Uputstvo Za Rukovanje I Odrz. 131 ENG

RUPE “BELARUSIAN AUTOWORKS”
DUMP TRUCK
BELAZ–75131
OPERATION AND MAINTENACE MANUAL

75131-3902015 IM
REPUBLIC OF BELARUS
Detailed description of design and operation principle of units, gears and systems
of dump truck BELAZ-75135 is given in Operation Manual. Recommendations on ad-
justment of gears and systems as well as basic directions on maintenance and opera-
tion are given too.
Manual is intended for drivers, technicians, and all persons operating and main-
taining dump trucks BELAZ.
Manufacturer is constantly busy on modernization of design of trucks and re-

serves the right for changes improving quality and increasing service life.
We request to send all opinions on design and operation qualities of trucks as

well as on contents of this Manual to the address: RUPE “Belarusian Autoworks”,
40 years of October str. 4; Zhodino, Minsk Region, Republic of Belarus, 222160
© RUPE “BELARUSIAN AUTOWORKS”, 2006

75135-3902015 IM
CONTENTS
1 GENERAL INFORMATION ........................................................................................................................................... 1-1
2 SAFETY REQUIREMENTS AND WARNINGS .............................................................................................................. 2-1
2.1 Safety requirements ................................................................................................................................................. 2-1
2.2 Preventive fire-fighting regulations ........................................................................................................................... 2-2
2.3 Warnings ................................................................................................................................................................. 2-3
3 TECHNICAL SPECIFICATIONS ................................................................................................................................... 3-1
4 CONTROLS, INSTRUMENTATION AND CAB EQUIPMENT ........................................................................................ 4-1
4.1 Controls and cab equipment .................................................................................................................................... 4-1
4.2 Control panel ........................................................................................................................................................... 4-2
4.3 Control panel of starting preheater ........................................................................................................................... 4-6
5 ENGINE SYSTEMS ....................................................................................................................................................... 5-1
5.1 Diesel-generator ...................................................................................................................................................... 5-1
5.2 Engine fuel supply system ....................................................................................................................................... 5-2
5.3 Engine air supply system ......................................................................................................................................... 5-6
5.4 Cooling system ........................................................................................................................................................ 5-8
5.5 Engine preheating system ....................................................................................................................................... 5-8
5.6 Engine air starter system ......................................................................................................................................... 5-10
5.7 Exhaust system ....................................................................................................................................................... 5-12
5.8 Engine systems maintenance .................................................................................................................................. 5-12
6 TRACTION ELECTRIC DRIVE ...................................................................................................................................... 6-1
7 ELECTRIC MOTOR-WHEEL ......................................................................................................................................... 7-1
7.1 Electric motor-wheel ................................................................................................................................................ 7-1
7.2 Electric motor-wheel reduction gear ......................................................................................................................... 7-2
7.3 Electric motor-wheel maintenance ........................................................................................................................... 7-5
7.4 Ventilating and cooling system of traction electric drive ............................................................................................ 7-7
7.5 Technical maintenance of ventilation and cooling system of traction electric drive ................................................... 7-9
8 RUNNING GEAR ........................................................................................................................................................... 8-1
8.1 Frame ...................................................................................................................................................................... 8-1
8.2 Suspension .............................................................................................................................................................. 8-2
8.3 Suspension maintenance ......................................................................................................................................... 8-6
8.4 Front axle ................................................................................................................................................................ 8-10
8.5 Front axle maintenance ........................................................................................................................................... 8-12
8.6 Wheels and tires ...................................................................................................................................................... 8-13
8.7 Wheels and tires maintenance ................................................................................................................................. 8-14
8.8 Wheels and tires assembly and disassembly ........................................................................................................... 8-15
8.9 Telemetering control system .................................................................................................................................... 8-17
9 STEERING .................................................................................................................................................................... 9-1
9.1 Hydraulic drive operation principle ........................................................................................................................... 9-1
9.2 Steering units ........................................................................................................................................................... 9-3
9.3 Steering system maintenance .................................................................................................................................. 9-9
10 BRAKE SYSTEMS ...................................................................................................................................................... 10-1
10.1 General data .......................................................................................................................................................... 10-1
10.2 Service brake system ............................................................................................................................................. 10-2
10.3 Parking brake system ............................................................................................................................................ 10-7
10.4 Auxiliary brake system ........................................................................................................................................... 10-9
10.5 Maintenance of brake systems ............................................................................................................................... 10-10
11 PNEUMATIC SYSTEM ................................................................................................................................................ 11-1
11.1 Composition and operation of pneumoapparatuses . .............................................................................................. 11-1
11.2 Apparatuses of pneumatic system ......................................................................................................................... 11-1
11.3 Pneumatic system maintenance . ........................................................................................................................... 11-4
I
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12 LOW-VOLTAGE ELECTRICAL EQUIPMENT ............................................................................................................ 12-1

12.1 System of power supply . ....................................................................................................................................... 12-1
12.2 System of engine start and shut-down .................................................................................................................. 12-3
12.3 System of light and acoustic alarm . ....................................................................................................................... 12-4
12.4 System of external and internal illumination . ......................................................................................................... 12-4
12.5 Protection of electrical equipment circuits .............................................................................................................. 12-4
12.6 Maintenance of electrical equipment . .................................................................................................................... 12-4
13 CAB AND BODY ........................................................................................................................................................ 13-1
13.1 Cab . ...................................................................................................................................................................... 13-1
13.2 Body ..................................................................................................................................................................... 13-3
13.3 Maintenance of cab and body . .............................................................................................................................. 13-5
14 DUMPING MECHANISM ............................................................................................................................................ 14-1
14.1 Principle of hydraulic drive operation ..................................................................................................................... 14-1
14.2 Components of dumping mechanism .................................................................................................................... 14-3
14.3 Maintenance of the dumping mechanism .............................................................................................................. 14-12
15 FIRE-FIGHTING SYSTEM .......................................................................................................................................... 15-1
15.1 Technical data ....................................................................................................................................................... 15-1
15.2 Design and principle of operation .......................................................................................................................... 15-1
15.3 Safety requirements . ............................................................................................................................................. 15-3
15.4 Maintenance ......................................................................................................................................................... 15-3
16 OPERATION FEATURES ........................................................................................................................................... 16-1
16.1 Running-in of dump truck ...................................................................................................................................... 16-1
16.2 Engine starting ...................................................................................................................................................... 16-1
16.3 Starting from place, acceleration, riding of dump truck .......................................................................................... 16-2
16.4 Braking and shut-down of dump truck . .................................................................................................................. 16-2
16.5 Engine shut-down . ................................................................................................................................................ 16-2
16.6 Towing of dump truck . ........................................................................................................................................... 16-2
16.7 Installation of jacks . ............................................................................................................................................... 16-3
17 TECHNICAL MAINTENANCE .................................................................................................................................... 17-1
17.1 Types and periodicity of maintenance . .................................................................................................................. 17-1
17.2 Lubrication of the truck . ......................................................................................................................................... 17-8
17.3 Centralized automatic lubrication system . ............................................................................................................. 17-12
17.3.1 Lubrication system technical data ................................................................................................................ 17-12
17.3.2 Lubrication system arrangement and its principle of operation . .................................................................... 17-12
17.3.3 Centralized automatic lubrication system maintenance . ............................................................................... 17-13
17.3.4 Lubrication system troubleshooting .............................................................................................................. 17-14
18 OPERATIONAL MATERIALS .................................................................................................................................... 18-1
18.1 Fuel ....................................................................................................................................................................... 18-1
18.2 Lubricants . ............................................................................................................................................................ 18-1
18.3 Coolant ................................................................................................................................................................. 18-2
18.4 Nitrogen . ............................................................................................................................................................... 18-2
18.5 Technical ethanol . ................................................................................................................................................. 18-2
19 DUMP TRUCK STORAGE RULES. TRANSPORTATION .......................................................................................... 19-1
19.1 Storage preparation . ............................................................................................................................................. 19-1
19.2 Maintenance service of the dump trucks which are on storage . ............................................................................. 19-2
19.3 Depreservation of the dump truck ......................................................................................................................... 19-2
19.4 Transportation . ...................................................................................................................................................... 19-2
APPENDIX А – Tightening torques of the most responsible threaded connections ................................................. 20-1
APPENDIX В – Procedure oil analysis from motorized wheels reducers ................................................................... 20-2
II
General information
75135-3902015 IM
1 GENERAL INFORMATION
Open-cast mining dump truck BELAZ-75131 (See Figure 1.1) with payload capacity of 130-136 metric
tons is designed for carrying overburden rocks and minerals in open-pit mines and also for dispose of the spoil
at building site.
Dump truck is intended for operation on specially equipped roads having longitudinal slopes of 6 - 8%
maximum. When the vehicles are operated on the roads with long longitudinal slope distance exceeding 6%,
there should be foreseen road sections with less slope (2% and less) or horizontal road sections of at least 50
m long for every 600 m of such long slope distance. The road surface must withstand a trucking with axial
mass of at least 140 000 kg.
The road surfacing must be even and provide normal vehicle run at rated speed. The clearance between
a three-meter long rack and the road surfacing coating should not exceed 2.5 cm.
If, on the surface of the road section equal to the vehicle chassis length, there are five pits of 3-5 cm
depth (clearance between the rack and the road surfacing) or one pit up to 10 cm depth, which exceed tire
contact point width, the speed within such sections should not exceed 25 km/h. With a 2-fold increment in the
quantity of pits, the speed should range within 15-20 km/h.
Vehicle operation is not permitted on the haul road sections with pits of more than 10 cm deep and on
passage sections in dumps and faces if the pits depth exceed 20 cm at sizes indicated above.
Dump trucks are being produced in climatic design У1, УХЛ1, ХЛ1, Т1 according to GOST 15150. The
type of climatic design is identified in the contract.
The dump truck is designed to be operated in regions at an altitude up to 2000 m above sea level at re-
spective changes of tractive-dynamic characteristics.
To increase the efficiency of the dump truck, it is recommended to use them in combination with excava-
3
tors, having capacity of the bucket up to 12.5 m .
In addition to this Manual, it is also recommended to follow directions stated in “The Engine Operation
Manual”, in the documentation on traction motor and in the operation manuals for additional assemblies and
systems mounted on the truck.
Strict observance of the Operation Manuals, correct applications of lubricants, frequency of maintenance
and proper operating will ensure reliable and trouble-free operation of the dump trucks and their highest effi-
ciency.
Figure 1.1 – Dump truck BELAZ-75131. Overall dimensions
1-1
General information
75135-3902015 IM
Location of basic identification, identification tags, tags of devices “FOPS”, “ROPS”.

Identification number is marked on the right side of bumper by percussion method.
Identification number looks like horizontally located row of 17 symbols without flashes between them.
Symbols are bounded by correction marks and comprise only necessary information on unambiguous and cor-
rect identification.
First three symbols (1, 2, 3) define international identification code of producer; next five symbols (4, 5,
th th
6, 7, 8) define index of good. 9 symbol is a check letter, 10 symbol means the year of production in accord-
ance with table 1. Symbols from 11 up to 17 define serial number of good.
Identification tag and tag of devices “FOPS”, “ROPS” are located on the outer left side of the cabin.
Table 1.1 — Designation of production year
Year Designation Year Designation

2006 6 2008 8
2007 7 2009 9
1-2
Safety requirements and warnings
75135-3902015 IM
2 SAFETY REQUIREMENTS AND WARNINGS
2.1 Safety requirements

When mounting, operating, maintenance and repairing the dump truck, it is necessary to observe the
general safety requirements for transport vehicles, and to follow the “Unique safety regulations to be observed
in open-cast mining of mineral deposit”, the ’’Operational regulations of User’s electric equipment’’, the ’’Safety
regulations of User’s electric equipment’’ and the ’’ Rules of arrangement and safe operation of pressurized
vessels’’ and ’’Operation rules of tubeless large dimension and super large dimension tires for dump trucks of
large and especially large capacity’’.
Besides, it is necessary to observe also the listed below requirements conditioned by the design of the
dump truck:
2.1.1 Before maintenance and repair of dump truck, apply it with parking brake and put stops under
wheels. Maintenance and repair should be carried out only with stopped engine, except for adjusting of electric
drive specified in this Manual.
2.1.2 In case of stopping of dump truck on slope take measures excluding it moving: apply it with parking
brake and put stops under wheels.
2.1.3 When leaving the cab be sure that the truck is immobilized by parking brake and the reversing
switch and the electric drive switch are in the «OFF» position.
2.1.4 When carrying out maintenance and repair of the dump truck, lock the lifted dump body by means
of special wire rope, for which purpose insert both rope ends into the eyes of the axle housing and secure
them with towing pivots. Do not perform any works under the lifted dump body locked with the wire rope, if
there is more than 3 t of stuck soil in the body, or if the velocity of the tail wind is over 6.5 m/sec.
STOP ROPE IS INTENDED ONLY FOR STOPPING OF EMPTY BODY.
IT IS PROHIBITED TO SINK BODY FORCEDLY, WHEN IT IS LOCKED UP.
When lifting the body, do not stay near the dump truck, so to avoid injury that may be caused by the
stuck soil. It is forbidden to leave the cab during lowering or lifting of the body.
2.1.5 Dump truck is equipped with ladders, sideboards, guardrails and decks for safe operation on as-
sembling, adjusting and maintenance.
When working without fences and guardrails it is necessary to use safety belt and also portable ladders
and supports. Safety requirements should be observed.
2.1.6 When moving on ladders and decks (fenders, hoods) it is necessary to hold on to the guardrails,
mounted on ladders, fenders, hoods and cab, so that to have three rest points each time (with two hands and
one leg or with two legs and one hand). Ladders and decks must be free from dirt, snow and ice.
Always go upstairs and downstairs on the dump truck with face towards the cab.
2.1.7 Electrical safety requirements, which should be observed during setting-up and adjusting of electric trac-
tion drive, stated in the Manuals on adjusting of electric traction drive, and safety requirements under assembling are
stated at the installation directions.
2.1.8 Before removing the suspension cylinders and the pneumo-and-hydraulic accumulators from the
truck, relieve gas from their chambers. For complete removal of gas from the suspension cylinder, open the
charging valve at least three times, with intervals of 3 – 5 min.
2.1.9 It is necessary to open charging valves prior to disassembly of suspension cylinders and pneumo-
hydraulic accumulators to be sure that there is no gas overpressure in their chambers. When checking the level
of operation fluid in oil intake of suspension cylinder, control plug should be unscrewed slowly to remove gas
overpressure in chamber. During this operation do not stand in front of the plug.
2.1.10 Before charging the suspension cylinders and pneumo-hydraulic accumulators with gas, make
sure that the charging unit is in good order and that the marking on the compressed gas cylinder is correct.
The gas cylinder must bear a yellow inscription NITROGEN ("A3OT") and should carry a brown circular mark-
ing strip.
IT IS STRONGLY PROHIBITED TO CHARGE THE SUSPENSION CYLINDERS AND PNEUMOHYDRAULIC AC-

CUMULATORS WITH OXYGEN, AS THIS WILL CAUSE AN EXPLOSION!
2-1
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2.1.11 Prior to unfasten the wheel from the truck, deflate the tire completely. To unfasten rear wheel, de-
flate both tires.
IT IS FORBIDDEN TO UNFASTEN AND MOUNT WHEELS IF THERE IS AN OVERPRESSURE IN TIRES.
Before mounting the wheel, inflate a tire up to 0,1MPa and make sure that locking ring is installed cor-
rectly. Secure the wheel on the hub and only then inflate the tire to the nominal pressure. When inflating the
tire, do not allow people to stand nearby.
2.1.12 It is prohibited to disassemble and dismount elements of steering unit and braking systems, if
they are under pressure of working fluid. Unscrewing of locking pins on the brake valve carries out reducing of
pressure in front and rear circuits of service brake system. Reducing of working fluid pressure in hydraulic
steering and parking brake systems are carried out automatically after planed stop of the engine within 80 sec.
Mounting and dismounting of pneumatic and-hydraulic accumulators should be carried out only at discharged
gas chamber.
2.1.13 It is forbidden to eliminate defects, dismount reinforcements, perform welding in the air-starter
and in the pneumatic systems of dump truck, if they are under pressure.
Pressure release is carried out through the condensate drain valves, at that stopcocks on air tanks
should be opened.
2.1.14 It is forbidden to adjust and operate the system of air-starter with defected manometers.
2.1.15 Application of air cylinders, manometers, safety valves, reinforcements (and also technical exam-
ination and repair) should be carried out in accordance with requirements and regulations, stipulated in the
“Rules of arrangement and safety operation of pressurized vessels’’ (ПБ 10-115-96).
2.1.16 Opportunely, within the specified terms and in accordance with recommendations of the present
Manual, remove dirt from the storage batteries and vent holes, check the level of electrolyte in the storage bat-
teries and bring it to normal value. Do not use unserviceable storage batteries (with short-circuited plates).
When servicing and repair storage batteries, keep in mind that electrolyte can cause deep burns when
getting on skin.
2.1.17 It is forbidden to carry out welding nearby charged pneumo-and-hydraulic accumulators and pipe-
lines connected to them.
2.1.18 Unscrew the cap of the overflow bottle carefully and only after reducing of coolant fluid tempera-
ture, since steam at the overflow bottles can be under pressure. Remember that antifreezing cooling fluid is
poisonous and can cause poisoning when breaking sanitary rules.
2.1.19 Changes in design of electrical drawings are strongly prohibited without consent of the manufac-
turing plant.
2.1.20 The dump truck cannot be transported to the operation site as an assembly unit, because of their
mass and overall dimensions. That is why the dump truck is assembled in workshops at place of operation.
Therefore, for safety mounting and setting-up operations, the personnel must be necessarily instructed on the
safety requirements, fire and electric safety regulations.
2.1.21. In case of cabin windows application as an emergency exit, it is necessary to brake down the
glass with hammer, included in tool kit that is placed under additional side folding seat in box.
2.2 Preventive fire-fighting regulations
To avoid fire on the dump truck, observe the general fire requirements in handling inflammables, and al-
so the following requirements:
2.2.1 Check regularly the hermiticity of fuel and oil pipelines in the engine system, steering gear, dump-
ing mechanism and service brake system.
2.2.2 Clean regularly the dump truck from inflammables: leaks of combustive-lubricating materials, coal
dust and elsewhere.
2.2.3 Do not leave the dump truck when the engine starting preheater is operating.
2.2.4 Dump trucks must be equipped with fire extinguishers and (or) fire suppression system for fire
fighting.
Use combined fire suppression system for fire extinguishing, previously shutdown the engine.
It is forbidden to use solution line for extinguishing of electric equipment under the voltage and extin-
guishing of fuel, oil spills.
It is forbidden to use powder line, if there are people in its zone.
2.2.5 In order to prevent inflammation of gases it is prohibited to bring an open fire to a neck of an ex-
tension tank of the engine cooling system when checking a level.
2-2
75135-3902015 IM
2.2.6 It is forbidden to use open flame when checking storage batteries. Before carrying out of welding
nearby storage batteries it is necessary to take due safety measures.
2.3 Warnings
2.3.1 Operation of dump trucks may be entrusted only to the persons, who have the driving license is-
sued by appropriate committee, have an appropriate qualified safety group according to the ’’’Safety regulation
of User’s electric equipment’’, familiar with dump truck design, operation rules and driving peculiarities and ex-
perienced in operating of open-cast mining vehicles.
2.3.2 Maintenance of the dump truck must be performed by mechanics and electricians who familiar with
the dump truck design, the rules of its operation and the fire safety requirements.
2.3.3 If faults are detected during dump truck operation, do not wait until the next scheduled mainte-
nance, and eliminate the defect immediately; this will prevent serious breakdowns.
2.3.4 Carry out maintenance of the dump truck within scheduled intervals, under conditions excluding
clogging of parts and units.
2.3.5 Use only combustive-lubricating materials and working fluids specified in this Manual. Application
of other fuels and oil grades is prohibited.
2.3.6 The traction electric drive is switched off and the dump truck is stopped in two minutes after
switching on of warning lamp of overheating of traction electric motors in flashing mode. So it is necessary to
stop the dump truck in the safe section of road for cooling of electric motors. If the temperature is down within
the specified time, the warning lamp and protector is off, and the driver can continue moving.
–1
2.3.7 Body lifting is carried out at engine rotation speed of 1200 – 1300 min . Reduce rotation speed up
to the minimal at the end of lifting on leaving of the last stage of hoist cylinder mechanism.
2.3.8 After engine start and at traction electric drive turned on, the body floating position is fixed, at this
position the piston chambers of hydraulic cylinders are connected with drain hydraulic line through the elec-
tromagnetic hydrodistributor, that excludes the body lifting during dump truck moving. Turn off the body floating
position at dump truck maneuvering during unloading by pressing switch on the dashboard, which disconnects
supply circuit of electromagnet hydrodistributor.
Stopping of the body in any intermediate position during its lifting is carried out by putting of switch han-
dle of body lifting on dash-board in middle position.
Stopping of the body in any intermediate position during its lowering is carried out by putting of switch
handle at first in “LIFT” (Подъем) position, and than in neutral position. It is forbidden to move with lifted body.
2.3.9 During the autumn-and-winter period, when the temperature is lower than +5 C, it is not allowed to
start a cold engine unless the coolant is heated by means of starting preheater to a temperature specified in
the Engine Operation Manual. After warming-up of coolant by means of starting preheater, turn off the discon-
necting valve of outlet pipe.
2.3.10 Fuel heater during the summer time should be disconnected from cooling system with help of
disconnecting valve.
For disconnecting of cab heating radiator from engine cooling system during the warm year period it is
necessary to shut off the valve on the pressure pipe.
2.3.11 It is forbidden to shut down loaded engine. It is allowed to switch off the “ground” of storage bat-
tery at scheduled engine shut down only after working fluid pressure release into the hydraulic steering sys-
tem. Indicator light in the switch of engine scheduled stop should switch off in 80 sec. after pushing.
2.3.12 If the engine is shut down for more than half an hour, cut off the “ground” of the storage batteries
to prevent their discharging.
2.3.13 The operation of dump truck is forbidden when auxiliary (electric) brake is faulty.
2.3.14 Recommended maximum speed when of loaded dump truck under downward motion is shown in
Table 2.1.
Table 2.1 – Recommended maximum speed of loaded dump truck at downward motion
Slope, % Speed, km/h Slope, % Speed, km/h
2 48 8 34
4 48 10 30
6 40 12 24
2-3
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2.3.15 Don’t shutdown the engine under the dump truck in motion, as the steering system does not op-
erate when the engine is shutdown.
2.3.16 When carrying out welding on the dump truck, automatic switches SF1, SF2, SF3, QF2 of control
circuits and auxiliary circuits in the control cabinet should be turned off.
It is forbidden to connect the welding unit wires to the wheel hubs, since local heating of parts may dam-
age bearings.
2.3.17 Purity of oil and inner chambers of the hydraulics secures reliable operation of the hydraulic system.
2.3.18 Loading into the dump truck body should be carried out only from aside or from behind. It is pro-
hibited to move the bucket over the cab.
2.3.19 The height from which the load is dropped onto the dump body deck when loading the dump
truck should not be over 3 m, and the weight of clods-monoliths should not exceed 4,5 t.
2.3.20 Loading of the dump truck must be done in compliance with its rated payload capacity specified
in the dump truck Log Book.
Redistribution of fully loaded mass at front axle should not exceed 5%.
Under mounting of additional mechanisms and systems, partial or full fettling of body, other alterations,
which increase truck service weight, it’s necessary to define new service weight and new capacity. At that, full
truck weight shouldn’t exceed the value specified in section «Performance» of present Manual.
As an exception, in rare instances, it’s allowed to increase nominal capacity within 10%. Number of such
cases shouldn’t exceed 10% of total trip amount during the given period (twenty-four hours), and average ca-
pacity within all trips during the given period shouldn’t exceed nominal.
In exceptional cases, one-time exceeding of nominal capacity are permitted within 10 – 20 %. They also
should be considered under determination of average capacity during the given period.
EVEN SINGLE INSTANCES OF NOMINAL CAPACITY EXCEEDING TO 20% AND MORE ARE STRONGLY
PROHIBITED.
Information about actual loading of the truck should be constantly registered and shown at first require-
ment. Truck overload make driving difficult and significantly reduces the service life of units and parts, as well
as of the whole truck.
2.3.21 Haulage of defective dump truck should be carried out by special tow-carrier. When towing the
truck fastened by the bumper the parking brake system should be released.
2.3.22 Road engagement is significantly reduced in icing conditions, as well as under motion on snow-
covered and moist roads. Under motion in such adverse conditions, the truck speed should be reduced up to
the value providing safety operation.
2.3.23 During operation of the dump truck, check constantly the system service parameters. It allows
timely detecting a fault and preventing serious damages.
Operation modes of units and systems should be within the ranges mentioned in Table 2.2
Table 2.2 – Controlled operational parameters of dump truck systems
Parameter
Controlled parameters
notation
Engine coolant temperature , 0С:
Minimum recommended………………………………………..…………… 70
Maximum allowable…………………………………………………..…...…. 95
Engine oil temperature, 0С:
Maximum allowable …………………………………………………………. 120
Oil pressure in lubrication system, МPа:
Minimum at idle speed………………………...………………………….... 0.138
At nominal speed…………………………………………………………..... 0.310 – 0.483
Operating fluid pressure in pneumohydraulic accumulators of service brake sys-
15.5 – 16.5
tem and steering, МPа...
Compressed air pressure at the pneumatic system, MPa…………………………. 0.65 – 0.82
2-4
Technical specifications
75131-3902015 IM
3 TECHNICAL SPECIFICATIONS
Technical specification of the dump truck is given at the table 3.1.
Table 3.1 – Specification
Parameters BELAZ -75131

Payload capacity, kg, not more 130-136
Service weight , kg 107100
Fully loaded mass, kg, not more 237100-243100
Fully loaded mass distribution, %:
Front axle 33
Back axle 67
Turning radius, m 13
Overall turning diameter, m 28
Maximum traveling speed with rated load weight on a horizontal road
48
section, km/h
Braking distance of fully loaded dump truck when usage of service
21
brake system at speed of 8.3 m/s (30 km/h), m
3
Rated struck dump body capacity, m 39.5
3
Rated dump body capacity (“heaped” 2:1), m 65.4
Gradient on which the parking brake system holds immobility of fully
16
loaded truck, %
Lifting time of rated weight dump body, sec 20
Dump body lowering time, sec 18
ENGINE
Model Cummins КТА50–С
Type Diesel, four-stroke, v-type, turbocharged and intercooled
Rated power, kW 1194
-1
Rotating speed corresponded to rated power, min 1900
Minimal stable rotating speed, idle, min-1 725
Maximum stable rotating speed, idle, min-1 2400
Number of cylinders 12
Displacement of cylinders, l 38
Cylinder bore, mm 159
Piston stroke, mm 159
TRACTION ELECTRIC DRIVE
The traction electric drive is of alternating-constant current type and includes synchronous generator, traction electric motors, power
three-phase rectifiers, vented braking resistors, switching equipment and automatic controls
Traction generator СГД 89/38-8, ГСН-500, ГСТ-1
Rod power, kW 800
Traction electric motor ЭК-420; ЭК-590; ЭДП-430; ЭДП-600; ТЭД-6
Power, kW 420; 590; 430; 600; 640
Electric motorized wheel reduction gear: double-row, differential
Gear ratio 30.36
3-1
75131-3902015 IM
Continuation of table 3.1
RUNNING GEAR
Frame Welded, made of high-strength steel, side rails of box sec-
tion are connected by cross-beams
Front and rear wheels suspension pneumohydraulic , axle suspension
Wheels Diskless, with split rims 24.00-51/5,0
Tires Tubeless, pneumatic

Dimensionality of radial tires 33.00R51 
Tire inflation pressure, MPa 0.725 0.025*
STEERING
Hydraulic drive Hydrovolumetric with two independent circuits
Emergency drive By pneumohydraulic accumulators
BRAKE SYSTEMS
Service brake system Brake mechanisms are of disk type with automatic clearance
adjustment between the linings and the disk. The drive is
hydraulic, separate for front and rear wheels. Power source
is the pump, power storage devices are pneumohydraulic
accumulators
Parking brake system The brake mechanisms are of disk type, constantly closed.
Hydraulically controlled spring drive
Auxiliary brake system Electric braking by traction electric motors in generator mode
Emergency brake system Parking brake system and operable circuit of service brake
system are used
ELECTRIC EQUIPMENT
Type of connection Single-wire type, negatives of current sources and consum-
ers are connected to “mass”. Underbonnet lights and porta-
ble lamp socket are connected by two wires
Current DC, 24 V
Storage batteries 6СТ-190А, series connection
CAB AND BODY

Cab All-metal, two-seated, hermetic, thermo-and-noise insulated.
It meets ROPS requirements. It is equipped with two sun vi-
sors, double-blade electrical windshield wiper, heater, wind-
shield washer, hooks and seats. Rear view mirrors are lo-
cated at both truck sides
Body Welded structure of bucket type, provided with protection vi-
sor over cab. Body floor is heated by exhaust gases. It is
equipped with a device for fixing the body in the raised posi-
tion and provided with rock ejectors
DUMPING MECHANISM
Type of mechanism Hydraulic
Cylinders Telescopic, three-staged
Pumps Axial-piston pump of varying capacity
A11VLO 260DRS/11R-NZD 12N00
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Continuation of table 3.1

FILLING CAPACITIES, l **
Engine lubrication system 195
Engine cooling system 410
Fuel tank 1900
Hydraulic system 510
Electric motorized-wheel reduction gear, (two) 46x2=92
Suspension cylinder, kg:
front (two) 15x2=30
rear (two) 26x2=52
PRECIOUS MATERIALS CONTENT
Gold 1.2853 g
Silver 456.292 g
Remarks
1 * The pressure is rated for “Bridgestone” tires. When mounting of radial tires of other firms, the pressure is defined by its manufactur-
er.
2 ** Filling capacities are tested values and given for reference. The actual filling should be performed in accordance with correspond-
ing instructions of this Manual.
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Controls, instrumentation and cab equipment
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4 CONTROLS, INSTRUMENTATION AND CAB EQUIPMENT
4.1 Controls and cab equipment

Location of controls and cab equipment is shown in Figure 4.1.
Switch 1 of turn indicator, dipswitch and horn are positioned on the left side of steering column. For
switch on right turn blinkers move switching arm to forward position, for switch on left turn blinkers move
switching arm to backward position. Switch has an automatic device, which returns switching arm to the neu-
tral position after the turn is made. When blinkers are on, signaling lamp located on dashboard is blinking.
Move switching arm upwards (non-fixed position) to switch on upper beam for signaling to oncoming
traffic. When the switching arm is in the fixed midposition and dipswitch control on the dashboard is on, lower
beam turns on. When the switching arm is in the fixed low position, upper beam turns on.
Horn is switched on by pressing onto the end face of the switching arm (non-fixed position).
Steering column and steering wheel 2 can be adjusted in height and tilt angle. Unlock the steering
column by turning handles placed on it and adjust the column in necessary position.
Windshield wiper, windshield washer and horn switch 4 is located to the right of the steering column. It
has four fixed and one non-fixed positions. Two back positions of the switch activate windshield wipers,
which operate in two different speed modes. With the switch in its front position the windshield wipers ope r-
ate with an interval.
Switching the handle in its upward position (non-fixed) from any fixed position the driver activates wind-
shield washer.
Horn is switched on by pressing onto the end face of the switching arm (non-fixed position).
Display panel 6 of traction electric drive is located to the right from the main dashboard 3.
Cab heater 7 is meant for the heating of the cab and windshield. Heater radiator is connected to the en-
gine cooling system via shut-off cock located in engine compartment. The air is blown through the radiator by
means of two fans. The right-hand fan delivers warm air to the windshield, and the left-hand one – to driver’s
feet. Handle 5 of the drive of the heater air inlet flap is meant to control the quantity of outside air incoming into
the cab.
Figure 4.1 – Controls and cab equipment:

