulbs coloured in black color, on the upper
part of a bulb the inscription "Nitrogen" of yellow color is put.
19-9
Operation materials
7513-3902080 RM
19-10
Appendix
7513-3902080 RM
APPENDIX А
(reference)
Assembly protocol of engine КТА 38С (КТА 50С) with alternator ГС-525
Chassis N__________________ Data ____________________
Engine N__________________ Alternator ____________________
1. Engine dimensions
1.1 Size of crankshaft axial movement (backlash) С __________________
1.2 Size А1 __________________
2. Alternator dimensions
2.1 Size of shaft axial movement (backlash) Е __________________
2.2 Size Г1 __________________
2.3 Size Гпр __________________
2.4 Size of rotor adapter К __________________
2.5 Size of fan wheel М __________________
2.6 Size for selection of gaskets Р __________________
2.7 Number of alternator adjusting gaskets
S=2 mm __________________
S=0,5 mm __________________
2.8 Size F __________________
2.9 Size В __________________
3. Assembly
3.1 Size П __________________
3.2 Number of engine adjusting gaskets
S=0,3 mm __________________
S=0,1 mm __________________
4. Results of assembly correctness check-up
4.1 Axial movement of crankshaft of diesel generator __________________
4.2 Radial runout of alternator rotor adapter __________________
4.3 Conclusion __________________________________________________________
________________________________________________________________________
________________________________________________________________________
Executor _______________________
Name, signature
Supervisor _________________________
Name, signature
20-1
Appendix
7513-3902080 RM
APPENDIX B
(reference)
Torques of the most crucial threaded joints

Torques of the most crucial threaded joints of dump trucks BELAZ-7514-10, BELAZ-75145 are specified
in table B1, of dump trucks BELAZ-75131, BELAZ-75132 – in table B2.
Torques of threaded joints that are not specified in tables are to be found in corresponding chapters of
this Manual.
Table B1 – Torques of threaded joints of dump trucks BELAZ-7514-10, BELAZ-75145
№ Name of threaded joint Torque, N.m

1 Nut of fan wheel fastening to shaft of traction alternator 882 – 980
2 Bolts of traction electric motor fastening to reducer of motorized wheel 800 – 1000
3 Bolts of motorized wheel fastening to rear axle housing 1300 – 1500
4 Bolts of motorized wheel reducer thrust ring fastening 400 – 440
5 Thrust bolts of thrust ring of motorized wheel reducer (for adjusting taper bearings of
600 – 640
motorized wheel reducer hub)
6 Trunnion ball nuts of front suspension cylinder fastening 1600 – 2000
7 Trunnion ball nuts of rear suspension cylinder fastening 2700 – 3150
8 Pressure nut of suspension cylinder 9000 – 10000
9 Bolts of lower bracket of front suspension cylinder fastening to pivot 700 – 900
10 Nuts of pivot bracket fastening to frame 1800 – 2000
11 Bolts of rear suspension central hinge covers fastening 360 – 440
12 Nuts of rear suspension central hinge eyelet fastening to central lever 1100 – 1400
13 Bolts of finger locking plate of rear suspension central hinge fastening 360 – 440
14 Nut of rear suspension central hinge finger fastening (after torquering tighten nut at
0 1800 – 2000
angle of 60 (one edge))
15 Bolts of pressure plates fastening to finger of transversal rod of rear suspension 360 – 440
16 Nuts of steering trapezoid lever to swivel member fastening 800 – 1000
17 Nut of front suspension pivot fastening to steering trapezoid lever 1600 – 2000
18 Bolts of pressure ring fastening to swivel member 100 – 140
19 Adjusting barrels (for adjusting taper bearings of front wheel hub) 100 – 140
20 Nuts of terminal joints of steering trapezoid pull-rod 110 – 140
21 Nuts on conic fingers of turning movement cylinders and steering trapezoid pull-rod 500 – 700
22 Bolts of brackets fastening to power takeoff box 180 – 300
23 Nuts of front wheels fastening 1150 – 1300
24 Nuts of rear wheels fastening 800 – 900
20-2
Appendix
7513-3902080 RM
Table B2 – Torques of threaded joints of dump trucks BELAZ-75131, BELAZ-75132
№ Name of threaded joint Torque, N.m