1 – blinker-dipswitch; 2 – steering wheel; 3 – dash board; 4 – windshield wiper and windshield washer switch; 5 – handle of the
drive of the heater air inlet flap; 6 – dash board display; 7 – cab heater; 8 – lever of parking brake system control cock; 9 – fuel delivery
control pedal; 10 – service brake system pedal; 11 – service brake system retainer; 12 – pedal of auxiliary brake system (of electric brake)
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Lever 8 of parking brake system control cock can be fixed in two extreme positions. With the lever in
vertical position the dump truck is braked. For un-brake it pull the cock lever upwards and move it forward to
the horizontal position. With the lever in the intermediate position braking efficiency will be proportionate to the
angle of its turn (monitoring action).
Fuel delivery control pedal 9 can be fixed in intermediate position with hand feed handle that restricts re-
verse motion.
Service brake system pedal 10 is equipped with retainer 11 to lock the pedal in braked position.
Pedal of auxiliary brake system 12 is connected to the brake controller and secures continuous keeping
of required velocity during slopes.
4.2 Control panel

The location of instrumentation equipment and controls on the main dash control panel is shown in
Figure 4.2, the location of controls on the additional dash control panel, placed above the windshield, is shown in
Figure 4.3, the location of controls on display panel – in Figure 4.4.
Indicator lights are built into switch buttons and start to signalize operation of corresponding systems
under press of button.
After pressing switch 1 (See Figure 4.2), deck illumination gets actuated.
When pressing the button of non-fixed switch 2 fuel cutoff and engine shutdown occurs, pressure re-
lease system in pneumohydraulic accumulators of steering is actuated automatically.
Pilot lamp 3 gets actuated when the switching arm of turn indicators is in operating position. This lamp
is blinking in synchronous mode with the lamps of turn indicators inside of front and rear headlights.
After pressing switch 4 chassis illumination gets actuated. The lights turn on automatically at dump
body lifting/lowering.
Tachometer indicator 5 shows rotational speed of the engine crankshaft. At disconnecting from dump
truck electric main the electronic tachometer doesn’t arrive at "zero" position, but indicates the revolutions at
which the device is turned off. When reconnecting to electric main, indicator needle arrives at "zero" position.
Pilot lamp 6 indicates emergency rise of coolant temperature in the engine cooling system. Noise-
signaling device simultaneously turns on. To cool the engine, operate it at idle running with the average rota-
tion speed of the engine crankshaft.
Speedometer indicator 7 indicates traveling speed (km/h) and the total run of the vehicle (km). The
lamp (blue light filter) built into the speedometer scale warns that the headlamp high beam is on.
Pilot lamp 8 signals about air pressure lowering below minimum at User’s receiver.
Pilot lamp 9 indicates emergency fuel level in the tank.
Switch 10 is intended for switching on of emergency signalization. Under pressing of fixed button all
turn indicators and pilot lamp mounted into switch button are switched on in blinking mode. For signalization
switching off, push the button once again.
When pressing button switch 11 "-" terminals of storage batteries via contactors get connected to the
dump truck "ground". To disconnect the "ground" repress the button switch once again.
Switch 12 check pilot lamps running order. When pressing these switches, all the pilot lamps should flash.
If pilot lamp 13 is on, perform servicing or replace air filters elements.
If pilot lamp 14 is on (noise signaling device simultaneously turns on), check the coolant level in expan-
sion tank and fill it up until the coolant reaches normal level position.
Pilot lamp 15 warns about emergency oil pressure in the engine. When the lamp is on (noise signaling
device simultaneously turns on), it is forbidden to operate the dump truck.
Pilot lamps 16 и 17 warn of working fluid pressure dropping in front and rear circuits of service brake
system up to emergency one. Simultaneously with lamps lighting sound alerter is actuated.
Pilot lamp 18 indicates in blinking mode the switching-on of parking brake system.
By pressing switch 19 an additional cycle of centralized lubrication system is actuated, system lockup
gets confirmed and the pump gets actuated after the locking-up. Moreover, it is possible to start the additional
lubrication cycle when checking system operation by pressing the button, placed on the pump.
Pilot lamp 20 indicates emergency pressure of working liquid in steering unit hydraulic system.
Pilot lamp 21 warns about clogging of the filter of hydraulic system oil tank. If the lamp flashes it is nec-
essary to replace the filter
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Figure 4.2 – Location of controls on main control panel:
1 – deck illumination switch; 2 – switch of engine operational shut-off; 3 – turn indicators pilot lamp; 4 – chassis illumination switch;
5 – tachometer indicator; 6 – pilot lamp of emergency temperature of engine coolant; 7 – speedometer indicator; 8 – pilot lamp of air pres-
sure lowering below minimum at consumer receiver; 9 – pilot lamp of reserve fuel level; 10 – switch of emergency signalization;
11 – "ground" switch; 12 – switch of pilot lamps running order checkout; 13 – pilot lamp of air filters elements clogging; 14 – pilot lamp of
the emergency level of engine coolant; 15 – pilot lamp of emergency oil pressure in the engine; 16, 17 – pilot lamps of emergency pres-
sure of working fluid in front and rear circuits of service brake system correspondingly; 18 – pilot lamp of parking brake system actuation;
19 – button switch of centralized lubrication system; 20 – pilot lamp of emergency pressure of working liquid in hydraulic system of steer-
ing; 21 – pilot lamp of extreme clogging of oil tank filter of hydraulic system; 22 – pilot lamp of emergency working fluid level in hydraulic
system oil tank; 23 – cigarette lighter; 24 – switch of turn headlamp; 25 – switch of electric drive; 26 – windshield defroster switch; 27 – re-
verser switch; 28 – switch of cab heater; 29 – switch of electric braking modes; 30 – light switch; 31 – light switch of side areas illumina-
tors; 32 – rear fog light switch; 33 – key-lock switch; 34 – front fog light switch; 35 – indicator of working fluid temperature in the oil tank of
integrated hydrosystem; 36 – voltage indicator; 37 – oil pressure indicator in the engine; 38 – indicator of the temperature of engine cool-
ant; 39 – rheostatic switch of instrument panel illumination; 40 – ladder illumination switch; 41– fuel priming pump switch; 42 – switch of
dump body lifting and lowering; 43 – switch of engine fan actuating and radiators shutters opening; 44 – dump body lock switch
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At emergency oil level in the tank of combined hydraulic system pilot lamp 22 gets actuated.
When pressing the button of cigar lighter 23 the pilot lamp built-into starts to blink. When the spiral gets
heated, the lighter turns automatically into home position.
After pressing switch 24 engine compartment illumination gets actuated.
Three-position switch 25: lever upper position – electric traction drive operates in generator mode, lever
intermediate position – the drive is off; lever lower position – the drive feeds from external current source.
Three-position switches 26 and 28 of cab heaters fans. The first position of the key – the fan is turned
off; the second position – low fan speed; the third position – high fan speed. Switch 26 turns on windshield de-
froster fan and switch 28 turns on the fan delivering warm air to the driver’s feet.
Three-position reverser switch 27: lever upper position – forward motion; intermediate position – turned
off; lower position – backward motion
When switch 29 is on, electric braking mode for dump truck moving with constant speed is set. The
driver sets the speed in dependence on the angle of electric braking pedal position. When the switch is off, the
mode of electric braking with braking parameters limitation is set
Three-position light switch 30:
– upper position of the key – turned off;
– intermediate position – sidelights in front and rear lamps and lamps illuminating instrument panel ele-
ments are on;
– lower position – sidelights in front and rear lamps, lamps illuminating instrument panel el ements
and low beam of headlights are on, when the lever on the left side of the steering column is in intermediate
position;
Switch 31 is meant to actuate lights of side areas illuminators.
Pressing button switches 32 and 34 actuates front and rear fog lights. To turn off the lights re-
press the button switch once again.
Lock-switch 33 is used to start the engine and has three positions: first position (when the key is inserted
into the lock up to the stop) – controls and measuring instruments are powered; the second position (when the
0 0
key is turned 45 until perceptible resistance) – not enabled; the third position (when the key is turned 90 up to
the stop) – start system is actuated.
Indicator 35 displays temperature of working fluid in the oil tank of hydrosystem
Indicator 36 shows the voltage of batteries when the engine is shut down and voltage of alternator
when the engine is running
Indicator 37 shows oil pressure in the engine lubrication system
Indicator 38 shows the temperature of engine coolant.
To adjust the brightness level of instrument panel illumination rotate the handle of rheostatic switch 39
with light switch 30 turned on.
After pressing switch 40 ladder illumination gets actuated.
Switch 41 is not fixed and is meant to prime the engine feed system with fuel after maintenance works or
long stand of the truck.
Three-position switch 42 of dump body hoist mechanism:
– horizontal position of the handle disengages the mechanism;
– with the handle turned counter-clockwise, the mechanism lifts the dump body;
– a clockwise turn of the handle ensures lowering of the body.
The switch handle can be shifted to any position only when it is pressed up to stop. The warning lamp
built into the handle flashes on when the handle is deflected from the neutral position.
For locking the dump body in any intermediate position during its lifting place the switch handle in inter-
mediate position.
For locking the dump body in any intermediate position during its lowering first place the switch handle in
"Lift" position and then in the neutral position.
Switch 43 is meant for forced actuating of engine fan and for radiators shutters opening. The switch is
used in the case of automatics breakdown and when checking the system operation. With the switch in off-
position, the system operates in automatic mode.
Button switch 44 unlocks the mechanism that prevent dump body lowering while the dump truck is in
motion, when the traction electric drive is actuated. It is necessary to lock the dump body in lifted or intermedi-
ate position when maneuvering the dump truck during unloading. To lock the dump body in lifted position it is
necessary to press the switch button and hold it pressed all the period of maneuvering. The pilot lamp in the
button constantly flashes at running engine and when the dump truck is in motion.
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Additional dash control panel.

See rules of control 1 (Figure 4.3) application in the technical specification and in Operation Manual for
combined fire suppression system.
When pressing button switch 2 cooling fan gets actuated. Pilot lamp is mounted into the button.
Signalization unit 3 of high-voltage line approach system.
Signalizing relay 4 is connected to the circuit in parallel with the lamps signaling about the emergency
pressure of working liquid in service brake system rear circuit, in steering system, about emergency pressure
of oil in the engine lubrication system and about the emergency level of coolant in the engine cooling system.
Plafond 5 illuminates driver’s work site.
See description and operation of load control system, included display 6 and signaling device 7, at the
system operating manual.
Figure 4.3 – Additional dash control panel :

1 – control panel of combined fire suppression system; 2 – plafond; 3 – switch of cooling fan; 4 – signalizing relay; 5 –signalization
unit; 6 – display of loading control system; 7 – signaling device
Display panel.
Display panel (See Figure. 4.4) is mounted to the right of the main control panel.
Indicator 1 (orange) warns about the actuation of speed limitation system. At that traction mode power
circuit turns off and electrodynamic braking mode power circuit turns on with maximum performance. For sub-
sequent traction mode power circuit actuation it is necessary to release throttle pedal and then press it again.
Indicator 2 (red) warns that one or more electric traction drive protections start functioning:
– when exceeding accepted value of power circuit voltage;
– when exceeding accepted value of power circuit current;
– when exceeding accepted value of traction motors anchor chains;
– at rectifiers short circuit;
– at wheels skidding;
– at dump truck reversing in the mode of forced electric braking.
Figure 4.4 – Display panel:

1 – indicator of speed limitation actuation; 2 – indicator of actuation of electric traction drive protections; 3 – indicator of "ground"
fault of power circuit; 4 – indicator of electric traction motor overheating; 5 – indicator of speed hold actuation; 6 – panel;
7 – basic module of system of telemetering control; 8 – display panel of electric traction motor
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Indicator 3 (red) warns that there is a "ground" fault of power circuit of electric traction motor. At
"ground" fault the driver should let the dump truck arrive at repair site under own power or call for specialists to
remove reasons of this protection actuation.
Indicator 4 (orange) warns in blinking mode about electric traction motor overheating. At once, automat-
ic count of time required to stop the vehicle (approximately 2 min), turns on. If at this period the temperature
reduces, the protector and the pilot lamp turns off and the driver can continue operating dump truck. If there is
a failure in the thermoresistor circuit, the lamp flashes constantly.
Indicator 5 (green) warns about the actuation of electric braking mode for dump truck moving with con-
stant speed when the speed hold switch, placed on the dash control panel, turns on.
See technical description, operating rules of the telemetering control system for automatic control of tire
pressure, included base module 7, at the system operation manual.
Display panel 8 description is given in the instruction, attached to the set of documents for the cab with
start regulating equipment of electric traction drive.
4.3 Control panel of starting preheater

Starting preheater control panel (Figure 4.5) is located in the front bumper near the heater and is closed
with a cover.
Check spiral 1 is connected in series with the plug and controls, in accordance with spiral glowing, the
plug’s readiness for heater start.
When turning clockwise the lever of switch 2, the glow plug and the check spiral get actuated. The lever
turns back in its initial position automatically.
Two-position electromagnetic switch 3:
– upper position "OPERATION" (РАБОТА) – solenoid is connected to circuit, fuel is supplied to the nozzle;
– lower position "BLEEDING" (ПРОДУВ) – the solenoid valve is de-energized and the flow of fuel to the
nozzle is shut off.
Three-position switch 4 of the electric motor:
– upper position "OPERATION" (РАБОТА) ensures high speed of the motor;
– intermediate – off position;
– lower "START" (ПУСК) position – the motor is connected to the circuit through a resistor and runs at a
low speed.
Bimetallic circuit breaker protects the starting pre-heater motor circuit against overloads. To restore the
circuit breaker after its actuation, push button 5.
Figure 4.5— Starting preheater control panel:

1 – check spiral; 2 – glow-plug switch; 3 – solenoid valve switch; 4 – electric motor switch; 5 – button for the actuation of bimetallic
circuit breaker
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5 ENGINE SYSTEMS
5.1 Diesel-generator
Engine 2 (See Fig. 5.1) and traction alternator 4 of dump truck are fastened to underframe 3 with bolts
and form one unit, called diesel-generator.
The diesel-generator is mounted on the dump truck frame on four shock absorbers 5. The shock ab-
sorber consists of rubber pad with vulcanized steel armature from both sides.
Figure 5.1 – Diesel-generator:

1 – bar; 2 –engine; 3 – underframe; 4 – traction generator; 5 – shock absorber; 6 – adjustment gaskets; 7 –lock nut; 8 –nut;
9 – thrust washer; 10 –bar absorber; 11 – finger 12 – cushion body; 13 – cushion; 14 – upper absorber flange; 15 – lower absorber flange;
16 – fly-wheel casing; 17 – starter adapter; 18 – generator body; 19 – ventilation wheel; 20 – rotor adapter; 21 –generator rotor
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Shock absorber is fastened with bolts between lower and upper flanges of shock absorber 14 and 15,
flanges in turn are fastened to the truck frame and underframe module with bolts. When mounting the upper
part of rubber pad should be located near the dump truck frame side beam. Flatness tolerance of four shock
absorbers upper surfaces should not exceed 1,5 mm, it is checked till mounting of module and adjusted with
shims 6. Maximum two shims can be placed under one shock absorber. The regulation can be executed by
means of selection of shock absorber altitude.
From longitudinal travels the diesel-generator is restricted to rod 1.
When dismounting of diesel generator, the factory installation of shock absorbers and adjusting shims,
installed under them, should not be disturbed. If for same reason, the initial factory installation of shock absorb-
ers was disturbed, so it is necessary to check flatness of their upper surfaces and to adjust with the help of
shims installation or by means of selection of shock absorber altitude.
When dismounting or replacing engine, generator or underframe it is necessary to align generator arma-
ture shaft with engine shaft to reduce dynamic loads. Connection of dump truck engine and traction-generator
is carried out in accordance with repair manual 7513–3902080 РС.
5.2 Engine fuel supply system

Engine fuel supply system consist of fuel tank with fuel priming pump installed on it, fuel heater with fil-
ter, fuel pipes and fuel supply control drive.
Control drive of fuel supply and run controller.
The drive of fuel supply and run controller secure engine operation at all modes and adjust the run con-
troller drum position with engine speed. Fuel supply control is performed by pedal 3 (See Fig. 5.2) or by handle
1. The pedal effects on lever 13 of revolution regulator through rod 4, three-arm lever 7, shaft 14, lever 17 and
distance control cable 10.
Pedal 3 is connected with handle 1 of rod manual control 2. When moving the handle in any position,
equal to specified fuel supply, for the same value of fuel supply moves also pedal, where return pedal move-
ment is restricted by handle position.
Adjustment of fuel supply drive:

– disconnect rods 2, 4 и 8;
– place manual handle primer 1 in the upper position and by moving of cable 10 in brackets to place
lever 7 in such position, that a distance from center of opening in the lever to cab floor was (22 + 1) mm;
– place pedal 3 of fuel supply at angle about (57 3) with respect to the cab floor. At this pedal position
to adjust length of rod 4 and connect it to the pedal;
-
– start engine and check correctness of drive adjustment. Adjustment should secure maximal (2400 min
1 -1
) and minimal (725 min ) engine speed at idle mode;
-1
– by means of manual fuel supply handle set the rotation speed of engine crankshaft 850 – 900 min
and , not changing handle position, stop engine;
– remove lower cap of run controller 11 and, turning the lever, put it in position corresponding to the be-
ginning of closure of contacts SАЗ:2, at that contacts SАЗ:1 should be opened;
– at this position of lever 7 adjust length and connect rod 8;
– put lower cap of run controller and fasten it with bolts;
– check the correctness of fuel supply drive adjustment. Start of the truck movement should begin at en-
-1
gine speed 850 – 900 min .
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Figure 5.2 – Control drive of fuel supply and run controller:

1 – manual control handle; 2, 4, 8 – rods; 3 – pedal; 5 – stop bolt; 6 – pneumatic cylinder; 7, 15, 18 – levers; 9, 20 – spring nuts;
10 – distance control cable; 11 – run controller; 12 – bracket; 13 – arm of fuel pump regulator; 14 – accelerator shaft; 16 –electromagnetic
valve; 17 –shaft; 19 –springs
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Fuel heater with filter.

Fuel heater with filter (See Fig. 5.3) serves for fuel primary purification and preheating of it during cold
period of time. Coil 4 is installed inside body 5, connected to the engine cooling system. Filter consists of
gauze elements 7 and intermediate washers 6, which are mounted on pin 2 by turns. End filter elements are
protected with safety washers 8. There is a drain hole in cover 1, closed by plug 10. The heater must be dis-
connected during the summer from cooling system by disconnecting valve. Filter can separate mechanical ad-
ditives from fuel in size more than 0,12 mm.
Figure 5.3 – Fuel heater with filter:

1 – cap; 2 – rod; 3 –locking device; 4 –coil; 5 –body; 6 –intermediate washer; 7 – filter element; 8 –protective washer; 9 – sealing
ring; 10 –drain hole plug
I –canal of fuel supply to heater; II –canal of coolant supply; III – canal of heated fuel removal; IV – canal of fuel intake to starting
preheater; V –canal of coolant removal
Fuel tank.
Fuel tank – of welded construction and has squared shape (See Fig. 5.4). Water collector, outtake and in-
take compartments are made in the tank chamber by means of bulkheads and dividing walls.
The tank is equipped with filler neck 2, fuel intake with suction pipe 11 with gauze filter and stopcock 6,
test lamp and electric gauges 3 and 5 of maximal and minimal fuel level, drain plugs 9, breather 1 and tank
cleaning hatches.
The fuel from suction pipe 11 through pipelines comes into fuel heater and than to the engine fuel filters.
Drain fuel from the engine comes into upper point of fuel tank.
At minimal fuel level in the tank, gage 5 gives a signal to test lamp on the dashboard. To avoid overflow,
gage 3 gives a signal to the lamp, mounted on the front side of the tank at maximum fuel level in the tank.
Probe 7 is mounted on the upper side of the tank for measuring of fuel level, on the metal tape of which
there are marks with figures, which indicates fuel amount in the tank in liters.
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Figure 5.4 – Fuel tank:

1 – breather; 2 – filler neck; 3 – gauge of maximal fuel level; 4 – fuel tank body; 5 –– gauge of minimal fuel level; 6 – stopcock;
7 – probe; 8, 10, 12 – caps; 9 –drain valve plug; 11 –suction pipe
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Fuel priming pump.

Fuel priming pump (See Fig. 5.5) is installed on the fuel tank and is intended for pumping of fuel feeding
system with fuel prior to starting the engine.
At the plant when installing the fuel priming pump on the dump truck, the spring and ball get removed
from reducing valve in order to bring the pump pressure down to 0,2 MPa. When replacing the pump under
operation it is necessary to unscrew plug 2 and to remove spring and ball from the reducing valve.
Figure 5.5 – Fuel priming pump:

1, 7, 9 – sealing gaskets; 2 –plug; 3 – electric motor; 4 –clutch; 5 – pump body; 6, 11 –pump gears; 8 –cap; 10 – fitting; 12 – collar;
13 – restrictive ring;
I – drainage canal
5.3 Engine air supply system

Engine air supply system serves for air intake, its purification and supply of purified air from filters to the
engine. The system includes two air filters and air pipes with fixing elements.
Air filter (See Fig. 5.6) is of combined, three stage type with cardboard filter elements. The first
stage – centrifugal inertial device (cyclone collectors) 9 of preliminary air purification, the second stage – paper
filter element 2 of final air purification and protective element 3.
Inertial device consist of ten cyclones 9, closed by cover 8. Under discharge effect in suction chamber of
engine turbocompressors outside air is sucked into cyclones through swirlers. In swirlers rotational motion is
given to air and as a result of this large-scale dust particles are separated from air stream and evacuated
through holes Е in cyclones.
The air cleaned in inertial device moves through filter element 2 of final air purification and safety ele-
ment 3. Filter elements are made of special porous paper, which has low resistance to airflow and high-
performance filtering capability. Filter elements are made as cylinders and consist of paper pleated filter, inner
and outer protecting cases out of metal perforated plate, upper and lower covers. Each filter comprises one
main and one safety filter element, fixed on holder 4 with nuts.
Safety element protects engine if main element gets damaged.
Purified in filters air through the suction pipeline comes to the turbocompressor. Filter dust level gaug-
es installed on pipes behind the air filter are used to control the main filter element. When filter clogging reach-
es maximum permissible level, negative pressure in suction pipe increases, which actuates the gauge and pilot
lamp lights on the dashboard in operator’s cab, indicating that the filter elements are to be cleaned or replaced.
Air filter works in mode of operation «winter – summer». The respective mode of operation is reached
with installation of additional covers on front and sidewalls of air filters.
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Figure 5.6 __ Air filter:

1 – Air filter body; 2 – main filter element; 3 –safety filter element; 4 – holder of filter element; 5, 10, 12 – gaskets; 6 – cyclone
holder; 7 – cyclone pipe; 8 – cap; 9 – cyclone; 11 – seal; 13 –nut; 14 – cyclone seal
Е – cavity at cyclone cap for dust emission
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5.4 Cooling system

Engine cooling system is of liquid type, closed circuit with forced circulation of liquid. Engine cooling sys-
tem of dump truck is of single-circuit. Optimal temperature condition of engine is maintained by automatic sys-
tem, which in dependence with cooling liquid temperature controls fan and radiators gills. At cooling liquid tem-
0 0 0
perature of 75 С, the radiators gills are opened and at 80 С the fan is turned on, but at temperature of 67 С
the inverse process is occurred.
Cooling of engine before its shutting-down is effected by switch of forced fan turning on, located on the
dashboard.
Impeller is mounted on the engine, and radiators gills have automatic operating gear from air cylinder.
For engines cooling system is recommended all-seasons to use special antifreezing liquids (antifreeze,
tosol, high-performance cooling liquid) in accordance with Engine operating manual.
Radiators – is of four-row type with seamless-drawn flat oval pipes, single-pass, split, are mounted in
front of the engine in two units. Each unit of radiator is installed on two supports and from both sides is fas-
tened with traction bars to fenders brackets.
Radiator consists of two frames: one upper and one lower with four-row seamless-drawn flat oval pipes
and cooling plates. Spacer plate 4 mounted between frames, sealed from both sides with shims. Frames
end plates and spacer plate are connected with bolts. Upper radiator tank 5 and lower radiator tank 2 are
fastened to the frames end plates with bolts, which are sealed with shims. From sides frames are closed by
supports 3, that fastened to the tanks and spacer plate.
Pairs in two units through the supports join radiators. Radiators gills are fastened to front unit, and fan
housing – to rear. Units mounting brackets to the dump truck frame are turned down to the lower tanks of radi-
ators unit.
Each expansion tank has filler neck, through which the system is filled with cooling liquid. Plugs of filler
neck are hermetic, with steam and air valves. Steam valve is adjusted on excessive pressure of
0,09 – 0,12 МPа, and air valve is set for exhaust of 0,001 – 0,013 МPа.
Cooling liquid level indicator is mounted in the extension tank of engine cooling circuit. At emergency
cooling liquid level in the engine cooling system a control lamp flashes on dashboard and at the same time the
alarm sounds.
Cooling liquid draining.
That quickly and completely to drain cooling liquid from the system, it is necessary to remove plug from
the extension tank of the respective circuit and open valves. After liquid draining to put the plugs into their posi-
tion and leave the valves opened.
For complete draining of cooling liquid from the cab heater radiator to open both valves on pressure and
drain pipelines.
As practice shows after cooling liquid draining from the engine through the all above mentioned valves,
full drain from the upper part of thermostat boxes and water pipes accordingly, connecting thermostats with the
radiator, is not performed due to engine design features. As thermostat valve in locked position shut off her-
metically bypass hole in the body and don’t let the cooling liquid come for drain. For full draining of cooling liq-
uid from thermostat boxes it is necessary to disconnect water pipes from them and through the opening holes
to strip or drain it by means of thermostats boxes disassembling on connector.
It is possible to install plugs instead of valves in the cooling systems.
5.5 Engine preheating system

Dump trucks are equipped with engine starting preheater, model ПЖД-600 (See Fig. 5.7), to facilitate
starting the engine at low ambient temperature, which burns diesel fuel. The preheater is connected to engine
fuel feeding and cooling systems.
The heat, released while fuel is burning in the preheater boiler, heats up cooling liquid of engine. Circula-
tion pump, that is equipped with a preheater, forces the liquid through the preheater jacket, where it gets heated,
then through the engine jacket and returns the liquid back to preheater boiler.
The preheater boiler incorporates four cylinders, made from stainless steel, that form outer and inner
cooling jackets.
Space between the second and the third cylinders forms reverse gas flue, and space inside of the forth
cylinder forms – combustion chamber. Outer and inner jackets are connected between each other with fife
holes. That secures constant liquid circulating and heats it quicker.
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Fluid is fed under pressure by circular pump 4 to the boiler through pipe 11 passes via outer and inner
boiler jackets, gets heated and through branch pipe 6 is directed to heat the engine.
Preheater burner comprises an outer cylinder 14 to which cover and flange of combustion chamber fas-
tening are welded and an inner cylinder 20. Swirler 16 of primary air is mounted between cover and inner cyl-
inder. To provide stable burning inner cylinder comprises three rows of holes, through which secondary air is
fed into combustion chamber.
Preheater pumping unit is actuated through electric motor 2 connected to the dump truck batteries. Air
supercharger 3 of pumping unit and circulation pump 4 are fastened to electric motor body on longer output
shaft side, and fuel gear-type pump 1 – on collector side
Fuel pump is equipped with reducing valve to adjust the quantity of fuel supplied.
To increase the quantity of the fuel delivered to the preheater through the nozzle adjust reducing valve
nut by turning its screw until the flame traces appear from preheater outlet.
Preheater nozzle 17 is of centrifugal type with a stacked plate filter. To clean nozzle from dirt remove it,
disassemble, wash the plate filter, remove dirt from chamber hole and clean central hole. After the assembly
check nozzle diffusion. To do this, actuate pump unit (without connecting electromagnetic valve to preheater
boiler) and open electromagnetic valve for fuel supply to nozzle. Fuel should be diffused as fog-like cone with
0
angle not less than 60 .
Electromagnetic valve 18 serves for cutting-off fuel supply to nozzle after preheater switching off.
Glow plug 15 ignites fuel at actuation of preheater.
At actuation of the preheater fuel is supplied by pump through opened electromagnetic valve to nozzle
under pressure and gets diffused in combustion chamber mixing with air fed by fan. In the moment of start the
mixture ignites from glow plug. After ignition glow plug switches off and combustion is automatically kept.
Before starting the preheater check if there is fuel in fuel tanks, open the cock on fuel tank and set
switch 4 (see Figure 4.5) of electric motor in “OPERATION” («РАБОТА») position for 10 – 15 sec. Switch 3 of
electromagnetic valve should be in “BLEEDING” («ПРОДУВ») position.
Switch on glow plug for 30 – 40 sec. by switch 2. At that check spiral 1, situated on the preheater control
panel and turned-on in series with glow plug, should become heated to scarlet color. In 30 – 40 sec. after ac-
tuation of glow plug set switch 3 of electromagnetic valve in “OPERATION” («РАБОТА») position and set
switch 4 of electric motor – in “START” («ПУСК») position.
At air temperature exceeding minus 15 °С switch 4 on the control panel can be set in “OPERATION”
(«РАБОТА») position bypassing “START” («ПУСК») position.
After fuel ignition in the preheater burner (it can be determined by flame “buzzing”) release lever of glow
plug switch and set switch 4 in “OPERATION” («РАБОТА») position.
Figure 5.7 – Starting preheater:

1 – fuel pump; 2 – electric motor; 3 – supercharger; 4 – circular pump; 5 – suction pipe; 6 – branch pipe; 7 – combustor;
8 – outside jacket; 9 – inside jacket; 10 – plug; 11 – pipe; 12 – drain valve; 13 – exhaust pipe; 14 – outer cylinder of combustor;
15 – glow plug; 16 – swirler; 17 – nozzle; 18 – electromagnetic valve; 19 – fuel pipe; 20 – inner cylinder of combustor
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If flame “buzzing” is not heard set switch 4 of electric motor in neutral position and switch 3 of electro-
magnetic valve – in “BLEEDING” («ПРОДУВ») position. Repeat starting sequence from the beginning. If pre-
heater fails to start within the period of 3 min., check if there is fuel in fuel pump. To perform checking unscrew
the pipe that supplies fuel to fuel pump and release air locks.
When fuel starts leaking, screw the pipe and repeat starting sequence. If even after these operations the
preheater fails to start, check fuel supply to combustion chamber and glow plug heating.
Preheater starting is considered normal, when in 3 – 5 min (at steady flame “buzzing” in boiler) the pipe-
line, that feeds liquid into the engine cooling jacket, gets hot and outer boiler housing is cold. If boiler housing
gets heated and if there are jerking of boiling liquid, turn off the preheater, define the cause of the lack of liquid
circulation and eliminate the failure.
To turn off the preheater it is necessary to cut off fuel supply to combustion chamber by setting switch 3
of electromagnetic valve in “BLEEDING” («ПРОДУВ») position. Turn the electric motor off by setting switch 4
in neutral position after 1 or 2 min. of operation without burning. To remove residues of combustion materials
and to rule out the possibility that gases explode at next starting.
When using starting preheater it is necessary to follow safety precautions:
– don’t leave dump truck when preheater is actuated, be ready to eliminate possible failure. In case of
fire cut off the valve on fuel tank, turn off preheater and only after that start suppressing the fire;
– it is forbidden to heat the engine in a closed non-ventilated room since it is possible that personnel
gets poisoned with exhaust gases;
– starting preheater is connected to the engine cooling system through stop valve, eliminating the circu-
lation of cooling liquid through the heater at running engine;
– It is forbidden to start preheater without cooling liquid in boiler and to refill an overheated boiler with
cooling liquid as it can cause boiler damage;
– after cooling system filling and before starting preheater unscrew for 2 – 3 turns the plug 10 (see Fig-
ure 5.7) placed on the pipe in front of the preheater pump inlet and on the outer jacket preheater and release
air from the system;
– simultaneous engine and preheater operation is not permitted. After heating the engine switch off pre-
heater and only then start the engine, because when the engine is running cooling liquid circulates backwards;
– after heating the engine at first switch off the heater, and then begin to start the engine;
– it is forbidden to restart preheater right after its shutdown without bleeding it previously for 3 – 5 min.
5.6 Engine air starter system