1 Nut of fan wheel fastening to shaft of traction alternator 882 – 980
2 Bolts of traction electric motor fastening to reducer of motorized wheel 800 – 1000
3 Bolts of motorized wheel fastening to rear axle housing 500 – 550
4 Bolts of thrust ring of motorized wheel reducer fastening 400 – 440
5 Trunnion ball nuts of front suspension cylinder fastening 1600 – 2000
6 Trunnion ball nuts of rear suspension cylinder fastening 1800 – 2000
7 Pressure nut of suspension cylinder 9000 – 10000
8 Bolts of lower bracket of front suspension cylinder fastening to swivel member and of
910 – 1020
upper bracket fastening to frame bracket
9 Bolts of front suspension central hinge eyelet fastening to central lever 910 – 1020
10 Bolts of finger of front suspension central hinge fastening 1100 – 1250
11 Nuts of rear suspension central hinge eyelet fastening to central lever 1200 – 1500
12 Nut of rear suspension central hinge finger fastening (after torquering tighten nut at
1800 – 2000
angle of 600 (one edge))
13 Bolts of fingers of transversal rod of front suspension fastening 2400 – 3000
14 Bolts of pressure plates fastening to finger of transversal rod of rear suspension 360 – 440
15 Bolts of pressure ring fastening to swivel member 100 – 140
16 Adjusting barrels (for adjusting taper bearings of front wheel hub) 100 – 140
17 Bolts of front wheels brake gear housing to swivel member 1500 – 1800
18 Nuts of steering trapezoid lever to swivel member fastening 800 – 1000
19 Nuts of terminal joints of steering trapezoid pull-rod 110 – 140
20 Nuts on conic fingers of turning movement cylinders 500 – 700
21 Bolts of inner sidepieces of rear wheels brake gears fastening 550 – 700
22 Nuts of outer sidepieces of rear wheels brake gears fastening 370 – 450
23 Nuts of front wheels fastening 1150 – 1300
24 Nuts of rear wheels fastening 800 – 900
20-3
Appendix
7513-3902080 RM
APPENDIX C
(reference)
List of equipment for repair

List of equipment for repair of dump trucks BELAZ-7514-10, BELAZ-75145 is specified in table C1, of
dump trucks BELAZ -75131, BELAZ-75132 – in table C2.
Table C1 – List of equipment for repair of dump trucks BELAZ-7514-10, BELAZ-75145
Designation Name of equipment No. of figure