The engine air starter system is connected to the dump truck pneumatic system through single safety
valve 5 (See Fig. 5.8). The operating pressure of compressed air in engine starting system compounds
0,65 – 0,82 MPa.
For the first engine start it is necessary to fill the system with compressed air from an outside source
through single safety valve 6, located on the left frame side beam. The operating pressure of compressed air in
engine starting system from the outside source of compressed air is limited by safety valve and compounds
(1,5 + 0,15) MPa.
At voltage supply from lock-switch electromagnetic valve 2 opens and compressed air is delivered from
receiver 3 to air-starter 1. The air-starter gear is engaged with gear ring of engine fly-wheel. At that the channel
in air-starter gets opened, through which compressed air moves to starting valve 8. The valve gets opened and
compressed air from the receivers is delivered to pneumatic motor of air-starter trough lubricator 9. When air-
starter gets actuated it rotates engine crankshaft. Valve 10 is installed on each receivers for draining of con-
densate.
Lubricator, starting valve and electromagnetic valve of air starter system dump truck are installed on
engine. Design, technical maintenance of air starter units of dump truck see in “CUMMINS” Engine operation
and technical maintenance manual.
Technical examination and repair of vessels, manometers, safety valves and armature are carried out in
accordance with the requirements and regulations, stipulated in ”Rules of arrangement and safe operation of
vessels operating under pressure” (ПБ 10-115-96).
Disassembly of the system and its elements, dismounting of armature and pipelines, preventive control
and welding operations are allowed to be performed only when the air pressure in the system is reduced down
to the atmospheric pressure.
It is prohibited to adjust and operate the air starter system, if the manometers are failed and if the seals
on safety valves are removed.
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Figure 5.8 – Schematic circuit of engine air starter system:

1 – pneumatic starter; 2 – electromagnetic valve; 3 – re-
ceiver; 4 – safety valve; 5, 6 – single safety valve; 7 – stopcock;
8 – starting valve; 9 –lubricator; 10 – valve
I – from truck pneumatic system; II – from outside source
of compressed air
Safety valve is screwed into the vessel body. The valve is adjusted on pressure of opening
(1,5+0,15 MPa) and closing (1,2+0,1 MPa). Safety valve adjustment is performed by screwing bushing 5 (See
Fig. 5.9) in body 3. After adjustment the valve must be sealed.
When operating a dump truck it is necessary to perform safety valves adjustment at least once in a year.
Figure 5.9 – Safety valve:

1 – seat; 2 – valve; 3 –body; 4 –rod; 5 – press-on hush; 6 –nut
Single safety valve (See Fig. 5.10) is intended for protection of circuit from the compressed air loss in
case of drive seal failure. The single safety valve provides air passing only in one direction – to the receivers of
pneumatic start system. The air can’t pass in the reverse direction.
If air pressure in circuit behind the valve is lower than 0,55 МPа, the single safety valve disconnects
drive with circuit. In starting position, diaphragm 2 is pressed to seat of body 1 by springs 5 and 9 and discon-
nects outlets I and III.
The compressed air comes through outlet I under diaphragm. When air pressure come up to 0,55 MPa,
the diaphragm is up and the air comes into chamber II, valve 11 is opened and the air goes in outlet III and
then to the receiver.
If pressure in outlet I is lower than 0,55 МPа, the diaphragm under force of springs is down on the seat
and disconnects outlets I and III. At the same time valve 11 locks channel II and passing of compressed air in
reverse direction is prevented.
Screw 7 regulates the valve so that the air comes in outlet III at pressure into outlet I within
0,55 – 0,555 МPа.
When tightening screw 7 into cover 3, pressure at which compressed air is crossed over from outlet I to
outlet III is up and when unscrewing is decreased.
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Figure 5.10 – Single safety valve:

1 – body; 2 – diaphragm; 3 – cap; 4 – piston; 5, 9, 12 – springs; 6 – plate;
7 – screw; 8 – lock nut; 10 – gasket; 11 – check valve; 13 – valve body; 14 – bush;
15 – thrust collar;
I, III – outlets; II – cavity
5.7 Exhaust system

Exhaust gases from a turbocompressor (See Fig. 5.11) through exhaust pipes 4 and 6 are delivered into
receiver pipe with thermoinsulation 2 and then through compensator, exhaust pipe with thermoinsulation 3 into
the branch pipe, and then to dump body for it heating. Spherical joints are mounted between the branch pipes
and exhaust pipe for compensation of their misalignment at mounting and during operation.
5.8 Engine systems maintenance

Technical maintenance of engine systems is periodical inspection of system conditions, their fastenings,
refilling by operating materials and checking of serviceability.
Schedule of engine maintenance and order of operations during technical maintenance see in the En-
gine operation and technical maintenance manual.
Daily maintenance.
At daily maintenance:
– check and if necessary to add oil in engine pan, cooling liquid in cooling system and fuel in fuel tank.
Oil level must be between marks (maximum and minimum) on oil measuring straight-edge, check not
earlier than 5 min. after the engine shut down, a dump truck should be in level position (see the Engine opera-
tion manual).
Cooling liquid must be filled up to lower face of filler neck tube (see the Engine operation manual).
Fill fuel in fuel tank up to the maximum level. To avoid overflowing at maximum fuel level the lamp, lo-
cated on the front tank wall, flashes;
– check and if necessary add oil in tank of pneumatic starter system;
– make sure that there is no leaking of fuel, cooling liquid and oil in the engine.
Brand marks of oil, fuel, cooling liquid are specified in chapter “Operation materials”;
– drain residue from the fuel tank. Residual should be drained in 30 – 40 min. after dump truck filling till pure
fuel appearance;
– start engine. The engine must run stable at the whole rotation range;
– check serviceability of engine shut-off system. When pushing the button of planned engine shut-off on
dashboard, the engine must shut down;
– each day at the end of shift drain condensate from the receivers of engine air starter. After full draining
of condensate from the receivers, again to pump the system till pressure regulator actuation and only after that
to shut down the engine;
– check ratio of engine air filters clogging by control lamp on the dashboard. If control lamp flashes to
carry out maintenance of filters.
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Figure 5.11 – Exhaust system:

1, 4, 6 – branch pipes; 2 – receiver pipe; 3 – exhaust pipe; 5 – joint
Sequence of air filter maintenance operations:

– unscrew fastening fly nut 13 (see Figure 5.6) of main filter element 2 (when unscrewing the nut, the filter
element will appear step-by-step from air filter body 1);
– remove sealing gasket 12;
– carefully take out filter element from the body;
– for dust removing: blow out filter element with dry compressed air from the side of cleaned air outlet. Air
pressure must be no more than 0,3 МPа. Air jet must be directed to surface at angel. Hold nozzle at distance no
less than 3 m. from the element surface;
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– after each maintenance of filter element and at installing a new filter element, check carton visually, light-
ing from the side of cleaned air outlet by lamp. Carton breakage, damage of filter elements are not allowed;
– clean inner chamber of the air filter body from dust and dirty with the help of rags/ old clothes, wetted
in cleaning solution;
– clean from dust air filter cyclones, and holes in it for removing big dust particles;
– install filter element into air filter body, tighten fly nut with torque from 30 to 40 N.m. (by hand force),
previously put sealing gasket 12.
Maintenance of the main element should be carried out at each actuating of air filter clogging gage (con-
trol lamp on dashboard). It is not recommended to use filter element, which passed six service cycles, because
filter carton may be broken. Approximate service life of main filter element is 500 h.
Safety filter element 3 is not maintained. Replacement of element is carried out during each third re-
placement of main filter element.
At replacement of safety filter element it is necessary:
– unscrew fastening nut of safety element, remove sealing gasket 5 and take out filter element 3;
– put new element, tighten nut with torque 30 – 40 N.m., previously install sealing gasket 5.
Technical maintenance 1 (ТM–1).
During ТM–1:
– wash out fuel heater filter.
Lock fuel tank with shutoff valve, drain fuel from body 5 (see Figure 5.3) through the opening, closed
by plug 10, remove cover 1 and put out set of filter elements. Unlock and remove filter element from pin.
Wash elements till full removing of sediments and blow out with compressed air. Damaged elements should
be replaced;
– clean cyclones and bodies of air filters from dust. If necessary to replace filter elements;
– check condition and functioning of fuel supply drive.
Drive pedal should move freely, without sticking. Pedal displacement should provide variation of engine
speed at idling conditions from minimum stable to maximum.
During ТM–2:
– check fastenings of all devices to the engine, and diesel-generator to the frame. All devices must be
fastened and if necessary to tighten fastening connections;
– check fastening of cooling system radiator to the frame and if necessary to tighten it, clean outer sur-
faces of radiators.
During ТM–3:
– check condition of diesel-generator rubber shock absorbers. Shock absorbers, having separation of
rubber ply or it separation from metal must be replaced by new.
Seasonal maintenance.
During seasonal maintenance:
– check serviceability of spherical joints of exhaust system. Joints should rotate by hand. In case of
sticking to remove spherical joints, disassemble and clean joints surfaces from carbon deposits;
– wash fuel tank, fuel pipelines and filter elements of fuel tank breather. Dismount fuel tank from a dump
truck. Bottom and side walls of the tank should be free from sediment, and filter elements should be clear;
– carry out maintenance of engine preheating system. Clean glow plug from carbon deposit, nozzle and
burner, wash filter of electromagnetic valve, clean fuel pump drain port of engine preheating system.
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6 TRACTION ELECTRIC DRIVE
Documentation on traction electric drive is attached to the operation documentation package as follows:
1 Documentation package to the traction alternator;
2 Documentation package to the traction motors;
3 Documentation package to the cabinet with starting controllers;
4 75131-2100030-21И – traction electric drive of trucks of capacity 120 – 220 metric tons. Setup instruc-
tion.
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7 ELECTRIC MOTOR-WHEEL
7.1 Electric motor-wheel

The electric motor-wheel includes the electric traction motor 2 (See Fig. 7.1), motor-wheel reduction
gear 8, rear wheel hub 4, brake gears of service 3 and parking 1 brake system and sensor of speed limiting
which is actuated from electric motor shaft.
The torque to I-row sun gear 9 of the reduction gear is transmitted from a flange of the traction electric
motor 14 through flange 13, connected with a flange of traction electric motor by bolts, and torsion shaft 12. On
spline ends of torsion shaft at the one side the flange 13 is mounted, and on the other side the I-row sun gear
9 is mounted. From axial movements the torsion shaft is retained by stop 17, and sun gear – by locking rings
10 mounted on the both sides of the gear in torsion shaft grooves.
Electric motor-wheel is clamped to rear axle crankcase. The description of brake gears is given in sec-
tion “Brake systems”.
Figure 7.1 – Electric motor-wheel:

1 – parking brake gear; 2 – traction electric motor; 3 – service
brake system; 4 – rear wheel hub; 5 – plug of drain hole; 6 – plug of
filling hole; 7, 15 – bolts; 8 – electric motor-wheel reduction gear;
9 – I-row sun gear; 10 – locking ring; 11 –cover; 12 – torsion shaft;
13 – flange of torsion shaft; 14 – flange of traction electric motor;
16 – adjusting washers; 17 – thrust; 18 – spherical thrust
В – clearance
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7.2 Electric motor-wheel reduction gear

The reduction gear of the electric motor-wheel is of two-row type, differential, with spur gears and is
mounted in the hub of the rear wheel.
The reduction gear consists of body 1 (See Fig. 7.2), in which three II-row pinions 40 are installed on ax-
les 41. On the body on two roller conical bearings 7 the rear wheel hub 8 is mounted, to which the II-row crown
gear 9 and driving cover 14 of reduction gear with parts of the first row are clamped with splines.
The I-row sun gear meshes with three pinions 24, which are mounted in I-row carrier 17 each on two cy-
lindrical roller bearings 25. The pinions 24 engage with crown gear 15, which through splines of driving cover
14 transmits the torque to rear wheel hub 8. The carrier 17 is mounted on two ball bearings 19.
In splined opening of an internal flange of I-row carrier 17 the II-row sun gear 23 is installed. It is re-
tained from axial movements by two locking plates 22. The II-row sun gear 23 meshes with three II-row pinions
40, and pinions – with crown gear 9, which transmits the torque to wheel hub 8 through spline joint.
The II-row pinions 40 are rotated on two-row spherical roller bearings 38 mounted on axles 41 in reduc-
tion gear unit 1. The axles are fixed in the unit by locking plates 37 fastened to the unit by bolts 36.
The fixed connections of the reduction gear are sealed by rubber sealing rings. The flange of torsion
shafts 13 (See Fig. 7.1) is sealed by collar 44 (See Fig. 7.2). Wheel hub 8 is packed with two large dimension
collars 6.
The cavity between collars 6 is filled in the process of operation by lubrication through two lubricators 34
installed in hollow fastening bolts of driving cover 14 of reduction gear and jointed with intercollar cavity by
hose. For output of completed lubrication from intercollar cavity when filling with new lubrication it is necessary
to unscrew the plug installed in the third hollow bolt.
Between clamp 3 and collars 6 the distance ring 4 is installed. In order to increase service life of under-
collar ring 2 it is necessary when repairing the reduction gear to place the distance ring 4 at the opposite side
relatively collars, at the same time changes the position of sealing edges of collars relatively surface of under-
collar ring 2.
The lubrication of pinions and bearing of I and II row of the reduction gear is executed by diving and
spraying of oil when rotating reduction gear elements
In order to purify oil from metallic and nonmetallic particles two unattended coarse filters 46 and 51 are
clamped to the body of reduction gear 1 by bolts 52. Oil through oil catchers 48 and 50, connected with hoses
47 is supplied inside body 2 of filter (See Fig. 7.3). Magnets 9 and filter element 4 clean oil, and it drains inside
the reduction gear body 1.
Adjusting of conical bearings of motorized wheel hubs.
The adjusting of conical bearings of motor-wheel hubs without their dismounting from the truck is carried
out with removed wheels, I-row of reduction gear and II-row sun gear.
Adjusting of conical bearings of motor-wheel hub is to be carried out in following order:
– remove cotter-pin and unscrew fastening bolts 11 (See Fig. 7.2) of thrust ring 10;
– check the torque of hub through the second row. It should be not higher than 500 N.m (on technologi-
cal gear of II row – not higher than 135 N.m). Note the value of the torque;
– rotating the hub through the second row tighten in turns two diametrically opposite bolts 11 with tighten-
ing torque of 20 N.m. Repeat the tightening of bolts in the same sequence till the torque of 20 N.m will be set on
eight bolts. Repeat the tightening of bolts in the same sequence till the torque of 40 N.m will be set on eight bolts.
Check with probe the clearance between the faces of rollers and bearing work side 4 (See Fig. 7.4). If the
clearance does not exceed 0.3 mm on 70% of rollers (it shouldn't be more than three rollers located by each oth-
er, which have the clearance more than 0.4 mm), do the next point. Otherwise repeat the tightening of bolts in the
same sequence till the torque of 60 N.m will be set on eight bolts.
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Figure 7.2 – Reduction gear of electric motor-wheel:

1 – reduction gear body; 2 – undercollar ring; 3 – clamp; 4 – distance ring; 5, 12, 21, 29, 32, 36, 42, 45, 52 – bolts; 6 – collar; 7, 19,
25, 38 – bearings; 8 – hub; 9 – II-row crown gear; 10 – thrust ring; 11 – adjusting bolt; 13 – drain plug; 14 – driving cover; 15 – I-row crown
gear; 16 – I-row carrier cover; 17 – I-row carrier; 18 – control plug; 20 – reduction gear cover; 22, 27, 37 – locking plates; 23 – II-row sun
gear; 24 – I-row planet pinion; 26 – axis of I-row planet pinions; 28, 31, 35 – sealing rings; 30, 39 – locking rings; 33 – spacing washer;
34 – lubricator; 40 – II-row planet pinion; 41 – axis of II-row planet pinion; 43 – ring; 44 – collar; 46, 51 – filters; 47 – connecting hose; 48,
50 – oil catchers; 49 – cotter-pin; 53 – sealant; 54 – screw; 55 – annular magnet; 56 – nut
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Figure 7.3 – Filter:

1 – ring; 2 – body; 3, 8 – cotter-pins; 4 – filter element;
5 – cover; 6 – nut; 7 – washer; 9 – magnet plug
Check with probe the clearance between the faces of rollers and bearing work side4 (See Fig. 7.4). If the
Check with probe the clearance between the faces of rollers and bearing work side4 (See Fig. 7.4). If the
Check with probe the clearance between the faces of rollers and bearing work side. If the clearance does
not exceed 0.3 mm on 70% of rollers (it shouldn't be more than three rollers located by each other, which have
the clearance more than 0.4 mm), do the next point. Otherwise, carry out disassembling and trouble-shooting of
the parts:
– check the torque of hub through the second row. It can increase comparing with previously measured
torque (not higher than 500 N.m) for not higher than 400 N.m (on technological gear of II row comparing with
previously measured torque (not higher than 135 N.m) – for not higher than 108 N.m);
– measure the clearance Б: Б1, Б2, Б3, Б4 with precision of +0.02 mm in four equally located points in
front of bolts 2 (See Fig. 7.4);
– grind distance rings (24 pieces) installed between thrust ring and reduction gear body, in size
С=(((Б1+Б2+Б3+Б4):4)+0.2) with precision of 0.015 mm;
– unscrew eight bolts 2;
– screw bolts (24 pieces) putting one spacing washer from ground set on each of them in order to posi-
tion the spacing washers in clearance Б;
– tighten in turns in twos diametrically located adjusting bolts with torque of 400 – 440 N.m;
– cotter the bolts in pairs by cotter-wire;
– if necessary when adjusting it is allowed to replace inner ring of
bearing.
Order of adjusting of conical bearings of motor-wheel hubs on the
reduction gear removed from the truck is to be in accordance with the
Repair Manual.
Figure 7.4 – Checking of clearance:

1 – reduction gear body; 2 –bolt; 3 – thrust ring; 4 – bearing;
А – place for putting the probe; Б – clearance
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7.3 Electric motor-wheel maintenance

Technical maintenance of electric motor-wheel includes periodical inspection of general condition, fas-
tenings, filling with operational materials and checking of serviceability.
List of used lubrication materials, periodicity of checking and replacing of lubrication is given in chamber
«Technical maintenance».
Daily maintenance.
– check visually the condition of large dimension collars. If oil leakage occurs in collars find out the rea-
son of breakage and repair the unit.
During ТM–1:
– add 150 gr. of lubricant in each of two lubricators of intercollar chamber, preliminary having turned off
the plug from the third hollow bolt;
– check oil level in electric motor-wheel reduction gears. For that put the wheels so that the plug of filling
hole 6 (See Fig. 7.1) is positioned vertically down. Oil level should be up to lower edge of hole thread. If nec-
essary add the oil;
– clean magnets 55 (See Fig. 7.2) installed in drain pipes 13 from metallic dust - wear marks. In case of
detection of big metal particles (chips, scobs) check gears, spline connections, bearings.
– take oil sample for analysis (order of making oil analysis from motor-wheel reduction gears see in Ap-
pendix B);
– disassemble thrust-breather 17 (See Fig. 7.1) of reduction gear and wash the filter filling;
– clean the drain holes from dust in lower part of pipe of rear axle casing.
During ТM–2:
– check and if necessary tighten fastening bolts of traction electric motor clamped to the electric motor-
wheel reduction gear, fastening bolts of electric motor-wheel clamped to rear axle casing. Tightening torque
see in Appendix B;
– remove cover 11 (See Fig. 7.1), take out torsion shaft in assembly with sun gear and check visually
their condition;
– check and if necessary adjust the clearance between torsion shaft and thrust.
Install thrust 17 in cover 11 till contact with spherical thrust 18 of torsion shaft 12. Measure the clearance
cover faces 11 and thrust 17. Collect a set of adjusting washers 16 with thickness for clearance size plus (1 –
2) mm and install them between cover faces 11 and thrust 17. Fix the thrust to the cover by bolts;
– carry out visual inspection for cracks in: connection of rear axle casing with electric motor-wheel re-
duction gear; places of welding of lever flange of rear axle casing; places of welding of lower bracket of torque
rod.
In case of cracks in reduction gear body of electric motor-wheel replace the body, on rear axle casing –
prepare the cracks and weld them.
Seasonal maintenance.
– check the necessity of adjustment of hub bearings of electric motor-wheels.
WHEN DUMP TRUCK REACHES THE RUN OF 150000 KM, PERFORM PLANNED REPLACEMENT OF I-ROW
PINION BEARINGS OF MOTOR-WHEEL REDUCTION GEAR.
Methods for determination the need for adjustment of hub bearings of electric motor-wheels.
Way of inspection the necessity for adjustment of hub bearings of electric motor-wheel:
– place the truck on the plain area;
– check air pressure value in tires and if necessary bring up to the norm;
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– clamp bracket 2 on rear axle casing 1 (See Fig.

7.5) at the right side (in direction of truck movement). Fas-
ten plate 4 on thrust ring of wheel rim 5;
Figure 7.5 – Lay out of equipment mounting:

1 – rear axle casing; 2 – bracket 75132-3924340; 3 – magnet
stand 47452/074562; 4 – plate 75132-3924380; 5 – rear inner wheel;
А – size
– mount magnet stand on bracket 2 so, that the head of micrometer rests on plate 4, and size А should
be within limits of (95 + 2) mm;
– zero the arrow of micrometer;
– lift a little the rear axle;
– put support 3 (wooden bar) under outer wheel 2 (See Fig. 7.6 a) and lower rear axle on support, at
that there shouldn’t be any contact of inner wheel 1 with area;
– read the micrometer indications;
– repeat two or three times lifting, lowering, reading of the micrometer indications and find the average
value of the micrometer indications;
– lift a little the rear axle;
– put support 3 (wooden bar) under inner wheel 1 (See Fig. 7.6 b) and lower rear axle on support, at that
there shouldn’t be any contact of outer wheel 2 with area and size B should be within limits of (470 + 10) mm;
– read the micrometer indications;
– repeat two or three times lifting, lowering, reading of the micrometer indications and find the average
value of the micrometer indications;
– determine the difference of average micrometer indications at putting of support under outer and inner
wheels. This value should not exceed 2.4 mm. If it exceeds 2.4 mm, adjust hub bearings of right motor-wheel;
– determine the difference of average micrometer indications for hub bearings of left motor-wheel at put-
ting of support under outer and inner wheels. This value should not exceed 2.4 mm. If it exceeds 2.4 mm, ad-
just hub bearings of left motor-wheel;
Figure 7.6 – Determination of the micrometer indications

a) support under outer wheel; b) support under inner wheel:
1 – rear inner wheel; 2 – rear outer wheel; 3 – support; В – size
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7.4 Ventilating and cooling system of traction electric drive

The ventilating and cooling system is designed for keeping optimal temperature mode of main parts op-
eration of traction electric drive.
Cooling air supply system provides air intake from the less dusted zone of the truck and air, cleaned
from impurities, gets through cyclones 1 and 3 (See Fig. 7.7), mounted on power cabinet 2, along hoses 4, 7
and pipe 5 into inlet pipe 8 of traction alternator 6 at the side of contact rings.
Part of air is used for cooling of traction alternator, passing through air ducts (through ventilation
openings in stator sheets, clearances between poles of rotor, poles of rotor and stator). Passing through
clearances air comes out of alternator through windows, protected by nets, in stator’s body, at the side o p-
posite contact rings.
The rest air gets into cooling fan of traction motors and then through pressure air line is supplied to rear
axle casing and through ducts in reduction gear bodies of electric motor-wheels goes for cooling of traction
electric motors. Air releases through ventilation windows of traction electric motors and openings in port cover
of rear axle casing port.
Figure 7.7 – Installation of suction air lines of traction units cooling:

1, 3 – cyclones; 2 – power cabinet; 4, 7 – hoses; 5, 8 – pipes; 6 – traction alternator; 9 – motor; 10 – dust separators; 11 – mono-
cycle; 12 – guide;
I – slot for dust release
Cooling fan of traction electric motors.

A fan impeller as an assembly consists of front disk 20 (See Fig. 7.8) and rear disk 15. Between disks
on bolts 17 aluminum blades 16 (24 pieces) are installed. The blades are fastened with nuts 18. Plates 19 are
intended for locking of nuts.
The fan impeller with hub 5 is mounted on the key 3 on shank of rotor shaft of traction alternator 2. The
hub is put on rotor shaft with tension and tightened by round split nut 6 with torque of 882 – 980 N.m. From
loosening the nut is fixed by bolts 9, which are locked between each other by cotter-pin-wire 10.
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The fan shroud 4 is fixed on bearing board of traction alternator. The gasket 1 between traction alternator 2
and fan shroud 4, and gasket 13 between cover 8 and fan shroud are put on glue 88 CA TУ 38.105.1760-89.
The fan impeller in the assembly with hub is dynamically balanced. The unbalance should not exceed 24
g.сm in the plane of front disk and 40 g.сm in the plane of rear disk. The mutual position of components is fixed
by pins 7 (2 pieces).
IT IS FORBIDDEN TO DISASSEMBLE THE FAN IMPELLER FOR COMPONENTS, AS THUS THE MUTUAL
POSITION OF PARTS OF COMPLETE SET IS VIOLATED, THAT AT THE SUBSEQUENT ASSEMBLY RESULTS IN
INCREASE OF UNBALANCE OVER THE ESTABLISHED NORMS AND EXCESSIVE VIBRATION OF THE ALTERNA-
TOR AND LIFE REDUCTION OF ITS BEARINGS.
Figure 7.8 — Cooling fan of traction electric motors:

1, 11, 13 – gaskets; 2 – traction alternator; 3 – key; 4 – shroud with air line; 5 – fan impeller hub; 6, 12, 18 – nuts; 7 – pin;
8 – cover; 9 – bolt; 10 – cotter pin-wire; 14 – bolt; 15 – rear disk; 16 – blade; 17 – bolt; 19 – plate; 20 – front disk
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7.5 Technical maintenance of ventilation and cooling system of traction electric

drive
Daily maintenance.
– check the condition of air lines. Soft hoses of air lines should not have any breakages. At minimal en-
gine speed the air should release from ventilation openings of electric motor-wheel;
– check visually the condition of door tightening of power cabinet. The doors should fit tightly.
During ТM–1:
– clean dust separators and monocycles of air lines from dust, paying attention, that slots for dust re-
lease shouldn’t be choked.
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8 RUNNING GEAR
8.1 Frame
The welded frame consists of two spars 4 and 6 (See Fig. 8.1), joint with power cross bars by means of
welding. Spars have box-shaped cross-section of variable height on length of a frame.
The first cross bar 1 is manufactured of a tube with diameter of 245х45 mm and serves for arm fastening
of the central bar of front axle. The second cross bar 2 represents closed circuit consisting of the lower cross
bar, frame connecting spars, the left and right racks to which brackets of a front suspension are fastened, and
the upper demountable cross bar connecting the racks. To the lower cross bar the transversal rod of a front
suspension is fastened.
The third cross bar 3 welded on spars, reinforces the middle part of frame. To it the central bar of
back axle is fastened. In butts of the third cross bar welded brackets of the lower bearing of the dumping
mechanism cylinders. It consists of two cast bearing parts, interconnected with tube with diameter of 325х36
mm.
In the rear part spars are connected by cross bar 5 on which the bracket of strengthening of transversal rod
of back axle is welded, brackets of the rear suspension and brackets of an end support bearing of the platform.
Spars and cross bars are made of low-alloy steel 10ХСНД ГОСТ19281-89.
At maintenance of dump trucks periodically examine welded connections on presence of cracks in the
most loaded frame places:
– in welding place of the second cross bar in a zone of a front suspension;
– in welding place of rear cross bar to spars;
– in welding place of racks of the second cross bar and its elements to spars;
– in welding place of brackets of the central hinge and a transversal rod.
It is recommended to apply a visual quality monitoring, color, magnetic or ultrasonic flaw detection to de-
tection of cracks. Inspection of availability index of frame, defects definition and repair is described in the Re-
pair Manual.
Figure 8.1 – Frame:

1 – first cross bar; 2 – second cross bar; 3 – third cross bar; 4, 6 – spars; 5 – rear cross bar
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8.2 Suspension
The front suspension – dependent, consists of two pneumohydraulic cylinders 3 (See Fig. 8.2), eyelet
28 with the hinge, bar of front axle and transversal rod 2.
The loads operating on the front axle wheels are transmitted to the frame through suspension cylinders,
transversal rod and eyelet with the hinge. Suspension cylinders react to the vertical loads, rod – only transver-
sal load and the central hinge – vertical, transversal and longitudinal loads.
The cylinder of a suspension is fastened with self-locking nuts 19 to upper 33 and to lower 21 brackets.
The upper bracket is fastened to the frame with bolts and is welded on by the welding. The lower bracket is
fastened with bolts to the upper butt of steering knuckle. The transversal rod 2 is connected hingedly by means
of taper fingers 7 to the frame cross bar and to the beam of the front axle. The eyelet 28 is fixed to bar of the
front axle with the help of bolts 29, to the frame bracket - hingedly by finger 25.
Figure 8.2 – Front suspension:

1, 15 – oilers; 2 – rod; 3 – suspension pneumohydraulic cylinder ; 4, 12, 20, 23, 29, 31, 36 – bolts; 5, 13, 30 – disks; 6 – barrel; 7,
25 – fingers; 8, 24 – stuffing boxes; 9 – retaining ring; 10, 26 – articulate bearing; 11, 27 – covers; 14 – adjusting washer 16 – buffer;
17 – bush; 18 – ring; 19 – nut; 21 – lower suspension cylinder arm ; 22 – suspension cylinder ball bearing ; 28 – eyelet with the grounding;
32 – lubrication tube of ball bearing; 33 – upper suspension cylinder; 34 – cover; 35 – lock plate ;37 – splint
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The rear suspension – dependent, consists of two pneumohydraulic cylinders 2 and 4 (See Fig. 8.3),
transversal rod of the suspension 3, bar of the rear axle and an eyelet 7 with the central hinge.
The loads operating on wheels of the rear axle are transmitted to the frame through suspension cylin-
ders, transversal rod and the central axle. Cylinders of suspension perceive vertical loads only, rod – transver-
sal, and the central hinge – vertical, transversal and longitudinal loads.
Pneumohydraulic cylinders of the suspension are fastened to brackets on the frame and the crankcase
of the rear axle by self locking nuts 29.
The transversal rod of the suspension 3 is fixed to brackets on the frame and the crankcase of the rear
axle with the help articulated bearings 23, fixed on the rod fingers 20 through distance sleeves 17, pinch plates
25 and bolts 18 and 26.
The eyelet 7 of the central hinge is installed on barrels 11 and fixed to the central bar with the help of
bolts 15 and nuts 14, to the frame bracket – hingedly by finger 9.
Figure 8.3 – Rear suspension:

1 – mud shield; 2 – left pneumohydraulic suspension cylinder; 3 – suspension rod; 4 – right pneumohydraulic suspension cylinder;
5 – lock plate 6, 15, 26, 32 – bolts; 7 – eyelet with the grounding; 8 – cover; 9 – finger; 10, 14, 29 – nuts; 11, 21, 24 – barrels;
12, 23 – articulated bearings; 13 – stuffing box of the central hinge; 16 – sealing ring; 17 – distance bushing; 18 – special bolt; 19 – oiler;
20 – rod finger; 22 – ring; 25 – pressure plate; 27 – rod stuffing box; 28 – disk; 30 – boot; 31 – suspension cylinder ball bearing
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The suspension cylinder (See Fig. 8.4) represents piston-type air spring in a combination with a hy-
draulic shock absorber. Working element in the cylinder is engineering gaseous nitrogen. As hydraulic fluid in
the suspension cylinder the damping fluid ЛУКОЙЛ – АЖ is applied. Front and rear cylinders of the suspen-
sion are analogous on a construction and differ in sizes of details, configuration of a chase on a stock of the
absorber, and amount of filled oil and gas pressure.
The suspension cylinder consists of the basic cylinder tube13 and stock 34 with the piston welded on it
and the shock absorber partition. To the heel of the stock by bolts the lower cover 25 which are drawing in to a
butt of the stock housing 11 is fastened, and to the upper part of the tube of the basic cylinder bolts the upper
cover 38 is fastened. In the upper and lower cover trunnion balls 40 are installed, fixed by covers 39. Between
the upper cover 38, lower 25 and cover 39 adjusting shims 24 are installed.
Between spherical surfaces of covers and trunnion balls liners 2 of metal-polymeric ribbons are installed.
Trunnion balls are greased through pressure lubricator.
Sensor valve 37 of weight control and tire pressure control systems (СКЗиТ) is installed in upper cover in
order to monitor dump truck's load status.
Between spherical surfaces of covers and trunnion balls liners 2 of metal-polymeric ribbons are installed.
Trunnion balls are greased through pressure lubricators.
On the partition of the shock absorber two compression valves 33 and the valve of the release 29 are
located. In the valve case of the release the stock of the shock absorber 36 with two long slots of a variable
section executing function of the throttle of a variable resistance of the valve of a release of the absorber dis-
places. The stock of the shock absorber intended also for the pump drive 28.
The housing 11 forms a cavity И in which the hydraulic fluid up to a level of control plug 15 is filled. The
hydraulic fluid intended for refill of cavity Л and К and lubrications of the housing sealing. Air-tightness of the
movable tube joint of the basic cylinder 13 and housing 11 is ensured with the sealing ring 53 and the safety
ring 54.For protection of the cylinder external surface from dust and mud serves the protective boot 9, timbered
between ring 30 and sealant 31.
Air-tightness of fixed joints is ensured with rubber ring gaskets of round cross-section. For prevention of es-
cape of hydraulic fluid from the suspension cylinder the movable joint the stock - tube of the basic cylinder is con-
densed by the fluoroplastic collar 57, working edges of which are unclenched by the rubber spacing ring 56. The
collar is mounted with tightness that is regulated by set of adjusting shims 61 and supported by spring 60. The col-
lar tightness at assembly should be 2.0 – 2.3 mm of inner diameter on the collar edge 217.7 – 218.0 mm for front
cylinders and 247.7 – 248.0 mm for rear cylinders). The joint tube sealing of the basic cylinder – piston is ensured
fluoroplastic washers 52 on the stock of piston 34.
For housing 11 protection from overcharges, at pressure boosts in its cavity at the expense of decrease
of volume at the cylinder pressure and because of possible escapes of the hydraulic fluid through the collar
and other joints, serves pressure-relief valve 10. For gaining operation condition the cylinder is filled by nitro-
gen through the priming valve 3.
At the compression stroke (at the head-on crash by the wheel) the piston displaces in the cylinder up
and squeezes gas. At the expense of the gas pressure increase above the piston the compression stroke is
elastic restricted.
At the release course (after overcoming an obstruction) the stock displaces downwards.
For blanking out oscillations originating at driving of the dump truck, the suspension cylinder has a hy-
draulic shock absorber consisting from two compression valves 33, release valve body 29 and shock absorber
stock 36 with two long slots of the variable section.
At the compression stroke the hydraulic fluid flows from cavity Л in ring cavity K through throttle bores of
compression valves and on ports in the shock absorber partition. Besides, oil flows through the ports formed
by the valve body of the release valve 29 and long slots on shock absorber stock 36. Stocks of shock absorb-
ers of front and rear suspension cylinders differ of the configuration of the variable cross-section slots. In order
not to mix stocks at cylinders repair on their lower butt identification mark is plotted.
At the release course compression valves are closed, and the fluid from the cavity K in cavity Л flows
only through the ports formed by the release valve body and long slots of the variable section on the shock ab-
sorber stock which flow section varies with cylinder release that creates necessary resistance to flow of the
hydraulic fluid and prevents the cylinder from full release.
At the suspension cylinder mounting on the dump truck, and at repair of the cylinder, it is necessary to
pay attention to identification mark, beaten out on two sides on tube of the basic cylinder about the upper cov-
er, against charge valves. The conditional index of the cylinder goes in marking (19–0 for front cylinders and
19–1 for rear cylinders), through dash or space the into two – three sign – cylinder serial number and through
dash – two last digits of manufacture year.
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Figure 8.4 – Suspension pneumohydraulic 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 – protective boot; 10 – safety valve; 11 – housing; 12 – stock guiding with an axle box; 13 – tube of the basic cylinder; 14 – pinch nut;
15 – control plug; 16 – filter; 21 – safety valve; 22, 53 – sealing rings; 24, 61 – adjusting shims; 25 – lower cover; 27 – lock screw;
28 – pump; 29 – release body valve; 30 – ring; 31 – sealant ;32 – ball; 33 – body of the compression valve; 34 – stock; 35 – plug of com-
pression valve; 36 – stock of the shock 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 body; 50, 60 – springs;
52 – washers; 54 – safety ring; 56 – spacing washer; 57 – collar of the stock; 58 – ring of the collar; 59 – pressure ring;
Н1, Н2 – dimensions; И, К, Л – cavities
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For maintenance of the fixed level of the hydraulic fluid in the cavity Л serves the plunger pump 28 which
is installed in boring of the lower cover 25 and timbered by means of flange 19 by bolts 26 with washers. The
pump design is shown in Figure 8.5.
The pump starts operation at significant oscillations of the dump
truck and only at the level lowering of the hydraulic fluid in the cavity Л. .At
the normal level of the hydraulic fluid in cavity Л the stock of the shock ab-
sorber 36 (See Fig. 8.4) does not touch the pump plunger 28. On the
plunger 6 (See Fig. 8.5) from above and from below the oil pressure avail-
able in cavity Л operates, but it constantly is in the upper position as the
square of its butt ring on the part of the cavity II is bigger and the force op-
erating from below, is higher.
In case of kickdown of oil level in the cavity Л of the cylinder (See Fig.
8.4) the shock absorber stock 36 at significant oscillations of the dump truck
displaces the pump plunger 28 downwards. The oil pressure in underplunger
cavity III (See Fig. 8.5) raises, the back-pressure valve 15 opens and oil from
underplunger cavity III on port I acts in the cylinder cavity. At the cylinder re-
lease the plunger under an operation of oil pressure in ring cavity II of pump
displaces up. In the plunger cavity III rarefying is created and it is filled by oil
from the cavity И (See Fig. 8.4).
The pump marking is plotted on the butt of sleeve nut 18 (See Fig.
8.5) and corresponds to the serial number and year of manufacture of the
pump.
Figure 8.5 – Pump:

1 – axle box; 2, 3, 4, 8, 9 – sealing rings; 5 – case; 6 – plunger; 7 – glass; 10 – barrel;
11 – ball; 12 – saddle; 13 – washer; 14, 17, 19 – protective washers; 15 – check valve;
16 – pump washer; 18 – nut;
I, II, III – cavities
8.3 Suspension maintenance

Suspension maintenance includes routine inspection of the condition, strengthening, refueling of the op-
eration materials and functional testing. The list of used greases, inspection frequency and replacement of oil
is given in "Maintenance" section.
Daily maintenance (DM).
– every shift, before stabilization of tightening torque check torquering of the vital threaded con-
nections, described in Appendix B;
– check by external examination condition and strengthening of suspension cylinders, rods, hinges of
bars of the front axle and the back axle. All details should be safely fixed, cracks on details and weld seams
are not permitted.
External fault symptom of the suspension cylinders is change of their height in comparison with their
working condition.
At abnormal suspension cylinders operation (dump truck roll, strong oil leak) check their serviceability
by definition of size Н1 for front (See Fig. 8.4) and Н2 for rear suspension cylinders. This size are defined by
a special (characteristic) ruler (See Fig. 8.6) with two scales: charge and working. Marks on scales mean
value of gas pressure in the cylinder (in МPа) of the given size at the correct cylinders charging. On the ruler
zones of admissible scatter of dimensions on working scale are marked out at operation of cylinders.
The charge scale located right on the ruler, intended for monitoring the newly charged cylinder or when
gas pressure in the cylinder is completely absent. The working scale located left on the ruler serves to check
charging of suspension cylinders in operation.
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Figure 8.6 __ Characteristic ruler:

1 – size for completely compressed cylinder; 2 – pressures working scale in the cylinder; 3 – cylinder
nominal size on loaded dump truck; 4 – cylinder size tolerance of the equipped dump truck; 5 – pressure cor-
responding to nominal cylinder size of the equipped dump truck; 6 – zone of maximum cylinder size deviation
of the equipped dump truck in maintenance; 7 – charge pressures scale in the cylinder; 8 – size of completely
unclasped cylinder; 9 – size of the rear cylinder dressed by oil.
Inscription on characteristic rule:
– зарядная характеристика – charge characteristic;
– рабочая характеристика – operating characteristic;
– передний цилиндр – front cylinder;
– задний цилиндр – rear cylinder
For the dimensions Н1 and Н2 inspection install empty dump truck on flat hori-
zontal platform. The front suspension cylinder is considered normally charged if the
center of control plug 15 (See Fig. 8.4) is against zone of admissible size scatter of the
ruler working scale.
The rear suspension cylinder considered normally charged if the housing butt 11
is against zone of admissible size scatter of the ruler working scale. At measurement of
dimensions Н1 and Н2 the ruler is interposed under protective boot 9 against the stop
into ring 30 so that it is not displaced from the mounting face.
Whereas sizes of all suspension cylinders are interconnected, size change of
one cylinder (defective) calls resizing of other cylinders. Defective cylinder is as rule,
the one with the least size. In addition measure gas pressure at the defective cylinder
by means of device (See Fig. 8.7) and, if it is below normal (on working scale of charac-
teristic ruler) for more than 0.3 МPа for front cylinders and 0.2 МP for rear cylinders
perform preventive recharge.
Sharp decrease of cylinder height testifies emersion of significant escapes of the
hydraulic fluid through joints, and the cylinder gas recharge on the dump truck without
elimination of failure is ineffective.
Remove the defective cylinder from the dump truck, disassemble observing safe-
ty precautions and eliminate failure (See Repair Manual).
During ТM–1:
– tighten fastening joints:
1. fastening bolts and nuts of eyelets of the central hinges of front and rear sus-
pension to bars;
2. fastening bolts of finger of the central hinge of the front suspension;
3. finger fastening nut of the central hinge of the rear suspension;
4. bearings covers fastening bolts of the central hinges front and rear suspen-
sion;
5. rod fingers fastening bolts of the front suspension;
6. pressure plates fastening bolts to finger of transversal rods of the suspension.
Tightening torques are shown in Appendix B.
During ТM–2:
– tighten fastening joints:
1. fastening bolts of the upper and lower arms of the front suspension cylinders
suspension;
2. nuts of trunnion balls of the front and rear suspension cylinders.
Tightening torques are shown in Appendix B;
– check condition of weld seams of the suspension arms. Weld detected cracks;
– check oil level in suspension cylinders housings 11 (See Fig. 8.4) and if neces-
sary add up to level of control plug 15.
Brands of used oil are shown in "Operation materials" section;
– check suspension cylinders charging by gas.
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Figure 8.7 __ Device for measuring pressure in cylinders:

1 – manometer; 2, 9 – sealing gaskets; 3, 8 – adapters; 4 – hose; 5 – nut; 6 – needle; 7 – ring gasket
If the oil level in the housing is higher than control plug, it should not be drained, as during operation
pump will pump it over inside the cylinder. If there is enough oil in the cylinder housing, and height of the cylin-
der is decreasing, it is necessary to remove the cylinder from the dump truck and eliminate leakage.
Refueling of the front suspension cylinders with oil is carried out as follows:
– with the help of device release gas completely from cylinders through the priming valve. Cylinders
should be squeezed up to stop. If after squeezing of the cylinder through the open valve foamed oil goes out,
close the valve, give oil to be settled till full separation of nitrogen;
– after full gas separation turn out the priming valve and through bore fill oil in the cylinder up to the level
of tapped hole;
– turn the priming valve in and charge the cylinder with nitrogen on charge scale of characteristic ruler,
having tested pressure of gas in the cylinder with the help of the manometer. It should coincide with pressure
on a characteristic ruler.
Refueling of the cylinders of the rear suspension with oil on the dump truck is carried out as follows:
– on the grounding of thrust blocks (on the crankcase of the rear axle) install the racks (7513–3924134)
applied to the dump truck, and release gas from cylinders of a suspension (see above). Cylinders thus should
be squeezed up to stop in spars of frame in installed racks.
After the cylinders squeezing check correctness of the groundings of thrust blocks installation. Inspec-
tion is performed with the characteristic ruler. At the compressed cylinders against the stop of spars of frame in
racks the butt of a housing of the cylinder should be at the level of a line 9 (See Fig. 8.6) of characteristic ruler
with accuracy up to 5 mm. The ruler is installed the same way as at sampling of H dimension. The refueling of
rear cylinders with hydraulic fluid is analogous to refueling of front cylinders.
Sequence of the cylinder, filled with hydraulic fluid, charging with gas (nitrogen):
– connect reducer of device with a bulb with nitrogen through adapter connector 2 (See Fig. 8.8);
– screw on the priming valve of the suspension cylinder adapter 17 of device;
– open valve on a bulb with nitrogen. Check gas pressure in the bulb on the manometer 3;
– turning regulating screw 12 of reducer create gas pressure in the cylinder before its release;
– close the valve on bulb and with sleeve 8 release gas from ports and hose of device;
– turn needle 15 before opening the refueling valve. Start of refueling valve opening is defined on the
moment of aberration of arrow of the manometer 10. The needle wrenching should be performed cautiously in
order not to damage valve spring;
– open valve on bulb and the screw 12 of reducer to achieve release of the cylinder up to such size that
pressure on the manometer 10 has coincided with the pressure indicated on characteristic ruler (See Fig. 8.6)
or according to table 8.1;
– turn out needle 15 (See Fig. 8.8), close valve on bulb, disconnect device from priming valve.
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Figure 8.8 – Device for suspension cylinders charging:

1, 9, 11, 18 – sealing gaskets; 2, 6, 17 – adapters; 3, 5 – manometers; 4 – reducer; 7 – valve; 8 – connecting pipe for gas outlet;
10 – manometer for monitoring gas pressure in the suspension cylinder; 12 – reducer regulating screw; 13 – hose; 14 – nut;
15 – needle; 16 – ring gasket
Table 8.1 – Gas pressure in the cavity of completely released cylinder
Suspension cylinder Cylinder designation Gas pressure, MPa

front 7513–2907020-20 2.8+0.016
rear 7513–2917020-20/021-20 1.06+0.016
It is not recommended to carry out preventive refueling of cylinders with oil and recharging with nitrogen
earlier than after 50 – 70 thousand kilometers of dump truck run.
IN AVOIDANCE OF GAS LEAKS THROUGH A MOBILE ROD SEAL STORAGE AND TRANSPORTATION OF
THE CHARGED SUSPENSION CYLINDERS SHOULD BE CARRIED OUT IN VERTICAL POSITION, THE ABERRA-
0
TION FROM VERTICAL SHOULD NOT EXCEED 30 .
AT REACHING THE RUN OF DUMP TRUCK 60 – 70 THOUSAND KILOMETERS PERFORM SCHEDULED RE-
PLACEMENT OF METAL-PLASTIC LINERS FOR EXCLUSION OF PROBABILITY OF POSSIBLE OPERATION OF
SUSPENSION CYLINDERS IN «STEEL ON STEEL» CONDITION.
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8.4 Front axle

Front axle – steered, not driving. Consists of beam 6 (See Fig. 8.9), right 4 and left wheels 9 with brakes
and the swivel gear, interconnected with the help cylindrical pins 17.
Front axle beam – welded, box-shaped cross-section with cast nozzles welded on the ends. The central
bar of the front suspension is welded on beam with turning arms cylinders which hingedly connected with the
frame cross bar.
The swivel member 7 (See Fig. 8.10) is connected with beam 36 by pin 17 (See Fig. 8.9) which is fixed
in nozzle of the beam motionlessly with the help of pin stop member 13. The swivel member is pivoted in four
metal-plastic barrels 16 installed in the upper and lower eyelets swivel member. Barrels are greased through
pressure lubricators 15 and sealed with collars 24.
Figure 8.9 – Front axle:

1 - hose of high pressure; 2, 23 – triangles; 3, 5, 8, 10, 12 – tubes; 4 – right front wheel with brakes and the rotation gear; 6 – beam
of the front axle with lever; 7 – T-connector; 9 – left front wheel with brakes and rotation gear; 11 – safety valve; 13 – pin stopper; 14 – plug;
15 – lubricator; 16 – pin plug; 17 – pin; 18 – nut; 19 – clinch; 20 – bolt; 21 – liner; 22 – connective valve; 24 – collar
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C (version)
Figure 8.10 – Swivel member with hub, brake and steering gears:
1 – limiter; 2 –left rotary bar; 3 – pin barrel; 4 – expansion barrel; 5 – nut; 6, 22 – studs; 7 – left rotary cam; 8 – brake plate;
9, 11 – bearings; 10 – volume limiter; 12, 15, 19, 24, 27, 41 – bolts; 13 – hub of front wheel; 14 – pressure ring ; 16 – adjusting barrel;
17 – drive gear of speedometer sensor; 18 – sealing gasket; 20 – external cover of the front hub; 21 – stuffing box; 23 – wheel;
25 – ring; 26 – cover; 28 – adjusting washers; 29 – buffer; 30 – liners; 31 – bearing; 32 – collar; 33 – internal cover of the front hub;
34 – stub; 35 – speedometer assembly harness; 36 – front axle beam; 37 – ring; 38 – brake case; 39 – splint; 40 – odometer;
42 – washer; 43 – lining
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Thrust bearing 31 (See Fig. 8.10) installed in the upper eyelet of swivel member 7 is fixed by cover 26
with bolts 27. Three antifrictional liners 30 installed on cover 26 act as friction bearing. From turning liners are
kept by the thrust whiskers which are entering bores in swivel member and cover. To the lower eyelet of swivel
member by means of studs 6 and expanding taper sleeves 4 the pivot rod 2 of steering trapezoid is fastened.
For limitation of upright conveyance of beam of front axle with pivot serves the ring 25. For clearance adjust-
ment between ring and butt the lower arm of the suspension cylinder the adjusting washer 28 width of 0.5 mm,
0.9 mm and 1.2 mm are intended.
For limitation of volume at lubrication of pivot barrels in the lower eyelet the limiter 1 is installed.
The hub of the front wheel 13 with the fastened brake disk 8 rotates on the wrist pin of the swivel mem-
ber 7 on two taper roller bearings 9 and 11. Sealing of bearings is carried out the collar 32 and the stuffing box
21. At assembly and maintenance spaces between rollers of bearings, cavities between bearings and limiter of
volume 10 and inner cavities of the fit ring should be filled with lubricant.
In the left wheel of front axle the drive gear of the speedometer sensor 17 is installed, in the right, on
customer order, odometer 40 is installed.
The front axle is connected to the frame by means of the central hinge, transversal rod and suspension
cylinders.
8.5 Front axle maintenance
Front axle maintenance includes routine inspection of condition, strengthening, refueling with operation
materials and adjustment of bearings of the wheels hubs. The list of used greases, inspection frequency and
oil replacement periods are specified in "Technical maintenance" section.
– each day prior to start of dump truck check by external examination condition of welding on ends of
front axle beam. Special attention should be paid to the most loaded places (special examination zones) ac-
cording to the Fig. 8.11.
Figure 8.11 – Examination zones:

1 – hub; 2 – swivel member; 3 – end; 4 – beam
А – special examination zones
Seasonal maintenance (SM).

– adjust taper bearings of the wheel hubs.
Adjustment of taper bearings of the wheel hubs.
Adjustment of taper bearings of wheel hubs in operation is to be carried out as follows:
– apply parking brake and put thrust blocks under rear wheels;
– hang out front of the dump truck up to full tear of wheels from a floor of platform and install special
jambs under spars of the frame;
– remove external cover of the front wheel hub;
– unsplint and turn out twelve bolts on two – three revolutions;
– turn out adjusting barrels on two – three revolutions;
– turning the hub in both directions, tighten 6 bolts installed in bores without adjusting barrels in press-
ring with torque of 100 – 140 N.m;
– turn the same bolts on 22 – 28º;
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– tighten adjusting barrels with torque of 100 – 140 N.m;

– tighten all twelve bolts with torque of 100 – 140 N.m;
– splint all bolts two by two (See Fig. 8.12);
– install external cover of the hub of the front wheel and fix it with bolts;
– remove the dump truck from jambs, remove thrust blocks from under rear wheels.
Figure 8.12 – Splinting of the fit ring bolts
8.6 Wheels and tires

On the dump truck six diskless wheels are installed, front axle wheels of single type, the driving axle – of
double type. Wheels are fastened to the hub by means of clamps and studs with nuts.
The wheel consists from rim 9 (See Fig. 8.13), two board 7, landing 10 and lock 5 rings. Between rims
of double rear wheels the spacing washer 10 (See Fig. 8.14) is installed.
The rim has conical internal surface for alignment and fixing of the wheel on the hub. Lock ring is split.
The rim and removable landing ring have conical shelves, on which the bead of tire 8 (See Fig. 8.13) are
mounted with tightness.
Tires – tubeless. Sealing of band with a demountable landing ring is carried out with rubber ring gasket 6.
Figure 8.13 – Front wheels installation:

1 – valve; 2 – clamp of the wheel fastening; 3 – stud; 4 –
nut of wheel fastening; 5 – lock ring of the wheel rim;
6 – ring gasket; 7 – bead ring; 8 – tire; 9 – band;
10 – landing ring; 11 – extension lead
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Figure 8.14 – Rear wheels installation:

1 – extension lead; 2 – tire; 3 – bead ring; 4 – rim; 5 – wheel fastening nut; 6 – stud; 7 – rear wheel clamp; 8 – landing ring; 9 – lock
ring; 10 – spacing ring; 11 – sealing ring; 12 – nut; 13, 15 – valves; 14 – extension lead fastening plate
In the thread (K 1/2") rim bore screwed in valve of БС type. For tires inflation and inspection of pressure
in them extension leads of front 11 (See Fig. 8.13) and rear 12 (See Fig. 8.14) internal wheels are brought out.
On the front wheel the flexible extension lead of valve УГ17-330, on rear internal – the flexible extension
lead of valve УГ17-1130 are installed. Adapter connectors of valve and extension leads have the increased
flow section, therefore for measuring tire pressure by the standard (regular) manometer it is necessary to
screw the adapter, which is supplied with the dump truck, in valve or extension lead.
8.7 Wheels and tires maintenance

Maintenance and servicing of wheels and tires includes inspection and retorque of fastening joints, in-
spection and adjusting tire inflation pressure to norm, and inspection of availability index of tires and rims by
visual inspection.
– daily before departure check by external examination condition of the wheels fastening and if neces-
sary tighten nuts. During replacement of wheels tighten up the nuts after the first trip with torque, specified in
Appendix A. Further retorque nuts after every two – three trips till stabilization of tightening torque on all nuts;
– check air pressure in tires.
Value of internal pressure in the tire at its temperature, equal to ambient temperature, should be (0.725 +
0.025) МPа for radial "BRIDGESTONE" tires, at mounting radial tires of other production pressure is to be speci-
fied by the manufacturer.
Value of internal pressure in tire can be specified by the manufacturer.
Inspection of air pressure in heated tire is to be performed daily after the end of the working shift on un-
loaded dump truck with metrological certified manometers. Pressure in heated tire should not exceed norm for
cold condition for more than 0.11 МPа.
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If pressure in heated tire exceeds admissible level, troubleshoot and eliminate the reason of high pres-
sure (bad availability index of tire, overloading, over-speed conditions, big distance of travel). In case the rea-
sons for high pressure are not found, the tire is to be cooled down to ambient temperature and checked for
conformity of pressure in it to norm in cold condition.
Operation of dump trucks in mode at which the air pressure in heated tires exceeds admissible is not per-
mitted. It is strictly forbidden to adjust air pressure in heated tire.
At monitoring pressure in the cold tire to nominal pressure take into account the correction according to
Table 8.2 depending on temperature difference between ambient and location temperatures. If ambient tem-
perature is higher than temperature at location, the correction is subtracted from value of nominal pressure,
and if it is lower – added.
Table 8.2 __ Corrections to nominal air pressure in the tire depending on temperature difference between ambient and garage
temperatures
Temperature difference, оС 10 20 30 40 50 60
Correction to nominal tire pressure, МPа 0.02 0.03 0.05 0.07 0.08 0.1
In due time clean protector cuts from stones and other subjects.
Maintenance of dump trucks is forbidden if tires have:
– protector wear at which the stayed height on the indicator of wear is equal to 0 mm;
– protector exfoliation and blister of integumentary rubbers irrespective of sizes;
– framework dog-leg and stratification;
– protector cracks reaching cord;
– cuts and breakdowns with damage of the framework cord ply;
– faulty valves and valve cores, and also valves without caps or with stub;
– air pressure which is not corresponding to specified norms. At tires assembly on the dump truck ob-
serve that the variance in external diameters of twin tires did not exceed 24 mm.
Tires transposition is to be performed only in case of their fault, uneven wear or necessity of correct se-
lection of twin tires.
During operation of dump trucks observe that quarry roads, porches to excavating machines and
mouldboards are in due condition which is not supposing faults of tires.
On stalls there should not be petroleum derivatives and other substances destroying rubber.
Parking of fully loaded dump truck for more than two days is forbidden. In case of rust-preventive treat-
ment the dump truck should be delivered on the jambs providing full unload of tires.
8.8 Wheels and tires assembly and disassembly

Prior to disassembly of wheels lift and install on stand the corresponding part of the dump truck. Prior to
unscrewing fastening nuts of the front wheel in order to prevent accidents release air from the tire.
Prior to disbracing rear twin wheels release air from both tires. This rule is to be strictly observed at any
operations connected with necessity of disbracing or removal of wheels. During wheel operation in lock part of
rim there can be cracks. If there is air in tire air, then at removal of wheel there can be a sudden rupture of rim
that can result in accidents.
DO NOT START DISBRACING OF WHEEL IF YOU NOT SURE THAT THE TIRE IS COMPLETELY DEFLATED -
IT IS DANGEROUS!
For removal of front heel wrench nuts and remove clamps. At nuts wrenching the wheel should be sup-
ported with pull device. For removal of rear wheels partly turn off nuts and shift clamps. Be convinced, that
clamps can move freely, turn off nuts completely and remove clamps, supporting wheel with pull device.
At removal and installation of wheels keep adapter connectors of valves and extension leads from dam-
age.
Assembly and disassembly of tires is to be performed on tire recapping stand providing smooth and uni-
form application of load on details of wheel, be guided by the Stand operation manual.
It is forbidden to beat out rims from tires with the help of sledge hammer in order to prevent deformation
of details of wheel, nicks and cracks.
Before assembly check completeness of the tire and details of wheel and perform assembly of wheel
with the tire of specified size only.
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For tires assembly only wheels at which coloring of all details from external and internal sides is mot
damaged. Application of details of the wheels subjected to corrosion can result in breakage during driving that
can cause accidents. Besides, application of unpainted details of wheels hampers not only assembly, but also
consequent disassembly as unpainted surfaces of tire bead adhere more strongly, than the colored one.
Before assembling by an external examination check condition of the tire. Internal cavity should be clean
and dry. A tire boards should not have leftovers of flash. Presence of moisture, mud and flash of rubber can
become the reason of hampered or impossible air exhaust further from the tire because of blockage of the port
of valve.
Carefully check condition of rim elements, pay special attention to absence of cracks on grooves under
lock and ring gaskets, on fluting planes clamp of the board base and landing ring, on welded connections weld-
ing lock part of rim and the board grounding to shell of band. It is recommended to apply visual quality monitor-
ing, color, magnetic or ultrasonic flaw inspection to detection of cracks. At visual control it is possible to use
magnifier.
It is forbidden to operate rims and other wheels details having such imperfections as crack, presence of
rust and rolls of color in places, contacting with the tire or other wheel details, and also with violation of geome-
try (heightened ovality of bead ring and rim, twisting of lock ring, nicks-and-burrs, etc.).
Do not use rims with bad condition of lock groove and lock rings with described above defects as at tire
inflation there can be a spontaneous disassembly.
Dirty wheel parts, especially landing rim shelves and place at gate bore should be cleaned of mud and
rust with metal sweeper, degreased and painted. At collapse more than 25 % of all coloring of wheels full col-
oring should be performed using grounds and enamels specified for metal.
Tire inflation is to be performed on tire stand the fixed screw-down mechanism on stock of the power
cylinder, securing safety of works, in the following order:
– preliminary pump up the tire with air up to pressure of 0.08 – 0.1 МPа and check correctness of as-
sembly of the tire with rim;
– pump up the tire with air up to pressure of 1.2 – 1.25 times exceeding working to secure dense fit of
the tire bead to shelf of rim and maintain this pressure for 10 – 15 minutes;
– lower pressure in tire up to recommended working level and check leakproofness, having filled suds in
groove of board flanged edge. Leakproofness of joints "valve – rim" and "spool chamber – valve core" is
checked with suds;
– lower air pressure in tire up to 0.08 – 0.1 МPа, unfasten and remove wheel from the stand.
Leakproofness of the second board side is checked analogously, but the wheel is stacked by lock ring
downwards.
Finally the estimation of leakproofness of wheel in assembly with the tire is made by the manometer on
pressure decrease for 24 hours. Pressure decrease is not permitted.
Lead up air pressure in tire to working level only after installation on the hub. There should be no people
near to the tire being inflated.
At tire assembling on rim observe caution in order to prevent damage of tire beads, ring gasket and rim
elements providing leakproofness of joints. The reuse of ring gasket is not permitted. Do not use valve bore for
strapping of rim.
There should be caps for valve protection from pollution and damage of adapter connectors of valves
and extension leads.
At tire transportation try to avoid damage of its board sides. The tire pulling is performed with soft tape
sling with width not less than 140 mm. Do not fasten the tire with hook for board side, with rope or chain slings,
and also for cord of binding of the safety device of board side.
Transportation and storage of tires is performed in vertical position. Assembled tires should be stored at
air pressure of 0.08 – 0.10 МPа.
Assembly wheel on the hub of front wheel as follows:
– turn the hub with groove downwards and install wheel on the hub, having combined band limiter with
groove of the hub;
– install upper and lower, and then the left and right clamps and tighten nuts;
– install other clamps and tighten nuts. Torque nuts no more than 10 mm diametrically opposite in order
to secure wheel from wobble on board of tire;
– tighten nuts by with torque of 1150 – 1300 N.m. After the nuts tightening inflate the tire with air up to
required pressure.
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Assembly rear wheels as follows:

– prior to assembly of internal wheel check leakproofness of joint of valve with the extension lead with
soap emulsion. Pressing rod of valve core of the extension lead make sure that air goes out from it. If air does not
go out, troubleshoot reason and eliminate failure or replace the extension lead;
– mount internal wheel with the extension lead of valve, spacing washer and external wheel on the hub
installed with groove downwards.
Install clamps and tighten nuts of the wheels fastening with torque of 800 – 900 N.m gradually in
3 – 4 moves under the cruciform scheme (serially diametrically opposite);
– inflate tires up to required pressure. The wheel wobble on board of tire should not exceed 10 mm.
Repeat nuts tightening on front axle and rear axle after the first trip, further, every two – three trips till
stabilization of tightening torque of all nuts.
Detailed description of the wheels removal, disassembly, assembly and installation is given in Repair
Manual.
8.9 Telemetering control system

By demand of the customer, dump trucks are equipped with telemetering control system (CKT) to pro-
vide monitoring of air pressure in tires. Telemetering system Operation Manual is a part of Operation docu-
mentation.
For assembly of system sensors on front and rear wheels with parts of system see Fig. 8.15 and 8.16.
For assembly of telemetering control system see Fig. 8.17.
Assembly of system sensors on front wheels.
Assembly of system sensors on front wheels is carried out as follows:
– after mounting and fixing of the wheel turn out adapter connector 10 from the extension lead 2 (See
Fig. 8.15) an screw it into telemetering system adapter 9;
– mount and fix transmitting module 4 on front wheel hub;
– connect adapter 9 with transmitting module 4 by hose 6 having installed the ring 11;
– connect adapter 9 with extension lead 2 by captive nut;
– mount and fix with bolts 8 protective cover 7;
– inflate the wheel up to nominal pressure;
– check leakproofness of threaded connections with the help of suds.
Perform analogous operations on the second wheel.
Assembly of system sensors on rear wheels.
Assembly of system sensors on rear wheels is carried out as follows:
– after mounting and fixing of the wheels turn out from the extension lead 5 (See Fig. 8.16) and valve 4
adapters 12 an screw them into telemetering system adapters 11;
– mount and fix transmitting module 2 on cover of motor-wheel reduction gear carrier;
– connect adapters 11 with transmitting module 2 by hoses 10 having installed the rings 6;
– connect adapters 11 with extension lead 5 and valve 4 by captive nuts;
– mount and fix with bolts 7 and 9 protective cover 8;
– inflate the wheels up to nominal pressure;
– check leakproofness of threaded connections with the help of suds.
Perform analogous operations on the second pair of rear axle wheels.
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Figure 8.15 – Assembly of system sensors on front wheels:

1 – front axle; 2 – flexible extension lead; 3 – valve; 4 – transmitting module; 5 – protective cover; 6 – hose; 7 – housing; 8 – bolt;
9 – telemetering system adapter of front wheels; 10 – adapter; 11 – ring
Figure 8.16 – Assembly of system sensors on rear wheels:

1, 8 – protective covers; 2 – transmitting module; 3 – driving axle; 4 – valve; 5 – flexible extension lead; 6 – ring;
7, 9 – bolts; 10 – hose; 11 – telemetering system adapter; 12 – adapter
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Figure 8.17 – Assembly of telemetering control system:

1 – base module; 2 – right board antenna; 3 – bolt; 4, 17 – washers; 5 – gasket; 6 – clip; 7, 10 – sleeves; 8 – left board antenna;
9 – antenna summarizer; 11, 16 – protective covers; 12 – wiring clamp; 13, 19 – harness; 14 – tube; 15 – clip; 18 – ring; 20 – cable tie;
21 – carrier cover; 22 – rear wheels transmitting module; 23 – front wheels transmitting module
I – to base module; II – to inner wheel valve; III – to outer wheel valve
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9 STEERING
Steering system of dump truck is of hydrovolumetric type, with internal hydraulic feedback. It includes
hydraulic steering mechanism A1 (See Fig. 9.1), connected by cardan shaft with steering shaft column, the
stream amplifier А2, collector А5, axial-piston pump H of the variable productivity, three pneumohydraulic ac-
cumulators АК3 – АК5, two turn hydraulic cylinders Ц11 and Ц12, filters Ф3, Ф5, oil tank and oil-ducts.
9.1 Hydraulic drive operation principle
After engine start-up the stream of working fluid from adjustable axial-piston pump H through filter F3
and return valve KO7 moves through collector А5 to the amplifier of stream А2. From collector the working fluid
charges pneumohydraulic accumulators of steering and working brake system. Pneumohydraulic accumulators
are intended for accumulation of working fluid under pressure, which acts in hydraulic system of steering for its
additional charging, and also in emergency when for any reason supply of working fluid from the pump will be
stopped.
Presence of pneumohydraulic accumulators in hydraulic system allows at sudden engine failure or re-
fusal of the pump to turn quickly enough steerable wheels from average position in extreme position and to re-
turn them back for drive down in safe place and shutdown of dump truck.
Working fluid moves to hydraulic distributor P1 of the steering mechanism through the amplifier of
stream А2, which is controlled by the same hydraulic distributor.
At neutral position of steering wheel (absence of turn) and the working engine the working fluid from the
pump and pneumohydraulic accumulators through collector А5 acts on hydraulic line HP to priority valve P5 of
the amplifier of stream А2 and further on hydraulic lines is brought to hydraulic distributor P3 of the amplifier of
stream and to closed hydraulic distributor P1 of hydraulic steering mechanism A1.
At turn of steering wheel to the left the valve of hydraulic distributor P1 of the steering mechanism turns
and allows oil to pass through hydraulic distributor P1 of the steering mechanism and to turn rotor. On the oth-
er rotor side oil passes through holes in the hydraulic distributor of the control unit block of the steering mech-
anism and acts in hydraulic line L and further to the hydraulic distributor Р2 of direction choice of the stream
amplifier. In process of pressure growth in hydraulic line L oil passes also in the valve cavity spring of hydraulic
distributor P2. Under oil pressure the valve of hydraulic distributor P2 is displaced in right side (on the circuit).
This moving allows oil to pass through canals in hydraulic distributor P2 valve to hydraulic distributor P3 and
through throttle hole in end face of its valve.
Under oil pressure the valve of hydraulic distributor P3 is displaced in left (on the circuit) and opens hole
in sleeve in order to pass the oil acting from the steering control unit through hydraulic distributor P2.
Simultaneously as result of valve moving of hydraulic distributor P3 open holes in zone spring of installa-
tion of hydraulic distributor, and oil from priority valve P5 acts in valve cavity of hydraulic distributor P3. Under
oil pressure acting from the valve cavity of hydraulic distributor P3, the valve of hydraulic distributor P4 is dis-
placed concerning its spring that allows through additional holes line in the hydraulic distributor valve P3 to di-
rect additional oil quantity in hydraulic distributor valve cavity P4. The total oil quantity through hydraulic dis-
tributor P3 of the amplifier of stream on pressure hydraulic lines moves in the piston cavity of the left hydraulic
cylinder of turn Ц11 and rod end of the right hydraulic cylinder of turn Ц12. There is turn of steerable wheels to
the left. From opposite cavities of hydraulic cylinders oil is superseded back in the stream amplifier and
through hydraulic distributor P2 on hydraulic line НТ drains to hydraulic tank.
At turn of the steering wheel to the right oil passes through hydraulic distributor P1 of the steering mech-
anism and acts in hydraulic line R and further to hydraulic distributor P2 of the stream amplifier. Under oil pres-
sure the hydraulic distributor valve P2 is displaced in left side (on the circuit).
Through the stream amplifier oil passes in the same way, as well as at turn in the left side.
The total oil quantity through hydraulic distributor P3 of the stream amplifier on pressure hydraulic lines
moves in the piston cavity of the right turn hydraulic cylinder Ц2 and the rod end of the left turn hydraulic cylin-
der Ц1. There is turn of steerable wheels to the right.
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Figure 9.1 – Principal hydraulic scheme of steering system:

Н – axial-piston pump of variable productivity; А1 – hydraulic steering mechanism; А2 – stream amplifier; А5 – collector;
НМ1 – hydraulic motor of the steering mechanism; Р1 – hydraulic distributor of the steering mechanism; Р2 – hydraulic distributor of the
direction turn choice; Р3, Р4 – amplifier stream hydraulic distributors; Р5 – priority valve; Р8 – hydraulic distributor for the pneumohydraulic
accumulators discharge; АК3 – АК5 – pneumohydraulic accumulators; Ф3, Ф5 – filters; К1 – retaining valve; КО1, КО2, КО3, КО4, КО5,
КО6, КО7 – return valves; КП1, КП2, КП3 – safety valves; PД3 – pressure relay; Ц11, Ц12 – turn hydraulic cylinders;
I – in brake hydraulic system; II – in hydraulic system of the dumping mechanism
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From opposite cavities of hydraulic cylinders oil is superseded back in the stream amplifier and through
hydraulic distributor P2 on hydraulic line НТ drains to hydraulic tank.
Shock-proof safety valves КП1 and КП2 intended for pressure removal in hydraulic cylinders in case of
emergency are installed in the stream amplifier. At absence of turning movement the valve of the hydraulic dis-
tributor of the direction of choice Р2 is in neutral (average) position and blocks output of oil from hydraulic cyl-
inders. It creates hydraulic "lock" on turn hydraulic cylinders, interfering their moving.
At driving on obstacle causing extreme loading, tending to turn wheels to the left, pressure in counter
cavities of hydraulic cylinders will increase. Safety valves are adjusted on pressure 24 МPа and at achieve-
ment of this pressure the valve opens and connects the specified cavities of hydraulic cylinders to the drain
hydraulic line. At the same time in opposite of hydraulic cylinders cavities pressure is lower than atmospheric
pressure. For alignment of oil pressure in hydraulic cylinders cavities in the stream amplifier return valves KO2
and КО3 which pass oil in hydraulic cylinders from the drain hydraulic line are installed.
Pressure of working fluid in steering hydraulic system is defined by gash valves adjustment, installed in
pumps, and makes 16 – 16.5 МPа.
At turn of steerable wheels on the motionless dump truck when the maximal pressure in steering hy-
draulic system is required, and at the minimal productivity of the pump on low engine speed decrease in steer-
ing efficiency ("heavy steering wheel") is possible. This phenomenon has positive character from the point of
view of tires safety.
9.2 Steering units

Steering column. For convenience of the driver
work the steering column (See Figure. 9.2) has adjust-
ments on the tilt angle and on height. Adjustment on the
tilt angle is carried out after turn of the handle 5 down-
wards. Adjustment on height is carried out after turn of
the handle 6 towards oneself.
Figure 9.2 – Mechanical drive of the hydraulic steering mecha-

nism:
1 – hydraulic steering mechanism; 2 – cardan shaft; 3 – steer-
ing column; 4 – steering wheel; 5 – adjustment handle of the steering
column on tilt angle; 6 – handle of the steering column adjustment on
height
Steering cardan shaft. Steering cardan shaft (See Fig. 9.3) interconnects shaft of the steering column
with shaft of the hydraulic steering mechanism to which it is fastened with the help of keys 9 and coupling
bolts.
Cardan shaft consists of two cardans 1, pipe 3 and spline shaft 6. Spline connection is closed by protec-
tive coupling 5, which is fixed on the shaft and pipe by wire cotter pins 4. Cardan consists of two forks 7, cross
piece 11 with the safety valve 9 and four needle bearings 14 which molded plugs holes and are fixed by lock
rings 13. Face seal 12 keeps greasing in the bearing and protects it from pollution. The forks connected to the
pipe and spline shaft at assembly should be positioned in one plane.
The greasing incorporated in the spline connection and needle bearings, ensures the functioning of the
cardan shaft during service life of the dump truck before capital repairs.
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Figure 9.3 – Steering system cardan shaft:

1 – cardan joint; 2 – coupling bolt; 3 – pipe; 4 – wire cotter pin;
5 – safety coupling; 6 – spline shaft; 7 – fork; 8 – plug; 9 – safety valve;
10 – bushing key; 11 – cross piece; 12 – face seal; 13 – lock ring;
14 – needle bearing
The hydraulic steering mechanism (pump – dosing unit) (See Fig. 9.4) consists of two elements:
distributive block 2 and the feedback hydraulic motor 1.
The distributive block 2 consists of case 17, valve 12, sleeve 9, combined seal 14 of rubber and protec-
tive rings, thrust bearing 15 and duster 13, molded in the ring groove in the top part of the case.
The valve is in the fixed position in sleeve by means of the pin 10 and leaf springs 11 inserted through
valve and sleeve grooves and has opportunity at the application of torque to turn concerning sleeve on corner
0
of 15 in both sides.
Pressure and drain canals of the distributive block are divided by the return valve 16.
The hydraulic motor of feedback 1 consists of wreath 5, star 6, cover 4 and distributive disk 7. The rotary
moment from star to pair "valve – sleeve" or vice versa is transferred by cardan 8. All elements of the hydraulic
motor are pulled together with the case by seven bolts 3.
Leakproofness of hydraulic motor and distributive block sockets is provided with rubber sealing rings 18
and 19.
Connection of the pump – dosing unit to the steering hydraulic system is carried out by means of four
carving holes on the case 17 of the distributive blocks 2: Р, Т, L and R.
In the neutral position of the valve 12 with the sleeve 9 working fluid supplied by the feed pump in line Р
of the hydraulic steering wheel acts on the case canals and sleeve drillings and the valve in line Т, and there
from is drained in the hydraulic tank.
At the steering wheel turn the fluid from the pressure head hydraulic line through sleeve and the valve
moves in the hydraulic motor of the feedback. At the same time the star of the 6 hydraulic motor starts rotation
under the fluid stream acting in the hydraulic motor and further in the cylinder line, and further by means of
cardan 8 and pin 10 turns the sleeve 9 to the direction of the valve 12 rotation. The valve is displaced and con-
nects pressure head lines from pumps to corresponding cavities of the turn hydraulic cylinders. Steerable
wheels turn.
At the stop of the valve 12 rotation and its holding the sleeve 9 turn to starting position till the moment of
pressure decrease in line Р up to value that is less than external loading, and finishing of vehicle turn. At the
valve 12 lowering under action of flat springs there is its turn in starting position concerning sleeve and full un-
loading of the pump on drain.
In the pressure hydraulic line of the steering mechanism the filter with set of the mesh elements separat-
ing mechanical impurity in the size more 0.063 mm is installed.
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Figure 9.4 __ Hydraulic steering mechanism:

1 – feedback hydraulic motor; 2 – distributive block; 3 – bolt; 4 – cover; 5 – wreath; 6 – star; 7 – distributive disk; 8 – cardan;
9 – sleeve; 10 – pin; 11 – lamellar springs; 12 – valve; 13 – duster; 14 – combined seal; 15 – thrust bearing; 16 – return valve; 17 – case;
18, 19 – sealing rings;
P – pressure line; Т – drain line; L and R – cylinder lines for turn accordingly to the left and to the right
The stream amplifier is intended for oil transfer through the hydraulic cylinders, required for mainte-
nance of steering work. The stream amplifier operated by the hydraulic steering mechanism. The stream am-
plifier (See Fig. 9.5) includes the priority valve 10, amplifier valve 8, valve direction turn choice 6, safety valve
11 for adjustment of the maximal pressure in hydraulic system, shock-proof safety valves 1 and 5, and return
valves.
At neutral position of the steering wheel the working fluid from pumps acts in cavity HP of the priority
valve 10 and from it on canal P moves to the hydraulic steering mechanism which valve is in the closed p o-
sition.
At the steering wheel turn the working fluid from the hydraulic steering mechanism under control pres-
sure acts to the valve 6 in cavity L or R (depending on the turn direction). In process of the pressure growth in
these cavities the working fluid also passes through throttle hole C in the spring cavity of the hydraulic distribu-
tor. Under pressure of working fluid the valve of the hydraulic distributor 6 is displaced working fluid from the
cavity B of the valve 6 acts in cavity D of the amplifier valve.
From cavity D working fluid through apertures in sleeve 8, the canal between sleeve and valve 9 acts in
aperture G where it is originally blocked. Besides the working fluid on an external sleeve groove 8 acts in cavi-
ty Н and through throttle hole J to end face of sleeve 8. Under working fluid pressure sleeve 8 is displaced and
opens hole G through which the working fluid from the hydraulic steering mechanism acts in control cavity Q of
the valve 6.
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As a result of the sleeve moving 8 apertures E open, that allows working fluid to pass from the priority
valve 10 in an internal sleeve cavity 8. Pressure of the working fluid acting in an internal sleeve cavity 8, the
valve 9 is displaced is relative its springs and opens a holes line K which are in the same cavity, as hole G.
The quantity of the working fluid which are taking place from an internal cavity of the sleeve 8 is dosed out by
holes K, opened proportionally to hole G.
The holes quantity K in sleeve 8 is equal to four. Through these holes the working fluid acts in the con-
trol cavity Q of the valve 6 in addition to the working fluid acting from the hydraulic steering mechanism. The
total quantity of the working fluid acting in cavity Q, through canals CL or CR moves in hydraulic cylinders for
turn of steerable wheels to the left or to the right.
In process of wheels turn the working fluid from opposite cavities of hydraulic cylinders passes in cavity M
of the amplifier and further through back shutoff valve 3 and through exit canal HT is drained in hydraulic tank.
Safety valves 1 and 5 are intended for removal of peak pressure in hydraulic cylinders in case of emer-
gency. At the dump truck movement and absence of turn the valve 6 is in neutral (middle) position and blocks
oil output from hydraulic cylinders of turn. It creates hydraulic "lock" on the hydraulic cylinders, blocking their
moving.
At driving on obstacle causing extreme loading, tending to turn wheels to the left, pressure in opposite
cavities of hydraulic cylinders will increase. Safety valves are adjusted on pressure 24 МPа and at achieve-
ment of this pressure the valve will open and will connect the cavities of hydraulic cylinders connected to turn
hydraulic lines to the right, to the drain hydraulic line. At the same time in opposite of hydraulic cylinders cavi-
ties pressure is lower than atmospheric pressure. For alignment of oil pressure in hydraulic cylinders cavities in
the stream amplifier return valves 2 and 4 which pass oil in hydraulic cylinders from the drain hydraulic line are
installed.
Figure 9.5 – Stream amplifier (constructive scheme):

1, 5 – safety valves suction and extreme loading; 2, 4, 7 – return valves; 3 – return stop valve; 6 – valve of the direction choice;
8 – amplifier valve sleeve; 9 –amplifier valve ; 10 – priority valve; 11 – safety valve;
CL, CR, HP, HT, LS, P, T – canals; A, B, D, H, L, M, PP, Q, R – cavities; C, E, G, J, K – throttle holes
9-6
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Collector
Collector (See Fig. 9.6) is intended for distribution of working fluid stream in pneumohydraulic accumula-
tors of steering and working brake system. On the collector the hydraulic distributor 2 intended for discharge of
oil cavity of pneumohydraulic accumulators of steering is installed.
The hydraulic distributor is controlled by electromagnet which is switched on from onboard electric net-
work of the dump truck by pressing the switch of engine shut down and also the push-button switch 6 located
on the electromagnet.
Pneumohydraulic accumulator of service brake system at pressing the switch are not unloaded because
of presence of the return valves installed in brake hydraulic system.
The return valve 4 prevents the charge of working fluid from pneumohydraulic accumulators through
pumps in emergency operation of steering.
Figure 9.6 – Collector:

1 – collector; 2 – electromagnetic hydraulic distributor; 3 – screw; 4 – return valve; 5 – bush; 6 – button of forced pressure release
in pneumohydraulic accumulators;
I, II, III – canals connected with pneumohydraulic accumulators; IV – canal connected with drainage; V – canal connected to the
control panel of the dumping mechanism; VI – canal connected to brake system; VII – canal connected to the stream amplifier
Pneumohydraulic accumulator.
In hydraulic system of steering there are three pneumohydraulic accumulators, accumulating emergency
stock of working fluid under pressure and giving out it in hydraulic system for its additional charging, and also
for dump truck control in case of sudden engine shut down or for other reasons that cause stop in supply of
working fluid in hydraulic system from pumps.
The design of pneumohydraulic accumulators of steering system is similar to pneumohydraulic accumu-
lators of service brake system which description is given in the "Brake systems" section.
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Turn cylinder
Turn cylinder – double action, consists from the case of the cylinder 4 (See Fig. 9.7) and rod 3 with the
piston 2. The piston 2 is fixed on the rod by the nut 1. The cover 6 is fastened to the case of the cylinder by
bolts. On the end of rod tip 9 is screwed, which is stopped by terminal-block connection.
Turn cylinders are fixed by cases by means of fingers 18 to arms of the front axis, and with rods to rotary
levers of the steering trapezoid. The jointing plane of external ring of the spherical bearing 20 should be perpen-
dicular of the cylinder axle. The internal ring is fixed on the finger by bolts with the help of the thrust washer 21.
Mobile piston connection with the cylinder is sealed with fluoroplastic rings 17 and elastic rubber rings
16 of square section. The piston moves on surface of basic rings 15 made from polyamide material.
Mobile rod connection with cover is sealed with polyamide rings 12 and elastic rubber rings 11. The rod
moves on the surface of the basic ring 13 from polyamide material.
For prevention of dirty hit inside of the cylinder in cover polyamide wiper ring 10 and elastic rubber ring
11 of the circular section are installed.
Motionless connections are sealed with rubber rings.
Figure 9.7 – Turn cylinder:

1 – nut; 2 – piston; 3 – rod; 4 – case; 5, 14 – sealing ring; 6 – front cover; 7, 8, 22, 25 – bolt; 9 – rod tip; 10 – wiper ring;
11, 16 – elastic rubber rings; 12 – rod sealing ring; 13, 15 – basic rings; 17 – piston sealing ring ; 18 – finger; 19 – scraper; 20 – spherical
bearing; 21 – thrust washer; 23 – oiler; 24 – cover
Steering trapezoid drawbar consists from drawbar pipe with tips 4 (See Fig. 9.8), two tips 3 and 5
which are screwed in drawbar 4 and locked with terminal connection. Drawbar is connected hingedly to rotary
levers jointed through spherical bearings 6 (See Fig. 9.9) by fingers 12.
Figure 9.8 – Steering trapezoid drawbar:

1 – lock ring; 2 – jointed spherical bearing; 3 – left drawbar tip; 4 – drawbar pipe with tips; 5 – right drawbar tip
9-8
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9.3 Steering system maintenance
Maintenance of steering system during operation includes oil level control in oil tank of combined hy-
draulic system, check of the system tightness, periodic greasing of rubbing surfaces, check tightening of tread
connections, control of the pneumohydraulic accumulators charging.
The list of used lubricants, intervals of inspection and replacement of grease is specified in "Technical
maintenance" section.
The list of maintenance operations for steering hydraulic system units that are common for combined
hydraulic system is specified in "Dumping mechanism" section.
Daily maintenance (DM)

– check by external examination condition and fastening of pipelines and hydraulic system hoses and if
necessary tighten them (in leak places);
– check by external examination fastening of cylinders, levers and steering drawbar. Bolts and nuts
should be tightened to the stop, castle nuts should be cottered;
– check by external examination condition of weld seams and integrity of turn cylinders arms, levers and
steering drawbar. Bends, cracks and other damages are not permitted;
– at the working engine check working fluid pressure in hydraulic system on pressure indicator on con-
trol panel;
– check running order of emergency steering drive.
With the working engine and full charging of pneumohydraulic accumulators the control lamp of emer-
gency pressure in steering hydraulic system should not be lit and there should not be any sound signal. At the
switch of the dumping mechanism in rise position, turn steering wheel on one full turn to the left and to the
right, steerable wheels should turn;
– check steering serviceability.
Technical maintenance 1 (ТM–1)
During ТM–1:
– check up integrity of sleeves and hoses of hydraulic system, and their fastening. Sleeves and the hos-
es having leaks, swellings and loss of elasticity have to be replaced. Tighten weakened fastening of hoses;
– check up steering wheel free course and clearances in drawbar hinges and turn cylinders of steering
trapezoid. The free course of steering wheel should be no more 25º. If the free course is more, remove clear-
ances in hinges of steering and tighten the weakened fastening;
– check up nitrogen pressure in pneumohydraulic accumulator of steering system. Methods of pressure
control and charging by nitrogen are specified in "Brake systems" section;
– tighten fastenings:
1. Nuts on cone pins of turn cylinders;
2. Fastening bolts of traction pins of the steering trapezoid;
3. Nuts of terminal connections of tips of turn cylinders and steering trapezoid drawbar;
4. Nuts of studs of steering trapezoid levers fastening.
The tightening torques are specified in the Appendix B.
During ТM–3:
– check up frequency of steering wheel rotation in extreme positions of steerable wheels ("sliding").
This phenomenon is caused by internal leakages in steering hydraulic system.
Check is performed on unloaded dump truck at working pressure of working fluid in hydraulic system of
(15.5 – 16.5) МPа.
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Operation sequence:
– start up the engine, set frequency of crankshaft rotation equal to 1500 rpm;
– turn steerable wheels in extreme position. Continuing to rotate the steering wheel in the same side de-
termine the wheel rotation frequency. It should be no more than 6.0 rpm. As a stop-watch it is possible to use a
watch with a second hand.
At dump truck run of 40 – 50 thousand km, in case of replacement on the dump truck of cross-section
bar, swivel members and increased tire wear check and if necessary adjust toe-in of steerable wheels.
Front wheels toe-in adjustment

Toe-in adjustment is carried out as follows:
– set front wheels in the position corresponding to movement of the dump truck on straight line;
– measure the dimension A (See Fig. 9.9) between end faces of rim bases on the level of axes of front
wheels in front of the dump truck;
– turn wheels on half-revolution and measure the dimension Б between the specified points behind;
– wheels toe-in is equal to difference between dimensions Б – A and should be within the limits of 5 – 10
mm. Adjustment is performed by length change of drawbar 3, at weakened bolts of terminal connections of cross-
section bar tips. The difference between dimensions B and Г should not exceed 5 mm. After toe-in adjustment
tighten nuts of bar tips with torque of 110 – 140 N.m
Figure 9.9 – Steering trapezoid:

1, 4 – turn cylinders; 2 – rotary lever; 3 – steering trapezoid drawbar; 5 – collar; 6 – articulated
spherical bearing; 7 – lock ring; 8 – bolt; 9 – pressure plate; 10 – distance bushing; 11 – oiler;
12 – finger (pin); 13 – thrust ring;
A, Б, B, Г – dimensions
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10 BRAKE SYSTEMS
10.1 General data
Dump truck is equipped with service, parking, auxiliary and reserve brake systems.
The service brake system with hydraulic drive divided in a circuit of front and circuit of rear brakes acts
on all wheels. It is intended for traverse speed control, for stopping of dump truck and for safe operation of
dump truck in any road and climatic conditions. It can also be used at deficit efficiency of the auxiliary brake.
The parking brake has a hydraulic drive and acts on the rear axle wheels. It is intended for braking of
dump truck during parking, at loading and unloading, and also in emergency situations at malfunction of ser-
vice brakes.
Auxiliary brake is of electric type, used during traction motor braking mode.
As the reserve (emergency) brake system the parking brake and the operable circuit of service brake
system are used.
Operation of brake system hydraulic drive.
At the operating engine working fluid from tank via filter Ф is supplied by axial-plunger pump of variable
productivity Н1 (See Figure 10.1) into collector А5, and charges pneumohydraulic accumulators АК3 – АК5 of
steering system.
Further via double protective valve K08, working fluid flows into pneumohydraulic accumulators АК1,
АК2 of rear and front circuits of service brake system and charges them.
Figure 10.1 – Basic hydraulic scheme of brake systems:

Н1 – axial-plunger pump of variable productivity; Ф – filter; А5 – collector; К07 – back-pressure valve; Р8 – hydraulic distributor for
discharge of pneumohydraulic accumulators; АК1-АК5 – pneumohydraulic accumulators; К08 – double protective valve; РД1 РД6 – relay
of pressure; А3 – service brake valve; А4 – parking brake cock; ВК1–ВК3 – cutout switch of signal of braking operation; Ц1, Ц2 – parking
brake cylinders; Ц3-Ц6 – cylinders of service brake gears of rear contour; Ц7-Ц10 – cylinders of service brake gears of front contour;
I – to hydraulic system of dumping mechanism; II – to hydraulic system of steering
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From pneumohydraulic accumulators АК1, АК2 working fluid is under pressure supplied to valve А3 of
service brake. When force from treadle gets removed the spool-valves of service brake valve overlap channels
from pneumohydraulic accumulators, and connect cavities of cylinders Ц3 – Ц10 of service brake with drain-
age. The dump truck is unbraked.
When treadle is pressed spool-valves of service brake valve A3, moving, overlap tank channels and at
further motion connect channels from pneumohydraulic accumulators with channels to brake cylinders, work-
ing fluid under pressure flows from fluid-flow cavities of pneumohydraulic accumulators АК1, АК2 under pis-
tons of brake cylinders Ц3 – Ц10. Dump truck gets braked by service brake system.
Separation of hydraulic drive in two independent circuits is carried out by double protective valve K08,
separate sections of valve of service brake А3 and separate pneumohydraulic accumulator for each circuit.
Relays of pressure, sending light and sound signals at pressure drop of working fluid in contour below
permissible limit are installed in front (РД2) and rear (РД1) contours of service brake system and contour of
hydraulic drive of parking brake and steering (РД3). Ach contour comprises switches of brake signal – relays of
pressure РД4 – РД6.
Unbraking of gears of parking brake occurs with feeding of working fluid under pressure under pistons of
cylinders Ц1, Ц2 by turning movement of lever of parking brake cock А4, which is powered from pneumohy-
draulic accumulators АК3 – АК5 of steering.
10.2 Service brake system
Service brake system powers up four brake gears of disk type, hydraulic drive, operating controls and
gears of monitoring operation of system.
Steering of service brake system is carried out by treadle of brake valve.
Brake gears of front wheels – one-disk, dry friction with hydraulic drive.
Case of brake 2 (See Fig. 10.2) is fastened to swivel member 1 of front axle with two bolts 12. Brake
disk 4 is fastened with bolts to hub of front wheel. Case of brake comprises six cylinders (three from each side)
into which pistons 6 are inserted. On bearing parts 10 of case of brake two brake-shoe linings 5, which pistons
at braking operation hold down to disk, are installed. Piston on outer diameter is sealed by rubber collar 14
with guard ring 13, and clutch 3 protects from hit of mud on working surface of piston. From outside cylinders
are enclosed by covers 7. Cylinders are connected by ports for input of working fluid under piston.
Figure 10.2 – Brake gear of front wheel:

1 – swivel member; 2 – case of brake; 3 – protective clutch; 4 – brake disk; 5 – lining; 6 – piston; 7 – cover; 8, 12 – bolts; 9 – rings;
10 – bearing part; 11 – adjusting washer; 13 – guard ring; 14 – collar
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Brake gears of rear wheels – one-disk, dry friction with hydraulic drive.
On bearing board of each traction motor 13 (See Fig. 10.3) two service brakes through brackets 22 and
23 are mounted. Service brake comprises two cheeks 3 and 17 which are strapped with studs 8 through in-
serts 19 and bearing parts 20. Eight cylinders 11 (four from each side) inside which pistons 29 are installed are
fastened to the cheeks. Piston on outer diameter is sealed by rubber ring 63 with protective washer 62, and
clutch 26 protects from hit of mud on working surface of piston. Cylinders are connected by internal ports in
cheeks 3 and 17 for input of working fluid under piston.
Each cylinder has device of automatic adjustment of spacing between brake disk 28 and linings 27. Ba-
sis of it is made with special spring frictional barrel 60 with given force of conveyance on stock 30. One end of
barrel rests against piston 29, another – in butt of glass 61. On glass squeezing spring 64, timbered in piston
with help of stop ring 57 and retaining ring 56 is installed.
At wear of lining 27 piston 29 at braking operation displaces frictional barrel 60 concerning stock 30 on
magnitude of wear of lining. At disengaging frictional barrel in opposite direction concerning stock does not
displace, ensuring spacing between disk and lining equal to 1 – 1.5 mm, corresponding to distance between
butt of glass of spring and thrust washer. This spacing is established at assembly of cylinder by setting of ad-
justing washers 58.
Brake disk 28 is fastened with bolts to flange 16 installed on slots of shaft of rotor of traction motor 13. At
braking operation pistons 29 hold down linings 27 to disk and brake dump truck. Response from brake forces
is perceived by bearing parts 9 which simultaneously are guiding for linings.
Valve of service brake – two-section, tracking pedal-driven operation intended for control of service
brake system. Upper section controls rear brake gears, lower – front brake gears.
Valve comprises two cases 6 and 11 (See Fig. 10.4), in each of which barrels 7 and 15 with valve cores
8 are installed. Cases are enclosed by cover 22 and fuse 13.
Latching of treadle 1 in braked condition is carried out by clamper 25.
Removal of pressure in hydraulic system at service and repair of brake systems is made by unscrewing
of locking needles 9.
Under-treadle thread clamper 4 ensures position of treadle that roller 2 densely fitted to pusher and did
not cause its conveyance.
Cavities III and V are connected to pneumohydraulic accumulators, outputs I and II – with drain in hy-
draulic reservoir, and cavities IV and VI – with cavities of cylinders of brake gears.
At removed force from treadle of cavity IV and VI and, consequently, cavities of wheel brake cylinders
are connected through outputs I and II with drain in hydraulic reservoir. Cavities III and V from pneumohydrau-
lic accumulators thus are blocked with valve cores 8 and working fluid does not act in cylinders of wheel
brakes. Dump truck is disengaged.
By pressure at footbrake pedal 1 valve cores 8 displace downwards (see figure) and outputs I and II
plum in hydraulic reservoir close, and then connect cavities III and V from pneumohydraulic accumulators to
cavities IV and VI to wheel cylinders. Pressurized fluid from pneumohydraulic accumulators through cavities III,
IV and V, VI acts in cylinders of wheel brake gears and puts them in action. Pressure of working fluid in wheel
cylinders is determined by magnitude of force to treadle.
Simultaneously fluid on radial and axial ports in valve cores 8 acts in face cavities of valve cores, than
tracking operation of brake valve on force to treadles is ensured. In face cavities valve cores are displaced
by force of pressure of working fluid up (see figure) overcoming force of equilibrating of element 20 and
overlap ports from pneumohydraulic accumulators. Feeding of working fluid and growth of pressure in wheel
cylinders stops.
For increase in brake effect it is necessary to make greater force to treadle. Force of pressure of fluid to
butts of valve cores will be coordinated to force of pressure to treadle and thus tracking operation of valve on
force to treadles is carried out. Tracking operation of valve on magnitude of conveyance of treadle is carried
out elastic equilibrating by element 20. Working fluid in cavities of pusher 10 and piston 12 executes role of
snubber, excepting auto-oscillations of valve cores.
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Figure 10.3 – Brake gears of rear wheels and parking brake:

1 – high pressure sleeves; 2, 6, 18 – triangles; 3, 17, 50, 52 – cheeks; 4, 10, 14, 21, 25, 54 – bolts; 5 – parking brake cylinder;
12 – T-connector; 7, 32, 34, 41 – nuts; 8 – stud; 9, 20 – bearing parts; 11 – cylinder of service brake; 13 – traction motor; 15 – plate;
16 – disk with flange; 19 – insert; 22, 23 – brackets; 24, 36, 38, 59, 63 – sealing rings; 26, 51 – protective clutches; 27 – brake-shoe lining;
28 – brake disk; 29, 48 – pistons; 30 – stock; 31, 49 – cases; 33 – thrust block; 35, 39, 62 – protective washers; 37 – fuse; 40 – locking
bolt; 42 – indicator; 43 – splint; 44 – nut of disengaging; 45 – washer; 46 – cover; 47, 55, 64 – springs; 53 – adjusting shims; 56 – retaining
ring; 57 – stop ring; 58 – adjusting washer; 60 – frictional barrel; 61 – glass
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Figure 10.4 – Valve of service brake:

1 – treadle; 2 – roller; 3, 14, 16 – springs; 4, 25 – clampers; 5 – plate; 6 – upper case; 7, 15 – barrels; 8 – valve core; 9 – locking
needle; 10 – pusher; 11 – lower case; 12 – piston; 13 – fuse; 17 – bolts; 18 – stock; 20 – equilibrating element; 22 – cover of valve body;
23 – boot; 24 – pusher;
I, II – outputs connecting with drain in hydraulic reservoir; III, V – cavities, connected with outputs to pneumohydraulic accumula-
tors; IV, VI – cavities, connected with outputs to wheel brake cylinders
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Double protective valve divides hydraulic drive of service brake system on two independent contours.
In case 3 (See Fig. 10.5) is installed piston 5 confined on average position from two sides by barrels 10.
Case is enclosed from both sides by plugs 1. Ball valves 4 dividing system on two contours seat on saddle of
piston from two sides with springs 11 through pushers 2.
Working fluid is brought to central port I. Under operation of hydrostatic force back-pressure valves 4
open and through outputs II and IV fluid moves to pneumohydraulic accumulators and sections of brake
valves. To valve of parking brake fluid directly acts from pressure line through port III.
Figure 10.5 – Double protective valve:

1, 7 – plugs; 2 – pusher; 3 – case; 4 – bead; 5 – piston;
6, 8 – sealing rings; 9 – washer; 10 – distance sleeve; 11 – spring;
I – port, connected with pressure hydro line; II and IV – ports,
connected with pneumohydraulic accumulators; III – port, connected
with control valve of parking brake
Relay of pressure (figure 10.6 b) is intended for turning on warning lamps installed on instrumentation
panel and buzzer when the oil pressure in hydraulic accumulators drops down below the permitted range of
(13 + 0.1) МPа.
Relay of pressure (figure 10.6 a) is intended for turning on the brake signal in the taillights when service
brakes are applied and for turning on warning lamp installed on instrumentation panel when parking brake is
applied.
Figure 10.6 – Pressure relay:

a) pressure relay of diaphragm type (working position – contacts are open); b) pressure relay of piston type (working position –
contacts are close);
1 – adjusting screw; 2 – spring; 3 – contact; 4 – contact disk; 5 – plunger; 6 – diaphragm; 7 – channel for working fluid supply; 8 –
piston
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Pneumohydraulic accumulator. In hydraulic system, in contour of service brake system two pneumo-
hydraulic accumulators, accumulating energy of working fluid under pressure and producing it in hydraulic sys-
tem at braking operation are installed.
Pneumohydraulic accumulator comprises steel case 10 (See Fig. 10.7), covers 1, 13 and piston 9. Pis-
ton is condensed with collar 7 with two spacing rings. Tightness of sealing collar 7 at assembly is to be of
2 – 2,3 mm at diameter by selection of adjusting shims 19. Rings 8 are guiding of piston. Piston divides barrel
on two chambers – fluid-flow and gas. At assembly in gas cavity of pneumohydraulic accumulator fill working
3
fluid in volume of (500 + 100) cm .
Covers are fixed by restrictive split rings 3, and thrust
blocks 2 keep covers from moving inside case.
Charging of gas chamber with nitrogen is carried out
through priming valve 15 under pressure of 8 MPa, using charg-
ing device for cylinders of suspender according to figure 8.7.
In pneumohydraulic accumulators, gas and working fluid
are under high pressure. Therefore, maintenance should be per-
formed according to operating rules on device and safety opera-
tion of bulbs working under pressure.
Figure 10.7 – Pneumohydraulic accumulator:

1 – lower cover; 2 – thrust block; 3 – restrictive ring; 4, 17 – bolts;
5 – spring; 6 – clamping ring; 7 – piston collar; 8 – ring-guiding, 9 – piston;
10 – case; 11, 18 – sealing rings; 12 – protective washer; 13 – upper cover;
14 – gasket; 15 – priming valve; 16 – extension lead; 19 – adjusting shims;
20 – clamping disk;
I – output of connection of pressure control device; II – gas cavity;
III – fluid-flow cavity
10.3 Parking brake system

Parking brake system is intended for braking of dump truck during parking, at loading and unloading,
and also in emergency situations at refusal of service brakes.
Brake gear of parking brake system – disk type, dry friction with two spring power accumulators has
hydraulic drive. Brake disk 28 (See Fig. 10.3) is common for parking and service brakes. Parking brake gear is
fastened to bracket 22. Cheeks 50 and 52 are connected by studs through inserts 19 and bearing parts 20. On
external cheek two cylinders 5 of parking brake with pistons 48 and springs 47 are installed.
In braked condition by spring 47 pressure piston 48 holds down linings to brake disk. For disengaging
controlling pressure of fluid is brought under piston which displacing squeezes spring and ensures spacing be-
tween linings and brake disk.
At wear of brake-shoe linings if parking brake was used as auxiliary, it is necessary to adjust spacing of
1 – 1.5 mm between linings and brake disk at disengaged condition of gear. Wear of linings is determined on
indicators 42. Distance from groove on indicator up to butt of cover 46 should be 10 mm in disengaged condi-
tion. If in braked condition groove on indicators displaces over butt of cover, it is necessary to replace linings.
Spacing between internal lining and brake disk is established by twirl of thrust block 33, and between
external lining and brake disk – by twirl of cover by 46 with special key at mechanically disengaged parking
brake and absence of pressure in parking brake cylinder.
For disengaging parking brake it is necessary to twirl disengaging nut 44 clockwise against stop. For
consequent turning on of cylinder in operation unscrew disengaging nut 44 counter-clockwise flush with butt-
end with disengaging screw and lock it with splint 43.
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Before clearance adjustment release lock nut 41, turn out locking bolt 40, and after adjustment tighten
bolt and lock it with lock nut.
In case of outage of gear of disengaging switching-off of dump truck parking brake is possible by un-
screwing nuts 7 pulling together studs 8 of fastening of cheek 50 of parking brake.
UNSCREWING OF DISENGAGING NUT 44 FOR DISASSEMBLY OF COVER OF PISTON AND EXTRACTION
OF SPRING 47 WITHOUT SPECIAL DEVICE PROVIDING RELIABLE FIXING OF PISTON 48, COVER 46 AND
SMOOTH SLACKENING OF SPRING 47 IS STRICTLY FORBIDDEN.
Control valve of parking brake – tracking operation with drive gear from bar intended for control of
parking brake.
Bake valve comprises case 1 (See Fig. 10.8) in which barrel 7 with valve core 6 are installed. Case is
enclosed by glass 21 and plug 3. Bar 17 of valve in switched-on position is locked by clamper 16. For moving
bar to switched–off position it is necessary to lever handle up and to move bar forward.
Hydraulic cutout switch of warning lamp of turning-on of parking brake is screwed in the case .
Output I is connected to pneumohydraulic accumulator, output III – to drain in hydraulic reservoir, and
output II – to cylinder of parking brake gear.
At setting bar 17 in "switched-on" position (В) cavity II and, consequently, cavity of parking cylinder is
connected through cavity III with drain in hydraulic reservoir. Cavity II from pneumohydraulic accumulator is
blocked with valve core 6 and working fluid does not act in parking brake cylinder. Parking gear is switched on
by force of power springs.
At setting bar 17 in "switched-off" position (А) – cam 20 effects on pusher 15 which in turn through
spring 12 plate 11 and pusher 8 displaces valve core 6 downwards (see figure). Valve core closes drain out-
put in hydraulic reservoir, and then connects cavity I from pneumohydraulic accumulator with cavity II to
brake cylinder.
Pressurized fluid from pneumohydraulic accumulator through cavities I and II acts under piston 48 (See
Fig. 10.3) of cylinder of parking brake gear. Piston displaces in extreme position and squeezes power spring
47. Parking brake gear is turned off.
At in-between position of bar 17 (See Fig. 10.8) pressure of working fluid in parking cylinder is deter-
mined by magnitude of course of valve core 6 which is proportional to bar rotation angle. Thus, working fluid
under pressure moves under piston of parking cylinder, and also on radial and axial ports in valve core 6 acts
in cavity under piston 27.
At established pressure under piston, force of this pressure and spring 28 valve core is displaced up
(see figure) and overlaps port from pneumohydraulic accumulator. Feeding of working fluid and growth of
pressure in parking cylinder stops, its piston occupies in-between position.
For increase in brake effect it is necessary to turn hand lever harder in direction of turning-on of parking
brake. Force of pressure of fluid to butt of valve core will be coordinated to force of spring wrap 12 and thus
tracking operation of valve on conveyance is carried out. Working fluid under pusher executes role of snubber,
excepting auto-oscillation of valve core. Spacing C = 0 – 0.3 mm between cam 20 and pusher 15 is adjusted
by washers 13 at assembly of valve.
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Figure 10.8 – Control valve of parking brake:

1 – case; 2 – shaft; 3, 24 – plugs; 4, 5, 9, 22, 23, 25, 26 – sealing rings; 6 – valve core; 7 – barrel; 8, 15 - pushers; 10 – bolt;
11 – plate of spring; 12, 28 – springs; 13 – adjusting washers; 14 – cover of valve; 16 – clamper; 17 – bar; 18 – protective boot; 19 – nut;
20 – cam; 21 – glass; 27 – piston;
I (1) – output, connected with pneumohydraulic accumulator; II (2) – output, connected with brake cylinders;
III (3) – output, connected with drain in hydraulic reservoir (digits marked on case are shown in brackets);
A – "switched-off" position of bar; B – "switched-on" position of bar
10.4 Auxiliary brake system

Auxiliary brake system is intended for long maintenance of necessary speed at driving on slopes. As
auxiliary brake system on dump truck electric braking operation mode of traction electric drive is used.
For heightening of efficiency of electric braking operation at driving in zone of low speeds and secure brak-
ing of dump truck to full stop it is necessary to press treadle of course in addition.
It is inadmissible to operate dump truck with out-of-order auxiliary brake as slowing down on slope with
service brake system will result in excessive heating of disks, strengthened wear of linings.
At dump truck speed of 10 km/h auxiliary brake system is not effective. For full stop of dump truck it is
necessary to use service brake system.
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10.5 Maintenance of brake systems

Maintenance includes routine inspection of condition, inspection of leakproofness and re-torque of
threaded connections, refueling with operation materials and functional testing of brake systems.
At visual inspection it is necessary to test fastening of brake disks, cases of brake gears, cylinders of
brake gears of rear wheels and parking brake, covers of brake gears of front wheels, fastening of pneumohy-
draulic accumulators, condition of brake shoes.
List of used greases, review of frequency and re-lubrications is specified in "Maintenance" chapter.
List of scheduled tasks of maintenance of hydraulic system of brakes being common for combined
hydraulic system is specified in "Dumping mechanism" chapter.
– check visually condition and fastening of pipe ducts and hoses of hydraulic system and if necessary
tighten them (in places of leakage);
– check by external examination condition of gears of working and parking brake systems. Bolts and
nuts should be tightened, castellated nuts should be splinted;
– at working engine check on pressure gauges on panel of gears pressure of working fluid in front and
rear contours of service brake system and contour of parking brake system;
– check serviceability of brake systems.
During ТM–1:
– check integrity of sleeves and hoses of hydraulic system, and their fastening. Sleeves and hoses, hav-
ing leakage, loss of elasticity and cracking should be replaced. Weakened fastening of hoses should be tight-
ened;
– check wear of linings of brake gears of front and rear wheels and if necessary replace linings. Brake
re-lining is made at wear of frictional material up to residual width less than 10 mm;
– check clearance between brake disk and linings of working and parking brake systems, adjust if neces-
sary.
Replacement of brake-shoe linings of brake gears of rear wheels and brake gears of parking
brake.
Brake re-lining is made without removal of reduction gear of electromotor wheel, directly in axle casing.
Brake re-lining of rear wheels and parking brake is carried out as follows:
– remove pressure in hydraulic system of brakes (removal of pressure is made by unscrewing locking
needles of brake valve);
– unlock disengaging nut 44 (See Fig. 10.3) and turn it against stop;
– unlock and turn out bearing parts 9 and bolts 54 on all cheeks of service brake and if necessary on
cheeks of parking brake;
– extract free brake-shoe linings;
– move pistons 29 of cylinders of service brake 11 against stop to case 31;
– install sequentially new brake-shoe linings 27, turn in bearing parts 9 and bolts 54 and lock them;
– perform adjustment of spacing between brake-shoe linings of parking brake and brake disk;
– unscrew disengaging nuts 44 till coincidence of bores of nut with bore of screw and lock by splint 43.
Adjustment of clearances between brake-shoe linings and disk.

Adjustment of clearances between brake-shoe linings and disk is carried out as follows:
– by twirling of thrust blocks 33 install clearance of 1 – 1.5 mm between brake-shoe lining 27 and brake
disk 28. After adjustment of necessary clearance thrust blocks 33 should be locked with nuts 34;
– twirling covers 46 in assembly with piston 48 with special key for bores in cover 46 install clearance of
1 – 1.5 mm between brake-shoe lining 27 and brake disk 28. Unscrew disengaging nuts 44 till coincidence of
bores of nut to bore of screw and lock with splint 43;
– tighten locking bolts 40 and lock nuts 41.
Replacement of brake-shoe linings of front wheels without disassembly of brake gears.
At wear of brake-shoe linings replace simultaneously linings of brake gears of left and right wheels.
10-10
Brake systems
75135-3902015 IM
Replacement of brake-shoe linings is carried out as follows:

– install thrust blocks under wheels of dump truck;
– remove front wheel from hub;
– remove pressure in hydraulic system of brakes (removal of pressure is made by unscrewing locking
needles of brake valve);
– disconnect pipe ducts of brake system from cases of brake 2 (See Fig. 10.2);
– release lower bolt 13 of fastening of case of brake to swivel member 1 before discharging spring
washer;
– supporting case of brake unscrew upper bolt;
– unroll smoothly case of brake holding on lower bolt, in horizontal position and remove brake-shoe linings;
– return pistons of case of brake in home position, having moved pistons against stop butts in covers 7;
– install new linings;
– tighten bolts 13 with torque of 1500 – 1800 N.m. With adjusting washers 12 provide clearance of min.
1.5 mm between butts of brake-shoe linings 5 and brake disk 4;
– connect pipe ducts of brake system to cases of brakes.
At replacement of linings do not install in one gear new and already used linings. After replacement of
linings it is necessary to wear them in having braked dump truck smoothly at speed of 10 km/h five times with
interval of 5 minutes. Wear-in of linings of parking brake is to be carried out by five-time braking of dump truck
at speed of 5 – 10 km/h smoothly hoisting hand lever of valve of parking brake actuation.
For long service of linings it is necessary to avoid often retardation with service brakes, whenever possi-
ble using electrodynamic brake.
It is inadmissible to operate dump truck at out-of-order electrodynamic brake as slowing down on slopes
will result in excessive heating of disks, strengthened wear of linings.
Excessive heating of disk can result in its warping and wear. It is admissible to use disk with wear of
working surfaces that does not exceed 3 mm from each side. At parking under loading with grade of more than
5 % it is recommended to use service brakes, fixing treadle of valve of service brake in pressed position with
clamper 25 (See Fig. 10.4). Before starting-off remove treadle from clamper;
– check pressure of nitrogen in pneumohydraulic accumulators.
INSPECTION OF NITROGEN PRESSURE IN PNEUMOHYDRAULIC ACCUMULATORS AND THEIR CHARGING
IS MADE ONLY AT LOWER POSITION OF PISTON, I.E. AT ABSENCE OF WORKING FLUID IN FLUID-FLOW CAVI-
TY.
Pressure of working fluid in pneumohydraulic accumulators is determined under observation of manome-
ters installed on panel of gears. At presence of pressure of oil pneumohydraulic accumulators should be dis-
charged by unscrewing locking needles of brake valve.
For inspection of nitrogen pressure unscrew cover of priming valve and in its place connect, depending
on executable operation, device for measurement of pressure (See Fig. 8.7) or device for nitrogen charging
(See Fig. 8.8). Gas cavity of pneumohydraulic accumulator should be charged with dry engineering gaseous
nitrogen up to pressure of 8 MPa.
Sequence of charging with nitrogen:
– connect charging device to bulb with nitrogen through adapter connector 2 (See Fig. 8.8);
– screw on priming valve of pneumohydraulic accumulator adapter connector 17 of device;
– unscrew valve on bulb with nitrogen (pressure of gas in bulb is inspected by manometer 3);
– turning regulating screw 12 of reduction gear create some insignificant pressure of gas in pneumohy-
draulic accumulator;
– close valve on bulb and with nipple 8 release gas from ports and hose of device. Arrow of manometer
10 should be installed on "zero";
– turn needle 15 till opening of priming valve, taking care not to damage valve spring. Start of priming
valve opening is defined by moment of aberration of arrow of manometer 10;
– open valve on bulb and with adjusting screw 12 of reduction gear achieve that pressure in pneumohy-
draulic accumulator (under observation of manometer 10) is little bit higher than required;
– turn out needle 15, enclose valve on bulb and disconnect adapter connector from priming valve;
– turning nipple 8 correct pressure in pneumohydraulic accumulator up to required. After adjusting, remove
device from priming valve and close valve cover;
– check leakproofness of priming valve with help of soap emulsion.
10-11
Brake systems
75135-3902015 IM

During ТM–2:
– check firmness of fit of roller of treadle to pusher of control valve of service brake system. At treadle lifted up
against stop in adjusting screw roller should fit to pusher, without causing it to move.
During ТM–3:
– tighten bolts of fastening of cases of brake gears of front wheels and nuts of fastening of brake gears
of rear wheels. Tightening torque is specified in appendix B.
10-12
Pneumatic system
75135-3902015 IM
11 PNEUMATIC SYSTEM
11.1 Composition and operation of pneumoapparatuses
The pneumatic system is intended for supplying compressed air in engine pneumatic starting system,
drive gear of radiator shutter and pneumatic mechanisms of control cabinet. It is also intended for powering the
vessel of driver’s seat pneumatic cushioning mechanism and for connection of accommodating for tire inflation.
The pneumatic system comprises compressor 1 (See Fig. 11.1), dehydrator 2, pressure regulator 4 with
pressure-relief valve 6, anti-freezing device 7, receiver 8 with condensate drain valve 10.
Source of compressed air is the compressor installed on engine. Compressor 1 sucks air from suction
line of engine and feeds it to dehydrator 2 where air is cooled and cleared of water. From dehydrator air acts to
pressure regulator 4, which keeps air pressure in pneumatic system within the limits of 0.65 – 0.82 MPa.
At increase of air pressure in pneumatic system for more than 0.82 MPa the regulator disconnects dis-
charge manifold of compressor with all other part of pneumatic system and simultaneously connects it to at-
mosphere. At this moment water is automatically deleted from dehydrator to atmosphere.
At decrease of air pressure in pneumatic system to the level of 0.65 MPa the regulator disconnects dis-
charge manifold of compressor with atmosphere and connects it with all other parts of the system – com-
pressed air acts in system again.
Pressure regulator incorporates pressure-relief valve for guard of pneumatic system from faults in case
of regulator outage. At pressure in pneumatic system equal to 0.90 – 0.95 MPa pressure-relief valve also
opens and part of air goes out to the atmosphere.
From pressure regulator air moves through anti-freezing device 7 in receiver 8.
The compressor is installed on engine. Its maintenance should be carried out according to recommen-
dations specified in "Engine operation manual”.
Pressure control device is installed in users’ receiver for monitoring of compressed air pressure. Pres-
sure gauge is installed in cab of dump truck on additional panel located above windscreen.
Figure 11.1 – Schematic diagram of pneumatic system:

1 – compressor; 2 – dehydrator; 3 – relief mechanism of pressure regulator; 4 – pressure regulator; 5 – controlling device;
6 – pressure–relief valve; 7 – anti-freezing device; 8 – receiver; 9 – air bleeding valve; 10 – condensate drain valve
I – to the vessel of driver’s seat pneumatic cushioning mechanism; II – to the receivers of engine pneumatic starting system
11.2 Apparatuses of pneumatic system

The dehydrator (See Fig. 11.2) serves for cooling compressed air acting from compressor, separation
of moisture and its automatic removal.
Compressed air moves from compressor to output II of dehydrator and further through canal in cover 1
in cooler 23 where it is cooled and moisture from it is condensed.
From cooler air, entraining drops of condensate, moves in cavity III in which guiding apparatus 9 for
swirling of incoming air is installed. Droplets of water are thrown by centrifugal forces to wall of case and drain
off downwards.
Water passes through spacing between disk of membrane 12, membrane 13, through cavities formed by
square bore in piston 15, round rod of slide valve 16 and gathers in cavity IV. Compressed air also passes the
same way to cavity for condensate gathering. Air pressure in both cavities becomes equal.
11-1
Pneumatic system
75135-3902015 IM
Membrane 13 is in equilibrium, and slide valve 16 is pressed with spring 3 to saddle. Cleared air moves
through bore of hollow screw 8 in canal of output I and further to pressure regulator.
When regulator cuts off the compressor output I is connected to the atmosphere and pressure in cavity
III drops. Because of pressure difference in cavities III and IV membrane 13 sags up, presses on disk 12 and
separates cavities. The valve core 16 moves up together with membrane. Thus, cavity IV through bore in cover
is connected to the atmosphere and water that has been accumulated in cavity pours out. After pressure
equalization in cavities membrane and valve core under operation of spring 3 are returned in primal position,
and cavity IV is disconnected from the atmosphere.
In case of freezing of water in cooler 23 air moves from compressor through vertical canal in cover 1 and
open valve 20 in cavity III and further to output I in forcing air manifold to the pressure regulator. Thus, air is
not cleared and not cooled. The pressure-relief valve is adjusted to the pressure of 0.4 MPa.
Figure 11.2 – Dehydrator:

1 – cover; 2 – sealing disk; 3, 18 – springs; 4 – stop ring; 5, 14, 24 – sealing rings; 6 – pin; 7 – case; 8 – screw; 9 – guiding appa-
ratus; 10 – locking ring; 11 – stop ring; 12 – membrane disk; 13 – membrane; 15 – piston; 16 – valve core; 17, 22, 25 – bolts; 19 – plate
of spring; 20 – valve; 21 – valve seat; 23 – cooler
I, II – outputs; III, IV – cavities
11-2
Pneumatic system
75135-3902015 IM
The pressure regulator (See Fig. 11.3) maintains the compressed air pressure in pneumatic system
within the limits of 0.65 – 0.82 MPa. The regulator comprises a pressure-relief valve adjusted on maximum air
pressure of 0.95 MPa connecting forcing manifold to the atmosphere in case of regulator failure.
The compressed air from compressor through dehydrator moves to output V and through back-pressure
valve 18 gets in output III that is connected to the receiver. From output III on port VII air acts also in ring cavity
of adjusting device membrane 29.
At air pressure in port III of more than 0.82 MPa the membrane 29 departs from saddle and air acts on
ports VI and II in head end I of relief mechanism. Piston 3 with rod 4 under operation of compressed air dis-
place downwards (as shown on figure), valve 20 displaces downwards and air from output V passes in cavity
IV which through point 21 is connected to the atmosphere. Pressure in forcing manifold drops, valve 18 sits on
saddle and prevents exit of air from output III in atmosphere through open valve 20.
At decrease of pressure in output III up to 0.65 MPa the membrane 29 is pressed to saddle by springs
26 and air intake in cavity I is stopped. Air in cavity I through throttle bore in bucket goes out in cavity IV and
further to the atmosphere. Piston 3 under spring pressure 1 is returned in upper (as shown on figure) position.
The valve 20 is closed, exit of compressed air to the atmosphere is stopped and compressor boosts air in re-
ceivers. Limits of air pressure automatic regulation can be restored by screw 33.
In case of regulator relief mechanism failure the pressure in port III at working compressor will increase. At
reaching the pressure level of 0.90 – 0.95 MPa the pressure-relief valve 15 moves up (as shown on figure) and
part of air goes out in atmosphere through radial bores in case 14 of the valve. The pressure-relief valve is ad-
justed to the required air pressure by screw 11.
Figure 11.3 – Pressure regulator:

1, 13, 17, 24, 26 – springs; 2 – cuff; 3 – piston; 4 – rod; 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 pressure-relief valve; 15 – pressure-relief valve;
18 – back-pressure valve; 19 – case of regulator; 20 – valve; 21 – fitting; 23 – relief mechanism valve body; 25 – filter; 27 – disk; 28 – stop
ring; 29 – membrane; 30 – adjusting device housing;
I, IV – cavities of relief mechanism; II, VI, VII – ports of relief and adjusting devices; III – output connected with receiver (through
anti-freezing device); V – output connected with compressor (through dehydrator)
11-3
Pneumatic system
75135-3902015 IM
The anti-freezing device (See Fig. 11.4) is intended for automatic feeding of anti-freezing agent in
pneumatic system in order to prevent freezing of condensate. Ethyl alcohol is used as anti-freezing agent (see
“Operation materials” section).
The turning-on device built in upper case 11 of anti-freezer comprises pull-rod 13 with hand lever, lock-
ing pin and sealing rings 14 and 15. The wick 8 stretched by spring 6 is installed between bottom of lower case
7 and pull-rod 13. In lower bore of wick with spring the plug 19 is installed. In filling hole of upper case 11 a
plug with measuring stick 1 is screwed in. In drain hole of lower case 7 the plug 4 is screwed in. The orifice
plug 10 intended for equalization of air pressure in manifold and fuse case at closed position is built in upper
case. The tankage is 200 ml.
When pull-rod 13 is in upper position, air from compressor passes by wick-evaporator and entrains anti-
freezing agent which selects moisture from air and converts it into nonfreezing condensate.
0
When ambient temperature is higher than 5 С, install pull-rod 13 in lower position by turning the hand
lever. Thus wick-evaporator 8 is completely lowered in crank chamber of lower case 7, and sealing ring 15 dis-
connects this cavity with manifold of pneumatic system.
Figure 11.4 – Anti-freezing device:

1 – measuring stick; 2 – bolt; 3, 14, 15, 16, 17 – sealing rings; 4, 19 – plugs; 5 – washer; 6 – spring; 7 – lower case; 8 – wick;
9 – bucket; 10 – orifice plug; 11 – upper case; 12 – pin; 13 – pull-rod; 18 – locking ring
11.3 Pneumatic system maintenance

Reliable operation of pneumatic system is secured only at leakproofness of system as whole and its
separate elements (apparatuses). Therefore at maintenance of pneumatic system it is necessary to perform
operations affecting leakproofness of joints of apparatuses and air pipes especially carefully.
Maintenance of pneumatic system includes routine inspection of system condition, inspection of
leakproofness, strengthening of apparatuses, refueling of anti-freezing agent and functional testing.
11-4
Pneumatic system
75135-3902015 IM
Daily maintenance.
– test leakproofness of pneumatic system.
The pneumatic system is checked on leakproofness at air pressure of not less than 0.65 MPa, with
switched off compressed air users and idle compressor.
Decrease of compressed air pressure in pneumatic system should be no more than 0.05 MPa for 30
minutes. Places of serious air leakage can be defined by hearing, and small – with help of soap emulsion. Air
leakage from joints of pipe ducts can be eliminated by retorque or substitution of separate elements of joints.
In case of failure disassembly of apparatuses and elimination of faults can be performed by skilled tech-
nicians in workshop condition only;
– test and if necessary adjust compressed air pressure in pneumatic system.
Air pressure in pneumatic system is 0.65 – 0.82 MPa. Readjustment is made by screwing (unscrewing)
of pressure regulator adjusting screw;
– drain condensate from pneumatic start system receivers and of pneumatic system receiver.
It is necessary to perform draining of condensate after the end of working shift. After full draining of con-
densate from receivers it is recommended to pump up system with air again till response of pressure regulator
and only after that to shutdown the engine.
At freezing of condensate it is forbidden to use open flame for warming-up.
Intensity of condensate accumulation depends on compressor technical condition and ambient air hu-
midity. Presence of large quantity of oil in condensate indicates compressor failure;
– test and if necessary add anti-freezing agent in anti-freezer reservoir.
0
Anti-freezing device is to be refueled with anti-freezing agent only at ambient temperature below 5 С.
Anti-freezing agent is filled in anti-freezing device through filling hole in cover, closed by plug. The tankage is
200 ml. Ethyl alcohol is used as anti-freezing agent.
TECHNICAL ETHYL ALCOHOL IS MADE OF NON-FOOD VEGETATIVE RAW MATERIAL. ON EFFECT ON

HUMAN BODY ETHYL ALCOHOL BELONGS TO SUBSTANCES OF 4-TH CLASS OF DANGER!
For fueling of anti-freezing agent and monitoring its level it is necessary to lower pull-rod in lower posi-
0
tion, to turn it on 90 and to turn out plug with measuring stick from filling hole. Fill anti-freezing agent in anti-
0
freezing device through funnel, then turn plug in filling hole and, having turned rod (with hand lever) on 90 lift it
into working position. Feeding of anti-freezing agent in system occurs automatically.
The level of anti-freezing agent in anti-freezing device should be inspected daily, and periodicity of filling
and norm of anti-freezing agent consumption is defined depending on temperature of ambient air.
Seasonal maintenance (SM)
– perform maintenance of dehydrator.
Clear cooler of dehydrator of dust and mud with paintbrush or sweeper. Without removing dehydrator,
disconnect cover 1 (see Figure 11.2), remove valve core 16 as assembly with details, remove guiding appa-
ratus 9. Wash out details and all disposable internal surfaces of dehydrator, dry and assemble dehydrator;
– once a year at seasonal maintenance remove, disassemble, wash out details and adjust pressure-
relief valve of pressure regulator.
11-5
Pneumatic system
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11-6
Low-voltage electrical equipment
75135-3902015 IM
12 LOW-VOLTAGE ELECTRICAL EQUIPMENT

The electrical equipment of dump trucks is of direct-current type with rated voltage of 24 V, made on
one-wire circuit. Negative poles of current sources and negative outputs of current users are connected to
“ground”.
Under-bonnet lamps of local illumination and the socket connection of droplight are connected in two-
wire circuit.
The low-voltage electrical equipment of dump trucks powers up the following basic systems: power sup-
ply, engine starting, monitoring tools, external and internal illumination, light and acoustic alarm, heating and
fanning, safety system.
Principal schemes of dump truck low-voltage electrical equipment, the list of elements of circuits of elec-
trical equipment, the wiring schemes of electrical equipment for the chassis and for cab are delivered with
dump truck in operation documentation set. Each dump truck is equipped with the corresponding electrical cir-
cuits only.
Contact pieces of sensors, contactors, relay and switches are figured on the schemes in "switched off"
position.
12.1 System of power supply

System of power supply of dump truck comprises sequentially connected accumulator batteries, alterna-
tor, powered in parallel with accumulator batteries, voltage adjuster, voltage meter, and «ground» remote
switch.
On dump truck the alternator with built-in voltage adjuster is installed.
Accumulator batteries. On dump trucks two accumulator batteries 6СТ-190А are installed.
Technical data of accumulator battery

Rated voltage, V ...................................................................................................... 12
0
Capacity at 10 hours discharge and temperature of electrolyte 30 С, Amp-hr ...... 174
Discharge current at 10 hours discharge, A ............................................................ 17,4
First charge current magnitude for dry charged batteries, A ................................... 19
For casting of one battery 12 l of electrolyte is required. Depending on climatic region in accumulator batter-
ies the electrolyte of the defined firmness is filled in according to table 12.1.
Table 12.1 – Dependence of firmness of electrolyte on climatic region