7808-7598 Suspender for removal of diesel-generator of dump truck BELAZ-7514-10 5.1
7808-7059 Suspender for removal of diesel-generator of dump truck BELAZ-75145 5.2
7808-8551 Suspender for traction alternator removal 5.3
ЭСБ 11-00.00.000 Stand for assembly-disassembly of block of radiators 5.8
7808-7263 Suspender for fastening of motorized wheel reducer 7.3
7808-7061 Suspender for fastening and transportation of motorized wheels 7.5
Device for removal-mounting of carrier of front row of motorized wheel re-
360-008 7.9
ducer
Stand for adjusting taper bearings of the second row of motorized wheel
281-30 7.22
reducer
282-6-1 Device for funning-in of motorized wheel reducer 7.24
360-014 Device for removal-mounting of suspension cylinder 8.1.8
7808-6675 Suspender for transportation of front suspension cylinders 8.1.9
7808-7026 Suspender for transportation of rear suspension cylinders 8.1.9
Stand for assembly-disassembly of pneumohydraulic suspension cylin-
ЭСБ 10 8.1.10
ders
ЭСБ 3 Stand pivot assembly-disassembly 8.1.14
280-62 Installation for adjusting suspension cylinder cuff tightness 8.1.20
531-3924370-10 Device for charging of suspension cylinders 8.1.21
Device for squeezing of outer ring of outer and inner bearings of front
360-006 8.2.5
wheel hub
75131-3918350 Device for removal and pressing of front wheel hubs 8.2.9
Device for supporting wrench at screwing-unscrewing of nuts of rear
360-012 8.3.3
wheels fastening
ЭСМ 5 Stand for mounting-dismounting of tires 8.3.5
360-016 Device for centering of inner wheel with tire on hub 8.3.6
11-3118010 УН-17 Device for tire inflation speed-up 8.3.7
75191-3918301 Device for squeezing of shafts of wheel chocks 10.9
7555-3918120-10 Device for assembly-disassembly of parking brake cylinder 10.12
7808-6452 Suspender for fastening of power takeoff box 11.5
СБ-50 Stand for assembly-disassembly of power takeoff box 11.6
СБ-9 Stand-turner for assembly-disassembly of power takeoff box 11.7
7808-6229 Suspender for mounting-dismounting of cardan shaft 11.10
360-015 Device for mounting-dismounting of dumping mechanism cylinders 12.4
СБ-61 Stand for assembly-disassembly of dumping mechanism cylinders 12.5
20-4
Appendix
7513-3902080 RM
Table C2 – List of equipment for repair of dump trucks BELAZ-75131, BELAZ-75132
Designation Name of equipment No. of figure

7808-8551 Suspender for traction alternator removal 5.3
ЭСБ 11-00.00.000 Stand for assembly-disassembly of block of radiators 5.8
360-007 Support for removal-mounting of motorized wheels 7.4
360-001 Device for removal-mounting of traction electric motor of motorized wheel 7.6
Device for removal-mounting of carrier of front row of motorized wheel re-
360-008 7.9
ducer
Stand for adjusting taper bearings of the second row of motorized wheel
ЧРЦ 1.00 -
reducer
282-6-1 Device for funning-in of motorized wheel reducer 7.24
360-014 Device for removal-mounting of suspension cylinder 8.1.8
7808-6675 Suspender for transportation of front suspension cylinders 8.1.9
7808-7026 Suspender for transportation of rear suspension cylinders 8.1.9
Stand for assembly-disassembly of pneumohydraulic suspension cylin-
ЭСБ 10 8.1.10
ders
360-017 Device for squeezing of finger of front suspension central hinge 8.1.12
360-018 Device for squeezing of finger of rear suspension central hinge 8.1.13
280-62 Installation for adjusting suspension cylinder cuff tightness 8.1.20
531-3924370-10 Device for charging suspension cylinders 8.1.21
360-013 Device for removal-mounting of front wheel hub 8.2.3
360-019 Device for squeezing of front axle pivot 8.2.4
360-006 Device for squeezing of outer ring of outer bearing of front wheel hub 8.2.5
360-009 Device for squeezing of outer ring of inner bearing of front wheel hub 8.2.6
360-005 Device for squeezing of inner ring of inner bearing of front wheel hub 8.2.7
Device for supporting wrench at screwing-unscrewing of nuts of rear
360-012 8.3.3
wheels fastening
ЭСМ 5 Stand for mounting-dismounting of tires 8.3.5
360-016 Device for centering of inner wheel with tire on hub 8.3.6
11-3118010 УН-17 Device for tire inflation speed-up 8.3.7
360-015 Device for mounting-dismounting of dumping mechanism cylinders 12.4
СБ-61 Stand for assembly-disassembly of dumping mechanism cylinders 12.5
20-5
Appendix
7513-3902080 RM
20-6

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PRODUCTION ASSOCIATION

OPEN-CAST MINING DUMP TRUCKS

8.1.9 Check-up of technical condition of suspension parts ......................................................................................... 8-16

10.3.4.5 Filter of hydraulic drive of the service braking system......................................................................... 10-22

11PNEUMATIC SYSTEM...................................................................................................................................................... 11-1

14.4.1.1 Disassembly of dumping mechanism cylinder ..................................................................................... 14-8

14.4.2.1 Disassembly of dumping mechanism cylinder ..................................................................................... 14-14

14.6.1.1 Assembly of dumping mechanism cylinders ........................................................................................ 14-20

14.6.2.1 Assembly of dumping mechanism cylinders ........................................................................................ 14-24

16.2 Preparation of frame (body) for repair........................................................................................................................ 16-1

18 RUNNING IN OF DUMP TRUCKS AFTER REPAIR ......................................................................................................... 18-1

19.2 Fuel ............................................................................................................................................................................ 19-8

APPENDIX Б Torques of the most crucial threaded joints............................................................................................. 20-2

2 TECHNICAL SPECIFICATION OF DUMP TRUCKS

Figure 2.1 – BELAZ-7514-10, BELAZ-75145 dump trucks. Overall dimensions

Figure 2.2 – BELAZ-75131, BELAZ-75132 dump trucks. Overall dimensions

Table 2.1 – Dump Truck Specification

Parameters BELAZ-7514-10 BELAZ-75145 BELAZ-75131 BELAZ-75132

Sequel to table 2.1

Sequel to table 2.1

Parameters BELAZ-7514-10 BELAZ-75145 BELAZ-75131 BELAZ-75132

Figure 2.3 – BELAZ-75145-0000110 coal carrier. Overall dimension

Figure 2.4 – BELAZ-75138 coal carrier. Overall dimensions

Table 2.2 – Distinctive features of coal carriers

Loading height along side board of body, mm 5580 5700

3 GENERAL INSTRUCTIONS AT REPAIRING

A T T E N T I O N : IT IS STRICTLY FORBIDDEN TO STRIKE ON THE BEARING RING BY THE HAMMER

4 SAFETY PRECAUTIONS AND FIRE-PREVENTION REQUIRE-

A T T E N T I O N : LOCK ТРОСС IT IS CALCULATED ON LATCHING ONLY THE EMPTY PLATFORM.

ATTENTION: IT IS STRICTLY FORBIDDEN TO PRIME THE SUSPENSION CYLINDERS WITH OXYGEN AS IT

4.2 Fire-Prevention Rules

For the dump trucks BELAZ-7514-10 and BELAZ-75132:

Figure 5.3 – Fastening diagram of the traction

For the dump trucks BELAZ-75145 and BELAZ-75131:

5.2 Engine connection with the traction generator

the engine crank shaft .

Install and fasten adapter of the stator 3 (75145-1001102, Fig-

Figure 5.4 – Connection of engine with traction alternator engine

By test ruler measure in fourth points: 3 and 9, 6 and 12 hours

Figure 5.7 – Diesel-generator assembly:

Arrangement of drain cranes:

Removal and installation of the radiators blocks

Disassembly of the radiators block is carried out in the following sequence:

upper and lower radiators tank, two linings, four strips;

Figure 5.9 – Installation diagram for

Figure 5.10 – Expanding fuses for radiator sockets:

Figure 5.11 – Tube test on the tightness:

Assembly to manufacture in inverse sequence. Before as-

5.4 Fuel systems service

Disassembly and washing of fuel heater with the filter.

Figure 5.13 – The Defroster of fuel with the filter:

5.5 Air filter cleansing

- test presence of the joint ring under the nut;

Figure 5.14 – Accommodating for setting of the retaining ring

Substitution of the filter element is made in the following sequence:

Figure 5.15 – Air filter:

- install a new element;

5.6 Service and repair of the pneumatic starter engine system

ATTENTION: SYSTEM DISMANTLING AND ITS ELEMENTS( PNEUMATIC STARTER, SHUT-OFF

Pneumatic starter dismantling

Figure 5.20 — Pneumatic starter:

Pneumatic starter assembly

Figure 5.17 – Pneumatic engine rotor plate

- not clean the parts by rags leaving fibers;