Firmness of electrolyte
Climatic region (average monthly air tempera-
Season reduced to plus 25 0С, g/cm3
ture in January, 0С)
Filled in At the end of charging
Very cold with temperature from minus 50 up to winter 1,28 1,30
minus 30 summer 1,24 1,26
Cold from minus 30 up to minus 15 all the year round 1,26 1,28
Moderate from minus 15 up to minus 8 all the year round 1,24 1,26
Hot dry from minus 15 up to plus 4 all the year round 1,22 1,24
Warm wet from 0 up to plus 4 all the year round 1,20 1,22
Note – Aberration of firmness of electrolyte on +0,01 g/cm3 is permitted
The electrolyte is prepared from sulfuric battery acid and distilled water in utensil, stable against sul-
phuric acid – ceramic, plastic, deflate ebonite, lead. In utensils water is filled in, then at continuous stirring sul-
phuric acid is filled. For deriving electrolyte of the corresponding firmness it is necessary to follow requirements
of table 12.2.
0
The temperature of the electrolyte which is filled in the battery should be not less than plus 15 С and no
0 0
more than plus 25 С in regions with cold and temperate climate and no more than plus 30 С in regions with
tropical climate.
12-1
75135-3902015 IM
Table 12.2 – Relationship between firmness of electrolyte, amount of water and sulphuric acid in 1 l of electrolyte
The required firmness of electrolyte at 25 0С, g/cm3 1,20 1,22 1,24 1,26 1,28 1,40
3
Amount of sulphuric acid with firmness of 1,83 g/cm , l 0,200 0,221 0,242 0,263 0,285 0,426
Amount of distilled water, l 0,859 0,839 0,819 0,800 0,781 0,650
Before casting of electrolyte turn out plugs from the battery and remove film closing vent hole from them,
and cut off protuberance at butt of plug. If instead of film and protuberance the hermetically sealing disk under
plug is applied, remove it. After fill-up of the battery with electrolyte vent holes should remain open.
Fill in electrolyte up to level of 10 – 15 mm higher above safety plate.
In the batteries having in covers ventilation fitting for automatic adjustment of level of electrolyte free
bores in fittings from hermetically sealing parts, turn out accumulative plugs and put them densely on venti-
lation fitting. After that fill electrolyte in accumulators with small jet up to the upper shearing of filling necks.
Remove plugs from fittings and level of electrolyte in accumulators will automatically decr ease up to re-
quired level.
After 20 minutes but not later than in two hours after casting of electrolyte check its firmness. If the firm-
3
ness of electrolyte decreases for no more than 0,03 g/cm against firmness of filled electrolyte batteries can be
commissioned.
3
If the firmness of electrolyte will reduce for more than on 0,03 g/cm batteries are to be charged.
0
The temperature of electrolyte in battery before charging should be no more than 30 С in cold and
0
moderate zones and no more than 35 С in hot dry and warm wet zones. If temperature of electrolyte is more
than specified, electrolyte needs to be cooled.
For charging the positive output of the battery is connected to positive pole of current source, and nega-
tive – to negative pole. Strength of charging current is 19 A.
Charge the battery until ample gas emission in all accumulators of the battery occurs, and the firmness
0
of electrolyte and voltage stays fixed within two hours. If the temperature of electrolyte is more than 45 С it is
necessary to reduce charge current by half or to interrupt charging for a period, necessary for decrease of
0
temperature up to 30 – 35 С. Voltage of batteries is to be inspected with voltage meter with scale on 30 V and
scale interval of 0,2 V.
In the end of charging if the firmness of electrolyte, measured taking into account temperature correction
(see table 12.3) differs from norm modify firmness of electrolyte. If firmness of electrolyte is above norm the
3
distilled water is to be filled, and if it is lower than norm acid with firmness of 1.4 g/cm is refilled.
After adjustment of firmness of electrolyte continue charging of batteries for 30 more minutes till full mix-
ing of electrolyte, and then disconnect batteries. In 30 minutes after cutting off of batteries measure level of
electrolyte in all accumulators of the battery.
If the level of electrolyte is lower than norm add electrolyte in the accumulator with firmness that is speci-
fied in table 12.1. If level of electrolyte is above norm take excess of electrolyte off with rubber bulb.
Negative output of accumulator batteries is connected to «ground» of dump truck through the switch.
Table 12.3 – Temperature corrections to firmness of electrolyte

Temperature of electrolyte at measurement of firmness, 0С Correction to observation of areometer, g/cm3
From minus 55 up to minus 41 Minus 0,05
From minus 3 up to plus 19 Minus 0,01
From plus 20 up to plus 30 0
From plus 31 up to plus 45 0,01
From plus 46 up to plus 60 0,02
0
Note – At temperature of electrolyte above plus 30 С the correction is added to the actual observation of areometer,
at temperature lower plus 20 0С the correction is subtracted.
12-2
75135-3902015 IM
The alternator on dump truck is of three-phase type with built-in voltage adjuster installed on the en-
gine. construction, maintenance see in the operating manual and engine servicing of firm «CUMMINS».
12.2 System of engine start and shut-down

The system ensures preheating of fuel system and coolant of the engine and its start-up.
System of engine start comprises pneumatic starter, oil and fuel pumps with the drive gear from elec-
tromotor, pre-start heater of coolant and the switching equipment. The pre-start heater of coolant is autono-
mous unit. It is used depending on seasonal operation of dump truck.
Sequence of engine start-up:
– press the button of cutout switch SB2 (see drawing scheme 75135-3700001 ЭЗ), located on the in-
strumentation panel, or the button of cutout switch S14 located on storage batteries box -- cutout switch S14
gets actuated, further it becomes self-hold and connects minus outputs of accumulator batteries to «ground» of
dump truck;
– insert key into key-lock switch S13 against the stop. In this position monitoring tools and indicating
lamps are powered up;
– switch on electromotor M4 of fuel pump by cutout switch SB1 and pump fuel system through;
0
– turn key in key-lock switch S13 on 90 ; from key-lock switch S13 voltage is supplied to relay К10 of the
oil pump М3 actuation. When pressure in the system reaches the prescribed one the sensor SP1 contact gets
opened, relay K10 stops oil pump and in 3-6 sec supplies voltage to solenoid YA8 of pneumatic starter actua-
tion. The engine gets started-up;
Simultaneously from terminal “CT” of key-lock switch S13 voltage is supplied to fuel feed electric magnet
YА7 and to coil of relay К9. Relay К9 becomes locked-up and voltage from fuse F22 through contacts of the
switch SB5 is supplied to fuel feed electric magnet YА7 relay K1 coil.
Pressure sensor SP3 connects relay coil K1 to “ground” at the working engine, relay acts and suppplies
voltage to sound buzzer NA2, motor hours counter PT, tachometer Р9 and through diode VD2.1, which dis-
connects contacts of relay K14, switch SB7 to electric magnet of drainage YА9 in system of lifting and lowering
of the body. At that it taps off voltage from button SB2, in that way excepting possibility turning off of «ground».
The engine shut-down is applied from button SВ5. Contacts are disconnect at the pressing on the switch
button, unloading voltage from coil of relay К9, which is de-energized, and taps off voltage from fuel feed elec-
tric magnet YА7.
12.3 System of light and acoustic alarm

The system of light alarm informs the operator on condition of systems of dump truck – change of pa-
rameters in limits of acceptable values, reaching of emergency values, and also gives the information on ma-
neuvers executed by the operator – braking operation and turning movements.
Transmitters of electric signals are installed in ports of systems and on correlate effectors of aggregates,
and receivers of signals (gears and lamps) on the panel of gears in cab. Lamps with red light filter provide
emergency signal, with green and dark blue – information.
At turning on of the alarm signaling all right and left trafficators of turning movements, and also warning
lamp built in the button of the cutout switch flashes. On the fuel tank the signal flashlight for exclusion of flood
of fuel is installed at filling.
The signal of braking operation is powered up at braking operation of dump truck by working, parking,
spare and auxiliary braking systems. At trigging by parking braking system lamp in the block of warning lamps
is powered up. The alarm lamp flashes.
Acoustical electric signals comprises system of acoustic alarm (С314 and С313), electric sound signal of
backward motion (С314Г) and the emergency noise signalizer (733.3747-10).
Electric sound signals are powered up by pressing butt of switch arm of turn indicators and light of head-
lights or switch arm of the window wiper and the window washer.
The electric sound signal of trailing side (С314Г) is powered up simultaneously with turning on of back-
ward motion. In its circuit there is relay-breaker – backup alarm is of faltering type.
The noise signalizer on dump truck is switched on in circuit in parallel to alarm lamps of emergency
pressure of hydraulic fluid in rear circuit of service braking system, in system of steering, emergency pressure
of oil in engine lubricating system and emergency level of coolant in engine cooling system.
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12.4 System of external and internal illumination

The system is intended System of external and internal illumination for illumination of section of road at
driving during the hours of darkness and in conditions of restricted view, illumination of ladder and side space,
the information on outline dimensions of dump truck, illumination of the panel of gears, cab and engine com-
partment. Lighting system comprises also the socket of droplight.
Sidelights and dipped headlights are powered up by the switch located on the panel of gears. Switching
from passing beam of headlights on long-distance is made by the switch located from left side of steering tube.
By the same switch turn indicators in front, behind and sideways dump truck are powered up.
At conveyance of switch arm indexes of right-hand turn, back – left-hand turn forward are powered up.
The switch has the automatic device for refund of bar in neutral position after turning movement. At turning on
of turning movement the warning lamp located on the panel of gears flashes.
At conveyance of switch arm up (not fixed position) high beam of headlights for the signaling to oncom-
ing transport is powered up.
At conveyance of switch arm to average fixed position (at powered dipswitch control on the panel of
gears), and the passing beam of headlights (light of opposing side track) is powered up in the lower arrested
position – high beam of headlights.
Flashlight of cab and under-bonnet lamp are powered up by individual cutout switches.
12.5 Protection of electrical equipment circuits

The electrical equipment of dump truck is protected by fuses, that are installed in the cabinet with low-
voltage electrical equipment in cab. Fuses and circuits defended by them are shown in schemes of low-voltage
electrical equipment of the dump trucks attached to operational documentation.
12.6 Maintenance of electrical equipment

At maintenance of electrical equipment it is necessary to observe the following:
– irregular connection of outputs, change of polarity is forbidden at connection of accumulator batteries
or ectogenic source of the electric power;
– at washing dump truck take measures to eliminate direct hit of water on the alternator;
– clear dust and mud from the alternator with brush moistened in benzine, or fabric napkin, or blow with
compressed air;
– clear electrolyte from accumulator batteries with napkin moistened in solution of spirit of hartshorn or
soda ash (10 % solution).
Maintenance of electrical equipment includes periodic clearing of elements from mud and dust and peri-
odical inspection serviceability of the alternator, accumulator batteries, voltage control box, monitoring tools,
and inspection of their fastening. Besides at maintenance the condition of wiring and pinned joints, fastening of
wiring to outputs of apparatuses and connective panels is checked.
Daily maintenance.
– test by external examination condition, stacking and connection of electric wires and cables of low-
voltage electrical equipment. The insulation failure of wires and cables, slackening of their fastening is not
permitted;
– test voltage of accumulator batteries before engine start on the voltage meter on the panel of gears.
During ТM–1:
– test level of electrolyte in accumulator batteries and fill it to specified level if necessary. Clean vent
holes in fuses of batteries.
Before inspection clear accumulator batteries with cleaning cloth moistened in 10 % solution of spirit of
hartshorn. The level of electrolyte should be on 10 – 15 mm above safety plate.
Inspection of level of electrolyte in the accumulator battery is carried out by means of glass tube with di-
ameter of 3 – 5 mm on which two labels on distance of 10 and 15 mm from butt (See Fig. 12.1) are put.
For inspection of level of electrolyte turn out plug in battery and insert tube into bore against the stop in
safety plate. Close running end of tube with finger and lift it, electrolyte should fill in tube up to level between
labels. It is the level of electrolyte in battery.
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Figure 12.1 – Inspection of level of electrolyte in the accumulator battery

During ТM–2:
– tighten fastening of nozzles to clips and fastening of accumulator batteries. Grease clips of batteries;
– test firmness of electrolyte in accumulator batteries. If necessary restore firmness of electrolyte and
recharge batteries;
– test correctness of resetting of light of headlights and fastening of gears of illumination and light alarm.
Inspection of firmness of electrolyte.
The firmness of electrolyte is checked with the help of areometer (See Fig. 12.2) in each element of the
battery.
Define extent of batteries discharge, having compared ac-
tual firmness of electrolyte with firmness for the given climatic
region under table 12.4.
The firmness of electrolyte is specified in the table at 25
0
С. It is necessary to charge the battery discharged more than
on 25 % in the winter and more than on 50 % in the summer, put
on charging.
Figure 12.2 – Inspection of firmness of electrolyte
Table 12.4 – Charge condition of the accumulator battery depending on firmness of electrolyte
Discharged battery
Fully charged battery
on 25 % on 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
Note – firmness of electrolyte is specified at 25 0С
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Adjustment of light of headlights.

Headlights with European asymmetric light distribution of passing beam give the sharp boundary be-
tween light and dark zones of light spots on the covered part of road. Therefore it is necessary to regulate
carefully position of light spots in order not to dazzle operator of oncoming transport.
Before regulating light of headlights, it is necessary to test performances of cylinders of suspension and
air pressure in tires, and in case of necessity adjust inspected parameters to required values.
Operation is to be carried out with special gears or with the shield marked according to figure 12.3. Val-
ues of parameters H, a, h, H1, a1 and h1 are specified in table 12.5.
Table 12.5 – Screen sizes for adjusting light of headlights
Screen sizes, mm
Lower headlights Lower headlights
H a h H1 a1 h1
1460 630 320 2370 2750 250
Figure 12.3 – Sectoring of the shield for adjustment the light of headlights:
I–I, II–II – center lines of the lower headlights; III-III– center line of light spots of the lower headlights; IV-IV, V-V – center lines of
the upper headlights; V1-V1 – center line of light spots of the upper headlights; 0-0 – line of the center between headlights; Н – distance
from floor up to the center of the lower headlights; Н1 – distance from floor up to the center of the upper 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; a – distance from shaft of dump truck up to the centers of the lower headlights; a1–distance from shaft of dump truck up to the
centers of the upper headlights
Operation is to be carried out in the following sequence:

– install empty dump truck on horizontal platform so that its direct-axis is perpendicular to plane of the
shield and coincided with shaft 0-0, and distance from the shield up to lower headlights diffusors is 10 m;
– on the shield make two vertical lines I-I and II-II according to distance from direct-axis of dump truck
up to the centers of the lower headlights;
– make horizontal line at level of altitude of the centers of headlights from platform;
– make second horizontal line III-III on distance "h" below line of the centers of headlights;
– switch on passing beam of the lower headlights and serially (one headlight should be closed with light-
tight material) with screws of horizontal and vertical adjustment achieve that the boundary of the covered and
dark sections coincided with line III-III, and slant restrictive lines started with cross-points of line III-III with lines
I-I and II-II.
The upper headlights are regulated on high beam for the same position of dump truck concerning the
shield. The centers of light spots of the upper headlights should coincide with cross-points of lines IV-IV and
V-V with line VI-VI
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Regulating of light of fog lights is made so that light was symmetric concerning shaft of dump truck and
the center of light stain attained ground on distance of 20 m.
– reduce firmness of electrolyte according to season and recharge batteries if necessary.
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13 CAB AND BODY
13.1 Cab
The cab – two-seat, all-metal, two-door, heat and noise-insulated with soft internal upholstery, is in-
stalled at the left on brackets and is fastened to them in four points with bolts 2 (See Fig. 13.1) through rubber
shock-absorbers 4, that damp cab vibration at dump truck motion.
The cab meets safety requirements of ROPS. Operator’s seat with pneumatic cushioning and fold-back
passenger’s seat, control panel, heater with two electric fans, electric window washer and double-brush elec-
tric window wiper is installed in cab. Cab is also equipped with two sun visors, plafond of illumination, rack for
clothes, pocket for documentation and operator’s fan. The place for medical first-aid set is also provided.
Locks (with locking devices from inside of the door) and sliding windows are built in doors. Doors are
equipped with external and internal handles. Leakproofness of door and windows is ensured with rubber seals.
Multi-layer soft upholstery is applied to the ceiling, side and rear walls. The upholstery is reveted with
perforated vinyl and leather.
The cab glassing ensures good visibility from operator’s working place. Windscreen is flat three-layered
(two polished glasses with high clarity plastic film between them) glass, rear and side glasses are toughened
safety glasses.
Figure 13.1 – Installation of cab:

1 – cab; 2 – bolt of cab strengthening; 3 – upper plate; 4 – pillow of cab strengthening; 5 – bracket; 6 – bolt; 7 – lower plate
Operator’s seat – pneumatically cushioned, with devices for adjustment altitude, length travel, rotation
of seat and fixing of seat back.
In order to move seat length-wise turn hand lever 1 (See Fig. 13.2) to the left, install seat in required po-
sition and release hand lever.
Rotation of seat and fixing of seat back 8 is carried out with hand lever 6. With hand lever in upper posi-
tion seat back is in its extreme front position.
Hand levers 2 and 4 adjust and fix altitude and incline of seat pillow. At turning of hand levers upwards
to the stop seat moves to its extreme upper position. Incline of seat pillow is adjusted by rotation of hand levers
done in turn.
The seat frame has two tapped holes 9 with size 7/16" for safety seat belt fastening. Fastening bolts are
included in seat belt delivery set.
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Figure 13.2 – Operator’s seat:

1 – hand lever of seat’s length travel mechanism; 2, 4 – hand levers of seat’s altitude adjusting and fixing mechanism; 3 – seat
jamb with pneumatic equipment; 5 – cover of adjusting mechanisms; 6 – hand lever of seat rotation and seat back fixing mechanism;
7 – pillow of seat; 8 – seat back; 9 – tapped hole for safety seat belt fastening
Pneumatic cushioning mechanism is powered by receiver of pneumatic system and is built in jamb 3.
The mechanism comprises pneumatic bulb 6 (See Fig. 13.3), pneumatic control valve 3, absorber 4, upper 1
and lower 2 bars and buffer 5.
Figure 13.3 – Seat jamb with pneumatic equipment:

1 – upper bar; 2 – lower bar; 3 – pneumatic control valve; 4 – absorber; 5 – buffer; 6 – pneumatic bulb
The cab heater is of fluid type. The heat-transfer agent is engine coolant. Hot fluid from head of ther-
mostat moves through suberose shut-off cock on rubber-fabric hose in radiator of heater and escapes from it in
engine supply pipe. Cold air, fed with two fans, passing through heated radiator, is heated and moves in cab.
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The amount of ambient air entering the cab is adjusted by cut-off plate. The cut-off plate can be adjusted so,
that ambient air only or part of ambient air together with cab air or only internal air enters the cab.
From heater warm air is moved by one electric fan on glass of windscreen, another fan blows air in zone of
operator’s legs and side deflector located to the right of operator on control panel.
Fans of cab heater are connected to electrical circuit through two cutout switches on double-duty
scheme that provides separate switching on and regulating of their productivity, and consequently air tempera-
tures in the cab.
The heater shut-off cock, installed in pressure manifold, reduces the amount of hot fluid coming in radiator
of heater, or completely blocks its flow for summer period. The shut-off cock is not installed on drain pipeline.
Paper filter intended for clearing the air that comes in cab through heater is installed outside on front
wall of cab. It is necessary to clear the filter from dust and mud periodically.
The window washer comprises polyethylene tank for fluid and pump with electromotor, installed in the
tank. The pump is connected to two orifice plugs by hoses.
When the pump is switched on fluid from tank moves through hoses in orifice plugs and is sprayed by
them on glass. In tank cover there is a bore, which ensures pressure equalization in the tank at operation of
pump. The direction of fluid jet is regulated by rotation of bead in plastic orifice plug so, that jet is directed to the
upper zone of sector circumscribed by wiper brush.
In order to eliminate blockage of orifice plugs and filter it is necessary to fill tank with filtered fluid and to
clean orifice plugs periodically. As working fluid for window washer it is necessary to use special low-freezing
liquids in blend with water in ratio as prescribed by instruction on fluid application.
Tank (with pump) of window washer it is installed in front lower corner of the cab.
The window wiper comprises electromotor with drive gear, tractions and bars with sweepers, fastened
on front panel of cab.
The air-conditioner. On customer’s request dump truck is equipped with block-type chladone air-
conditioning system that comprises compressor, block of evaporator and block of condenser. Flexible cold-
resistant rubber pipes connect air-conditioner units.
The filling of air conditioner, its commissioning and repair is to be carried out according to air-conditioner
maintenance manual by specialists of air-conditioner supplier or supplier’s regional representatives.
13.2 Body
Body is metal, welded construction of bucket type with protective canopy above cab. Body design is well
adapted to loading dump truck by excavating machine and frontal loader. Body is equipped with rock ejectors,
defending tires and feathering from damage that may be caused at loading by falling pieces of rock. The body
is heated by engine exhaust gases.
The floor and sideboards of body are made of high-strength wear-resistant sheet steel, strengthened by
box section buttresses. Upper crimps of sideboards are supplied with massive boosters from rolled steel of
round section, defending sideboards from damage at loading.
In order to provide good efficiency during operation in more severe conditions (at transportation of highly
solid and abrasive rocks) the body floor on customer’s demand can be fettled with additional decking.
The body is hingedly fastened to brackets of frame by means of fingers 10 (see Figure 13.4). Axial
clearances in hinges between supports and lugs of brackets are adjusted by washers 11 and should not ex-
ceed 2 mm. Clearance is defined in zone of least distance between planes. Lock plate of finger is combined
with cut of clamp.
Absorbers 13 are fastened with bolts 14 to spars of body basis. Installation of adjusting gaskets 12 en-
sures uniform fit of absorbers 13 to seating of frame spars. Clearance between absorber and frame should not
exceed 1 mm. In some places wedge-shaped spacing up to 3 mm is admitted. Squeezing of some absorbers
according to remote element Е is admitted.
Guiding rails limiting body cross motion are welded on body basis. Clearance of 0 – 1.2 mm between
guiding rails and contact plates 4 is adjusted by plates 3.
End plate of first bottom cross bar incorporates bore for removal of smoke black from engine exhaust
gases, closed by cover 16.
If it is necessary to provide exhaust gas outlet on the right side installation of choke plug 18 on the left
side with simultaneous removal of bin cover 16 from the right side is admitted.
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In order to lock body in lifted position at visual inspection and repair of dump truck units the bracket for
fastening of locking cable is welded to sixth bottom cross bar. The cable with thimbles on its ends is fastened
to eyelets of crankcase of rear axle by means of two towing fingers.
It is necessary to splint fingers in order to prevent shedding of fingers from eyelets. Prior to each body
locking it is necessary to test condition of cable and welding of bracket of locking device.
LOCKING CABLE IS DESIGNED FOR EMPTY BODY LOCKING ONLY.
For the moving of rock pieces, which are stuck between double tires of driving axle rock ejectors 19 are
installed.
In order to provide proper operation of rock ejectors it is necessary to remove fastening clinches from
spacing washer of rear wheels and to smooth out welding place (in order to exclude damage to rock ejectors).
Figure 13.5 – Installation of body:

1 – body; 2 – cylinder of dumping mechanism; 3, 12 – adjusting plates; 4 – contact plate; 5, 8, 14, 15 – bolts; 6, 10, 20 – fingers;
7 – spacing bushing; 9 – cover; 11 – adjusting washers; 13 – absorber; 16 – cover of bin; 17 – layer pad; 18 – choke plug;
19 – rock ejectors
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13.3 Maintenance of cab and body

Daily maintenance.
– test operation of window wiper and window washer. Fluid jet should get on windshield in upper zone of
sector circumscribed by wiper brush;
– clear cab windows, headlights, front and rear lights, side turn indicators, rear-view mirrors.
During ТM–2:
– tighten cab and feathering elements fastening. All elements should be safely fixed;
– clear filter of cab air intake;
– test condition of welded connections of body and frame. There should be no cracks. Detected cracks
are to be welded.
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14 DUMPING MECHANISM
Dumping mechanism provides the lifting and lowering of bed, as well as putting it in any intermediate
position during the lifting or lowering. Mechanism is equipped with electric drive of translational motion with the
electrohydraulic control. It consists of two three-stage telescoping hydraulic cylinders Ц13 and Ц14 (See Fig-
ure 14.1), hydraulic distributor А7, control unit А6, reciprocating pump Н, two filters Ф3, plate (magnet filter)
ФM, oil tank of united hydraulic system with filter Ф5 and oil pipes joining them.
Dumping mechanism is controlled from the cab by electrical switch placed on instrumentation panel.
14.1 Principle of hydraulic drive operation

WHEN STARTING THE ENGINE WITH RAISED BODY IT IS NOT ALLOWED FOR ANY PERSON TO STAY
NEARBY, BECAUSE THE BODY GETS SUNK AUTOMATICALLY AFTER THE ENGINE START-UP
When the switch of dumping mechanism control is in the neutral position the working fluid, pumped by
reciprocating pump of variable delivery type Н, is fed to distributor Р12 and through filter Ф3 to distributor Р11
of hydraulic distributor А7 of dumping mechanism; through filter Ф3 it also flows to the collector of steering hy-
draulic system and to reducing valve РД of control unit А6.
Reducing valve РД reduces pressure of working fluid from 16 to 3 MPa and sustains its steady state in
hydraulic system of dumping mechanism.
From reducing valve working fluid flows to hydraulic distributor Р9.
Hydraulic distributor Р9 with electric magnets controls body lifting and sinking and its stopping at any in-
termediate position.
Hydraulic distributor Р10 with electric magnets ensures “floating” position of hydraulic cylinders Ц13 and
Ц14, connecting their piston spaces to drain line, while truck riding, regulating overflow valves К2 of hydraulic
distributor А7 and gets locked at the switching of dumping mechanism control switch to the position «Lifting ».
Hydraulic distributor А7 changes the direction of working fluid flow from the hydraulic system pumps to
the head and rod ends of hydraulic cylinders Ц13 and Ц14, depending on positions of the hydraulic distributors
Р11 and Р12 spool valves
Safety valves КП4, КП5 adjusted for pressure of 21 MPa, protects hydraulic line of pump against over-
loading while body raising.
Safety valve КП6, adjusted for working fluid pressure of 8 MPa, protects hydraulic system against over-
loading at body sinking.
With the switch in the neutral position, electromagnets of hydraulic distributor P9 are de-energized and
its spool valve is in the middle position, closing hydroline channel from pump. The pressure hydroline of pump
is connected with the hydraulic system of steering and brake systems.
When the switch on the instrumentation panel is set to “LIFT” ("Подъем") position the electromagnet
shifts the spool valve of hydraulic distributor Р9 into the extreme left-hand (in the figure) position. The working
fluid along control hydroline is supplied to left (in the figure) head end cavities of hydraulic distributors P11 and
P12 spool valves and shifts them into the extreme right (in the figure) position.
Working fluid flows from pump along pressure hydraulic lines into piston spaces of hydraulic cylinders
Ц13 and Ц14, which members expand and raise body. At this rod spaces of hydraulic cylinders are connected
by means of hydraulic distributor P12 with drain line to oil tank trough filter Ф5.
Safety valves КП4, КП5 are of non-direct type and consist of main and auxiliary valves. In case of hy-
draulic system overloading while body raising (Р > 16, 5 МPа) main valves get opened and connect space be-
hind throttle of auxiliary valves with drain line.
Pressure difference created by fluid flow through the throttle upsets main valves balance. They get
opened and connects piston spaces of hydraulic cylinders with hydraulic drain line. The pump Н gets to zero
delivery.
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Figure 14.1 – Schematic hydraulic diagram of dumping mechanism:

Н – reciprocating pump of variable delivery type; А6 – control unit; А7 – hydraulic distributor; Р9 - Р12 – distributors;
КП4 - КП6 – safety valves; К2 – overflow valve; РД – reducing valve; Ф3, Ф5 – filters; ФМ – plate (magnet filter); Ц13, Ц14 – cylinders of
dumping mechanism
I – to the systems of steering and brake systems
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When the switch on the instrumentation panel is set to “Sinking” ("Опускание") position the spool valve
of hydraulic distributor Р9 moves into the extreme right -hand (in the figure) position. The working fluid along
control hydroline is supplied to right (in the figure) head end cavities of hydraulic distributors P11 and P12
spool valves and shifts them into the extreme left (in the figure) position. Working fluid flows from pump along
pressure hydraulic line into rod spaces of hydraulic cylinders Ц13 and Ц14, which members get put together
and sink body. At this piston spaces of hydraulic cylinders are connected by means of hydraulic distributors
P11 and P12 with drain line to oil tank trough filter Ф5.
For stopping of the platform at the any intermediate position during lifting the switch should be set into
the position “Neutral”.
For stopping of the platform at the any intermediate position during sinking the switch should be set into
the position “Lifting”, and then to the position “Neutral”. At that spool valves Р11, Р12 and Р9 are set into the
middle position. Working fluid at the head and rod ends of hydraulic cylinders is stuck and the body is kept at
the intermediate position.
After the engine start and at actuated traction motor the current is supplied to the electromagnet of hy-
draulic distributor Р10. The spool valve of hydraulic distributor moves and connects throttle cavities of the over-
flow valves К2 with drain hydraulic line. The pressure behind throttle of the overflow valve is reduced, the valve
gets opened and connects head ends of hydraulic cylinders with the drain hydraulic line, which excludes the
body lifting while the truck moving.
To exclude spontaneous body lowering while the truck maneuvering during the unloading the electromag-
net of hydraulic distributor Р10 is disconnected from the circuit by the special switch, mounted on the instrumen-
tation panel.
TO EXCLUDE THE HARD BODY FIT ON FRAME WHILE THE LOWERING OF EMPTY BODY, IT’S RECOM-
MENDED TO SWITCH ON «FLOATING» POSITION AFTER PUTTING TOGETHER OF THE FIRST STAGE OF HY-
DRAULIC CYLINDERS BY SETTING OF BODY LOWERING AND LIFTING SWITCH ON THE INSTRUMENTATION
PANEL TO THE «NEUTRAL» POSITION FROM THE POSITION «LOWERING».
14.2 Components of dumping mechanism

Pump. The reciprocating pump of variable delivery type A11VLO260 «Вosch Rexroth»is installed at the
hydraulic system of dumping mechanism. The pump is installed on the third frame cross-bar. The pump actua-
tion is realized from the traction generator 1 flange (See Figure. 14.2) by the cardan shaft 3 through flange 4,
mounted on the spline shaft of pump module.
Figure14.2 – Mounting of united hydraulic system pump:

1 – flange of traction alternator; 2, 6, 9 – bolts; 3 – cardan shaft; 4, 10 – flanges; 5 – bracket of pump; 7 -- reciprocating pump; 8 –
right spar of frame; 11 – nut; 12 – bushing; 13 – adjusting plates; 14 -- coupling
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Pump 7 with bracket 5 is mounted coaxially to the traction generator.

Permissible axes shifting:
– in the vertical plane 0 – 40 mm, tune by washers 13;
– in horizontal plane up to 3 mm, tune by shifting of bracket 5.
-- misalignment of axes up to 0.5 mm on the length 100 mm.
Reciprocating pump of variable delivery type with the infinitely variable control of working fluid flow.
Pump consists of delivery unit and regulator unit. Delivery unit converts the shaft torque into the variable
motion of pistons, which suck the working fluid by the first half-turn, and deliver it by the other half-turn.
Delivery unit includes the shaft 3 (See Figure 14.3), mounted in the body 5 on the bearings 4 and 12.
From the side of shaft driving end the pump is closed by cover 1 with cup 2. Cylinders block 10 is installed on
the power shaft on splines. Pistons 18 move in the cylinders block, sucking and delivering the working fluid
through the distributor 15 grooves into the canals of regulator 8 unit.
Figure 14.3 – Reciprocating pump:

1 – cover; 2 – cup; 3 – power shaft; 4, 12 – bearings; 5 – pump body; 6 – base plate; 7 – adjusting screw; 8 – regulator unit;
9, 14 – springs; 10 – cylinder block; 11 –lever; 13, 16 – plunger; 15 – distributor; 17 – link; 18 – piston; 19 – plug; 20, 21 -- valves
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Regulator unit is intended for stageless change of pump supply. Piston stroke value is defined by the
slope angle of base plate 6, which is defined by the spool-valve position of working fluid shutoff valve 21 by the
pressure and maximum supply restriction. The valve is adjusted to the maximum pressure of 16, 5 МPа.
The spool-valve is adjusted to pressure of 1.8 MPa and serves for restriction of working fluid flow to the
steering system.
Maximum and minimum pumpage is limited by the adjusting screws 7.
The pump is main and the most expensive part of hydrosystem, so reliable operation of pump influences
on successive operation of the hydrosystem in whole.
Basic causes of pump failure and serviceability fall:
– pollution of working fluid and its expired term;

– usage of discordant brands of working fluids or not in accordance with season;
– overheating of working fluid;
– air ingress into suction line;
– rarefied in the suction line exceeds 0.2 atm. because of air filter clogging, low level of working fluid and
loose choke of oil tank;
– operation of the pump after repair of the hydrosystem without preliminary refilling of drainage cavity
with working fluid or start of the pump with raised body (the level of working fluid is lowered in this case);
To exclude operation of the pump without grease after repair or maintenance of the hydrosystem it is
necessary to move away the air from suction ducts. For that:
– open choke of oil tank;
– loosen plug 19, remove air from the pump casing. Then tighten the plug.
Filters. At the delivery line of the reciprocating pump two filters Ф3 are installed (see Figure 14.1).
At the body 4 (See Figure 14.4) the filtering element 3 is installed. For provision of impermeability the
plug 2 is placed from the one side, the bushing 6 is from the other side, the packing rings are installed in their
slots. Plug, filtering element and bushing are tightened by spring 1 to the filter 5 cover, which is heaped up on
the body. The overflow valve, which actuates under the clogging of filter element, is mounted into the filter
cover. The filter separates the mechanical impurities with size of 0,01mm from the working fluid.
Figure 14.4 – Filter:

1 – spring; 2 – plug; 3 – filter element; 4 – body; 5 – filter cap; 6 – bush;
7 – valve; 8 – bearing sleeve; 8 – nut
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Plate (magnet filter) ФМ (figure 14.1) is mounted in the drainage line of the hydrosystem and is intended
for purification of working fluid from metal particles.
Working fluid flows along drain oil ducts via apertures in the plate 3 (figure 14.5) into the inner space.
Magnets 2 clean working fluid from metal particles. Then working fluid flows to drainage into oil tank via aper-
ture in the adaptor 4.
Figure 14.5 – Plate (magnet filter):

1 – magnet separator; 2 – magnet; 3 – plate; 4 – adaptor of the hydroaccumulator
Hydraulic distributor is intended for change of the working fluid flow direction from pumps of united
hydraulic system to the rod and head ends of hydraulic cylinders or for the drainage to the oil tank. It consists
of two delivery bodies 1 and 3 (See Figure 14.6), drain casing body 2, two distributors of slide type 5, overflow
valves 8, safety valves 6 and auxiliary valves 7.
Spool-valves 18 of hydraulic distributors – three-positioned, with spring return to the neutral position.
Spool-valves are shifted by the working fluid pressure from the control unit, which feeds to the end caps 9 of
hydraulic distributors.
Safety pump valves, located on the feeding bodies 1 and 3, are constructively the same. Each valve
consists of auxiliary valve 7 and safety valve 6.
Safety valve is operated in the following way. Under the pressure excess higher than the pressure of tun-
ing valve 22, the tuning valve gets opened and joins to the behind – throttle cavity with drainage. At that valve15
is shifted, squeezing the spring, and joins the main flow of working fluid to the drainage, as the differential pres-
sure is formed on the throttle valve 15 opening. The rod 20 supports the tuning valve 22 and prevents from the
valve auto-oscillations.
The working fluid flows from the impeller pump of the united hydraulic system to the ducts VII and VIII.
Under the neutral position of spool-valve the ducts VII and VIII are joined to the drain ducts III. Under the sup-
ply of control pressure from the control unit to the ducts I or V the spool-valve 18 is shifted in opposite direction
and direct the flow of working fluid from pumps through ducts II or IV to the certain cavities of hydraulic cylin-
ders. At that reverse cavities are joined to the drain hydraulic line.
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Figure 14.6 – Hydraulic distributor:

1, 3 – forced blocks; 2 – drain block; 4 – reducing plate; 5 – distributor; 6 – safety valve; 7 – auxiliary valve; 8 – overflow valve;
9, 17 – caps; 10, 28 – spring leg; 11, 27 – tangs; 12, 16, 23, 26 – springs; 13 – casing; 14 – seat; 15 – valve; 18 – spool-valve; 19 – plug;
20 – spindle; 21 – sleeve; 22 – tuning valve; 24 – adjusting bolt; 25 – bush
I, V – ducts of pressure supply from control unit; II, IV – ducts communicating to head and rod ends of hydraulic cylinders; III, VI,
IX – cavities communicating to drain hydraulic line; VII, VII – cavities communicating to pressure pump hydraulic lines; X – duct of control
pressure supply from control unit to floating position
14-8
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Control unit. Control unit is intended for control of body raising, sinking and stop in intermediate posi-
tions. It consists of casing 8 (figure 14.7) to which hydraulic distributors 10 with electromagnetic control are at-
tached. Casing channel contains sleeve 6 and spool valve 7 of reducing valve which is being adjusted for cer-
tain pressure with adjusting bolt 1. Casing channels are marked with letters by percussion method.
Reducing valve reduces working fluid pressure flowing from pumps from 16 MPa up to (3 +0.2) MPa and
sustains it at constant level in hydraulic system of dumping mechanism control.
To adjust reducing valve provide working fluid pressure of 4 - 20 Mpa into channel P, connect drain line
from channel T into tank, connect pressure gauge with measuring range 10 Mpa to c channel M. With electric
magnets switched off adjust reducing valve by adjusting bolt for pressure (3+0.2) MPa.
Figure 14.7 – Control unit:

1 – adjusting bolt; 2 – spring cap; 3 – spring; 4, 9 – covers; 5 – ring; 6 – sleeve; 7 – spool-valve; 8 – casing; 10 – hydraulic distribu-
tors; 11 – nipple;
Т1, Т2 – drain cavities; X, Y – control cavities; А, В – cavities of safety valve control
Cylinders of dumping mechanism – telescopic, three-staged, with one stage of double action.
Under the lifting the operation fluid feeds through the cavity IV (See Figure 14.8) and inner tube 3 into
the head end I. Under the operation fluid pressure the cap 1 and external tube 7, rigidly joined to it, are moved.
At the end of moving forward the external tube is abutted by bead against the bead of the second telescopic
tube 6 and its moving forward begins. Then the third tube 5 moves forward together with bush 8. Under the ful-
ly moved forward third tube the bush moves pushers and opens balls 2 of the overflow valves and communi-
cates the head and rod cavities between them. The pumped operation fluid is drained into the oil tank.
The bed lowering is realized forcedly. The operation fluid feeds through cavity III to the rod end II, and
the tube 3 together with bush is shifted down up to the piston stop to the limited ring. Displaced out of piston
ends operation fluid by the inner pipe 3 drains into the oil tank.
Fastening of hydraulic cylinders to the frame and bed is realized by the ball bearings 5 (See Figure
14.9). Lubrication of low and upper rests is realized through lubricators 6.
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Dumping mechanism
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Figure 14.8 – Cylinder of dumping mechanism:

1, 10 – caps; 2 – ball of relief valve; 3 – inner tube; 4 – rod with piston; 5, 6, 7 – tubes; 8 – bush; 9 – lock nut;
I – head end; II – rod end; III, IV – cavities communicating to head and rod ends
Figure 14.9 – Mounting of dumping mechanism cylinder:

1 – bracket; 2 – cylinder of dumping mechanism; 3 – cap; 4 – gland; 5 – ball bear-
ing; 6 – lubricator
Oil tank of united hydraulic system of dumping mechanism, steering and brake system of load-carrying
structure, is mounted on the right frame longeron.
Working fluid feeds from tank to pumps under the opened throttle 20 (See Figure 14.10) through suckers
6 located in the tank bottom. Drainage of operation fluid to the tank from hydraulic system through plate 3
ports.
The level of operation fluid at the tank is controlled by sight by lower and upper indicators through eyes
11 of level. The level of working fluid should be not higher the middle of upper eye under the uncharged hy-
draulic accumulators and not lower the middle of lower eye under the charged hydraulic accumulators.
Oil tank is equipped by electric gauge, which under the reducing of working fluid level up to the emer-
gency one and under the dumping mechanism operation gives signal to switching of pilot lamp, located on
control panel, by gauge of filter element 17 clogging and by gauge of working fluid temperature control.
Surplus of working fluid is drained through overflow valves 4. For full drainage of working fluid from tank
the magnetic drain plugs 7 are extra unscrewed.
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Figure 14.10 – Oil tank:

1 – breather; 2 – tank bed; 3 – plate; 4 –overflow valve; 5 – filling valve; 6 – suction pipes; 7 – relief fitting magnetic; 8 – relief fitting
bed; 9,13 – balls; 10,14 – caps; 11 – eye; 12 – nipple; 15 – safety valve; 16 – filter cap; 17 – filter element; 18 – plug; 19 –filter bed with bas-
ket; 20 – sleeve valve; 21 – cap; 22 – pressing of flange
14-11
Dumping mechanism
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Before removal of suction hoses of pumps the oil tank is overlapped by the sleeve valve 20. The sleeve
valve is closed by the cap 21 rotation counterclockwise.
Before engine start, after hydraulic system repair, it’s necessary to open the sleeve valve as under the
closed sleeve valve the operation fluid don’t supply to the pumps and they will be out of order.
The one-stage oil filter with safety valve15, actuated under the clogging of filter element 17, is mounted in
the tank body at the drain pipe line of hydraulic system.
Filling of tank with working fluid is carried out from oil-dispensing column through mouth, which by plug
18 is closed or by special filling device through filling valve 5.
Mechanism of the body lifting limitation.

0
The restriction device is meant for automatic shut-off of the body lifting. Under the lifting to 43 – 45 (lift-
ing stop) the body presses onto the movable part of arm switch 5 (See Figure 14.11), which rotates around its
axe and breaks contact of end switch 2.
The interruption of lifting electromagnet supply circuit and automatic bed stop, hence the dynamic load
on hydraulic cylinders is reduced.
0
Before mounting of spring 3 the switch arm 5 should be free rotated round its axe to the angle (45 + 10) .
After the switch 2 setting tune the trailer actuation in the following order:
– unscrew to the one turn the nut 6;
– raise the body up to the maximum separation of cylinders;
– lower the body down to 80 – 90 mm on cylinder stripping, at that size В should be (700 + 10) mm;
– rotate the switch 7 bracket around its axe, tune the actuation of end switch 2 (the roller of end switch
should touch the plate of switch arm 5).
Figure 14.11 – Mechanism of the bed lifting limitation:

1 – bracket; 2 – end switch; 3 – spring; 4 – puller; 5 – switch arm; 6 – nut; 7 – switch bracket
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14.3 Maintenance of the dumping mechanism

Maintenance of dumping mechanism lies in the control of operation fluid level at the oil tank of united
hydraulic system and fluid change, hermeticity check up and timely retorque of threaded joints, periodic lubri-
cation of attrition faces, replacement or washing of filter elements of oil filters and breathers.
Special attention should be paid to the quality of operation fluid purification, timely change of filter ele-
ments of hydraulic system filters and air filters of breather, as the purity of operation fluid is one of the main
factors influencing on the reliability and durability of hydraulic system operation.
Daily maintenance.
– check by sight the state and fastening of pipes and hoses of the hydraulic system and if necessary
tighten them (at the leakage places);
– check the level of operation fluid at the tank of united hydraulic system.
The level of operation fluid at the tank should be not higher the middle of upper eyelet under the dis-
charged pneumohydraulic accumulators, and not lower the middle of lower eyelet under the charged ones (after
the engine start).
At the hydraulic system the operation fluids should be used in accordance with the operation season and
ambient air temperature. Recommended fluids depending on climatic service conditions are shown at the table
14.1, at that the import oils are recommended.
Don’t mix different oil grades.
Table 14.1 – Recommended oil types depending on the operating conditions
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Operating characteristics of operation fluids should correspond the values at the table 14.2.
Table 14.2 – Operating characteristics of operation fluids
Designation of parameter Value

Contamination class by the GOST 17216 12
2
Kinematic viscosity, mm /s:
Optimal 20 – 35
Maximum starting 1500
Minimal short -term 10
Filtering capacity (nominal), mkm 10
There is need to remember that dirty operation fluid is the main reason of premature wear and faults of
dumping mechanism, steering, brake system and pump units.
__
It’s recommended to perform the first change of operation fluid in 300 500 operation hours. The follow-
__
ing changes are in 4000 5000 hours, but not later than seasonal servicing.
In case of operation fluid overheat (tр>95ºC) it’s required after the elimination of overheat reason to carry
out extra change of operation fluid, as under the long operation of the hydraulic system with high temperatures
the rapid degradation of operation fluid and lost of its operational properties.
Before the exit to the line under the low ambient temperatures the operation fluid at the oil tank should
be heated. For operation fluid heating, launch the motor and operate without pump loading up to the achieve-
0
ment of temperature 15 С at the tank.
During ТM–1:
-- check hoses of hydrosystem and their fastening, Hoses with leeks, blisters, cracks, inelasticity are to
be replaced. Tighten hoses attachment.
During ТM–2:
– replace filter element at the oil tank of united hydraulic system;
– replace filter element of tank breather of united hydraulic system;
– replace filter element of filters (two filters) installed at the pressure line of axial-plunger pump;
– unscrew magnet separator 1 (figure 14.5) from plate 3, clean magnets 2 of metal particles and screw
in the separator back;
– wash the tank of united hydraulic system. Internal tank face should be clear, without sludgy deposits.
Pay attention to that at the hydraulic system the mounting of the following filter elements is provided:
– Реготмас 690А-1-24/19 УХЛ2 ТУ 3689-003-26361511-94 (rated consumption not less 700 l/min, maxi-
mum differential pressure not less 4 bar) – in the oil tank of united hydraulic system;
– Реготмас 631В-1-19 УХЛ2 ТУ 3689-003-26361511-94 (rated consumption not less 160 l/min, maxi-
mum differential pressure not less 9 bar) – at the steering filter of axial-plunger pump pressure line;
– ЭВФ-3-1 ТУ 3689-004-26361511-94 – at the breather of oil tank.
UNDER THE TRUCK UNLOADING WITH DEFECTIVE DUMPING MECHANISM AND USE OF TOWING HAUL-
ER, IT’S REQUIRED ,UNDER THE BED LOWERING, TO DRAIN THE OPERATION FLUID OUT FROM CYLINDER TO
THE HYDRAULIC SYSTEM OF TOWING HAULER, FOR AVOIDING OF OPERATION FLUID OVERFLOW THROUGH
BREATHER UNDER THE OIL TANK OVERFLOW AT THE DEFECTIVE TRUCK.
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Fire-fighting system
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15 FIRE-FIGHTING SYSTEM
The combined fire-fighting system is intended for extinguishing of inflammations of A, B and C danger
grades and for extinguishing of fire on electrical equipment energized up to 1000 V. On customer’s demand
dump truck can be equipped with fire-fighting system with automatic actuation of powder-type fire-fighting line.
15.1 Technical data

Types of fire-fighting agents:
powder-type fire-fighting line ……………...…………………... fire-fighting powder
solution-type fire-fighting line ..………………………………… water solution of chloride calcium
Weight of fire-fighting agent, kg ( + 5 %):
combined .………………………………………………………. 83
powder-type line ………………………………………………... 50
solution-type line ……………………………………..………… 33
Gross weight of fire-fighting system, kg, not more …….….……….. 210
Working gas …………………………………………………………….. nitrogen or air
Gas cylinder volume, dm3, not more:
powder-type line…………………………………………….…... 8
solution-type line………………………………………………… 7
Gas cylinder pressure in powder- and solution-type lines, MPa ….. see table 15.1
Working pressure in system tanks, МPа, not more ………………… 1,2
Distance of ejection, m, not less:
solution ..………………………………………………………… 10
powder..…………………………………………………………. 4
Period of fire-fighting agent ejection, s, not more:
solution ..……….………………………………………………… 60
powder ………..…………………………………………………. 60
Length of the solution-type line flexible pipe, m, not less …………. 15
6
Supply voltage of remote actuation device, V 24
4
Current consumption, А, not more:

in operating mode ……….……………………………………... 0,5
In system actuation mode ……………………………………... 10
Actuation:
powder-type line……………………………………………….... remote, manual
solution-type line………………………………………………… manual
15.2 Design and principle of operation

The fire-fighting system comprises two independent lines – powder-type line I (See Fig. 15.1) and solu-
tion-type line II, which can be actuated both simultaneously, and separately. The powder-type fire-fighting line
is intended for fire extinguishing in engine compartment, fuel and oil tanks.
The device for remote actuation control comprises control unit 9, remote actuation console 10 and
locking-starting head with pyrocartridge, installed on gas cylinder 12 of powder -type fire-fighting line.
Remote actuation device provides:
– monitoring and warning of remote actuation console and pyrocartridge line fault;
– voltage presence signaling;
– actuation of powder-type fire-fighting line at pressing control unit button from cab, or at pressing re-
mote actuation console button from land when dump truck is not running.
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Figure 15.1 – Combined fire-fighting system:

1 – powder tank; 2 – bolt; 3 – filling neck; 4 – powder pipeline; 5 – spraying contour; 6 – membrane fuse; 7, 15 – gas pipelines;
8, 14 – reducers; 9 – control unit; 10 – remote actuation console; 11 – wires; 12, 13 – gas cylinders; 16, 18 – hoses; 17 – reel;
19 – locking device; 20 – intake; 21 – solution tank;
I – powder-type fire-fighting line; II – solution-type fire-fighting line
In locking-starting head (See Fig. 15.2) gas make from cylinder is locked by membrane 15. Primer 4
serves for holding pyrocartridge 3 and current supply. Wire 5 "+" is connected to central terminal and wire 6 "–"
is connected to case.
At pressing of electric start-up button voltage is applied on pyrocartridge 3, pyrocartridge operates and
powder gases displace piston 13 downwards, membrane 15 gets broken and gas from bulb 12 (see Figure
15.1) passes through reducer 8, then through gas pipeline 7 it moves in powder tank 1 where it effects the
powder. Gas suspension of dust under pressure of 1,2
МPа, tearing membrane fuse 6, which serves for pre-
vention of steam penetration from atmosphere, is eject-
ed through powder pipeline 4 into the engine compart-
ment and on fuel and oil tanks.
The system can be actuated manually. In order to
do that pull out the cotter on locking-starting head 9 (see
Figure 15.2) and push the bar 10. Rod 11 moves down-
wards, pushes piston 13, membrane 15 gets pierced
and gas moves in powder tank.
Filling of tank with powder is performed through
corresponding bore on case of tank. In order to prevent
clogging of powder-type fire-fighting line canals, the size
of powder lumps should not exceed 2 mm.
Figure 15.2 – Locking-starting head:

1 – valve; 2 – bolt; 3 – pyrocartridge; 4 – primer in assembly;
5 – wire "+"; 6 – wire "–"; 7 – central terminal; 8 – screw; 9 – cotter;
10 – bar; 11 – rod; 12 – case in assembly; 13 – piston with cutter;
14 – working fitting; 15 – membrane; 16 – case
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Solution-type line serves for fire extinguishing in places outside of powder-type fire-fighting line protect-
ed zone and in places of repeated inflammation. At opening of valve of bulb 13 (see Figure 15.1), gas through
reducer 14 moves into tank 21 with solution of chloride calcium. Over solution the pressure of 1.2 МPа is cre-
ated, the pressure displaces solution in intake 20 and hose16. Solution is ejected at pressing of locking device
bar 19 to given direction on distance up to 10 m.
15.3 Safety requirements

Operators of dump trucks and persons which are carrying out preparation of fire-fighting system to opera-
tion, performing maintenance and repair of system, should be guided by fire-fighting system operation manual,
“Rules for Construction and Safe Operation of bulbs working under pressure”, “Rules of engineering safety at
operations on load electrical equipment with voltage up to 1000 V”, and following instructions:
– it is forbidden to use solution-type line for suppression of fire on energized electrical equipment and
spillages of fuel and oil;
– it is forbidden to power up powder-type fire-fighting line if there are people inside the protected zone;
– at hit of solution in eyes carefully wash eyes with water;
– at filling of system with powder use personal protective equipment to protect upper airways;
– gas cylinders and tanks for fire-fighting agent should be subjected to water tests once in five years.
At mounting and maintenance of gas cylinders it is necessary to observe following precautions:
– impacts on bulb, locking-starting head and valve and falling of bulbs are not permitted;
– bulbs with compressed gas should not be exposed to direct heat by heat sources;
– after filling of bulb with valve install choke plug on working fitting;
– on bulbs with locking-starting head cotter that protects bulb from exposure at accidental pressing of
head bar should be installed permanently;
– valve of bulb, cotter of bulb with locking-starting head, reducers, control unit and remote switching-on
console should be sealed up;
– choke plug is supposed to be removed from working fitting of bulb only after mounting on dump truck
directly prior to connecting sleeves to them;
– storage and transportation conditions should meet demands of Rules for Construction and Safe Oper-
ation of bulbs working under pressure.
15.4 Maintenance
The tank of powder-type fire-fighting line is filled with powder. Prior to beginning of operation of dump
truck fill tank of solution-type line with solution of chloride calcium, loosen powder, check pressure of gas in
cylinders, vent powder pipelines and pipe ducts, install pyrocartridge (included in spare parts kit) in locking-
starting head of bulb.
Daily maintenance.
– shiftly perform external examination of the system. During visual inspection test reliability of threaded
connections, presence of seals on bulbs, reducers, control unit and remote actuation console.
– wash solution tank intake, vent powder pipeline and pipe ducts, and apply gas to clean powder (air or
nitrogen) under pressure of 0.5 – 1,2 MPa;
– test pressure of gas in bulbs and if necessary recharge them;
– check the density of aqueous solution of calcium chloride of sprinkler solution line.
In order to perform washing of solution tank intake unscrew hose 16 (see Figure 15.1) from solution
tank 21 and take out intake 20. Wash intake, install it back on its place and connect hose.
In order to perform venting of powder pipeline 4 and pipe ducts disconnect them from tank 1 and
connect with source of compressed gas. Open valve and make sure that there is a gas make from bores of
pipe duct. Disconnect powder pipeline from source of gas and connect powder pipeline with tank, having pre-
liminarily made sure that membrane fuse 6 is installed in its place.
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Loosening of powdering.
Procedure of operation:
– disconnect reducer 8 from gas cylinder 12;
– disconnect powder pipeline 4 from tank 1 and take out membrane fuse 6;
– install on place of membrane choke (included in spare parts kit). Connect with tank powder pipeline 4;
– turn out bolt 2 of filling neck 3;
– connect reducer 8 with bulb containing compressed nitrogen or air under pressure of 2 – 15 MPa;
– open valve of bulb up to exit of dust from bore of filling neck 3. If air with dust from bore of neck does
not go out define reason and eliminate failure;
– switch off feeding gas and after gas make is over from filling neck disconnect bulb from reducer;
– connect reducer 8 with bulb 12 of powder-type fire-fighting line, turn on filling neck bolt 2, disconnect
from tank powder pipeline, remove choke, install membrane and connect powder pipeline 4.
For inspection of pressure in bulb with valve unscrew from bulb cap nut of reducer and connect
measuring device (included in spare parts kit). Open valve of bulb and define pressure of gas on manometer of
measuring device. Enclose valve on bulb and, having pressed button release gas from measuring device. Dis-
connect measuring device and connect reducer to bulb. At misfit of pressure of gas recharge bulb up to pres-
sure specified in technical data. Recharging of bulbs with air or nitrogen is to be performed with corresponding
compressors or from transport bulbs up to pressure specified in table 15.1.
For inspection of pressure in bulb with locking-starting head unscrew from bulb cap nut of reducer and
to screw choke on working nipple 14 (see Figure 15.2) head. Unscrew from head fuse 4 take out pyrocartridge
3 and disconnect ‘minus’ wire 6. Take out bulb from basket and fix horizontally valve 1 downwards in special
device or bench screw. Turn out bolt 2 and turn manometer (included in spare parts kit). Define pressure of
gas on manometer. Turn out manometer and turn against stop bolt 2. Install bulb in basket, remove choke from
working nipple 14 and connect reducer. Insert pyrocartridge 3, turn fuse 4 and connect ‘minus’ wire 6.
At misfit of pressure of gas recharge bulb up to pressure specified in technical data. Recharging of bulb
with locking-starting head is to be performed on specialized factories.
Table 15.1 – Operating pressure in bulbs depending on ambient temperature

Operating pressure in bulbs, МPа
Ambient temperature, 0С
minimal maximal
Minus 55 9.0 10.0
Minus 50 9.5 11.0
Minus 40 9.7 11.3
Minus 30 10.0 11.6
Minus 20 10.3 11.9
Minus 10 10.6 12.3
0 11.0 12.7
10 11.3 13.1
20 11.7 13.5
30 12.1 14.0
40 12.5 14.5
50 13.0 15.0
Charging of gas cylinders with valve is performed in the following sequence:

– disconnect reducer 14 (see Figure 15.1) from bulb 13;
– connect bulb through gas pipeline 4 (See Fig. 15.3) with T-connector 3, and T-connector to transport
bulb 1;
– connect measuring device 5 with T-connector 3;
– open valves of transport 1 and charged 2 bulbs;
– at reaching pressure (monitoring on manometer of measuring device 5) according to table 15.1, for
corresponding ambient temperature enclose valves of transport and charged bulbs. Having pressed button re-
lease residual gas from measuring device. Disconnect gas conduit 4 from T-connector 3. Screw choke on
working nipple and seal up bulb.
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Figure 15.3 – Scheme of charging bulb of fire-fighting system from

transport bulb:
1 – transport bulb; 2 – small-displacement bulb; 3 – T-connector;
4 – gas pipeline; 5 – measuring device
Check density of the calcium chloride water solution.

Density of chloride calcium water solution should correspond to data of table 15.2. Density (mass densi-
3
ty) of chloride calcium water solution is to be checked by areometer with margin error of + 0,005 g/cm .
Table 15.2 – Freezing temperature of chloride calcium water solution

Content of chloride calcium in 100g of
Mass solution strength (at 150С), g/cm3 Freezing temperature, 0С
water, g
1,13 Minus 10 17.5
1,19 Minus 20 27.5
1,24 Minus 30 34.0
1,27 Minus 40 38.0
1,275 Minus 45 39.0
1,28 Minus 50 42.0
1,285 Minus 55 42.7
If by results of measurement density of chloride calcium water solution does not correspond to the val-
ues specified in table 15.2 replace solution or finish density with maintenance of dump truck required depend-
0
ing on climatic region. Solution with freezing temperature minus 50 С is to be prepared at rate of 42 kg of an-
hydrous chloride calcium on 100 l tap water, and for other temperatures – according to table 15.2. In a day so-
lution is to be carefully mixed and it is necessary to measure its density: it should correspond to data of table
15.2. Shelf life of solution is unrestricted. In filled in solution there should not be mechanical admixtures with
size of more than 2 mm. Filling of tank with solution is made through any of bores on case of tank.
If it is detected during operation, that fire-fighting agent is not ejected from tanks; this fault can be elimi-
nated through following operations:
– test pressure of gas in bulbs. If necessary charge bulbs or replace them;
– vent powder pipeline and pipe ducts;
– perform loosening of powder;
– test whether the solution in tank of solution line has frozen. If necessary, replace solution.
If on control unit LED "Failure" is lighted it is necessary to test wires and joints of device of remote ac-
tuation control.
AT OPERATION AND MAINTENANCE OF FIRE-FIGHTING SYSTEM IT IS NECESSARY TO BE GUIDED ALSO
BY OPERATION MANUAL SUPPLIED WITH SYSTEM.
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15-6
Operation features
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16 OPERATION FEATURES
16.1 Running-in of dump truck

During initial stage of dump truck operation there is wear-in of surfaces of rubbed pairs of units and sta-
bilization of conditions of their lubrication. Reliability and longevity of units and systems depends on quality of
wear-in of surfaces of parts.
Duration of running-in of dump trucks is 100 motor-hours (about 1000 km of run).
Before beginning of running-in it is necessary:
– check technical condition having paid attention on torquering of all external thread fastening joints;
– check oil level in units, aggregates and systems, fuel in the tank and coolant in cooling system, and al-
so check presence of grease in units of friction according to list of used lubricants.
For period of new dump truck operation following limitations are inducted:
– maximum speed of riding should not exceed 35 km/h;
– dump truck should be operated on hard-surface roads;
– pay load of dump truck should be of 75 % from nominal one.
In initial stage of running-in of dump truck it is necessary:
– to observe thermal operation mode, not supposing excessive heating of engine, reducers of motorized
wheels and haul electromotors;
– to inspect and tighten threaded joints periodically, paying special attention on fastening of wheels,
units of steering, braking systems, diesel-generator set, propeller shaft and electric machines.
After finishing of running-in it is necessary to execute operations foreseen through 500 operation hours
(Maintenance 2, see "Maintenance" section) and to replace oil in reducers of motorized wheels.
16.2 Engine starting
Before start the engine it is necessary to perform all operations, foreseen in section “Daily maintenance”.
Set all the switches on the instrumentation board in the position “OFF”.
Connect negative terminals of storage batteries to “ground”, having pushed the button of switch, mount-
ed on the instrumentation board.
0
If temperature of ambient air is lower than 5 С heat coolant of engine pre-heater, and fuel – with electric
heater up to temperature recommended in Engine operation manual.
Switch off pre-heater of coolant and electric heater of fuel if they have been switched on.
Insert key into lock-switch against stop. After long parking of dump truck and after maintenance pump
fuel system with fuel for removal of air from it, having pushed the button of switch of fuel pump.
0
Turn key on 90 : electromotor of fuel pump and, at reaching of defined pressure of lubrication system,
electromagnet of pneumatic starter actuation are switched on. The engine gets started.
Details of the engine start-up and shut-down are described in «Low-voltage electrical equipment» chap-
ter.
After the engine is started, release key of lock-switch and it will return to initial position.
Warning lamps of emergency condition of system should not light up. Warning lamp signaling on actua-
tion of parking braking system should light up blinking.
Install heightened speed of crankshaft by cutout switch of adjuster of engine speed on instrumentation
panel or by hand lever of manual control of fuel supply in order to avoid coking of jet nozzles dispersers, and
warm up engine idling during three-five minutes at speed of approximately 1000 rpm. Long operation (over ten
minutes) with low revolutions results in clogging with coke of jet nozzles and piston rings.
16.3 Starting from place, acceleration, riding of dump truck

Set minimum stable speed of engine crankshaft by switching-off adjuster of heightened revolutions or re-
turn hand lever of manual control of fuel supply in home position.
Connect switch of electric drive to power supply circuit of haul electric drive control, and switch of re-
verser set in "Forward" or "Back" position depending on motion direction.
Give signal about beginning of motion and, simultaneously smoothly augmenting by motion treadle fuel
supply, switch off parking braking system. Dump truck will start moving.
Speed of motion is set by operator depending on angle of motion treadle position.
16-1
Operation features
75135-3902015 IM
To slow down dump truck reduce speed of crankshaft, having released motion treadle. If treadle is set in
zero position, power circuit of haul mode is disconnected and stops torque transfer to driving wheels, dump
truck goes in running-out mode.
When speed of dump truck motion exceeds admissible one, the haul mode of electric drive automatically
is set to the mode of electric braking operation and warning lamp lights up on instrumentation panel. For con-
sequent turning on power circuit of haul mode it is necessary to release motion treadle in zero position and
press it again (so long as dump truck speed is reduced approx. up to 30 km/h).
Haul electric drive comprises safety device:
– at exceeding of admissible value of voltage in power circuit;
– at exceeding of admissible value of current in power circuits;
– at exceeding of admissible value of current of armature circuits of haul motors;
– at short-circuit of rectifiers;
– at skidding of motorized wheels;
– at reversing of dump truck in regime of augmented electric braking operation;
– at exceeding of admissible values of temperature of electrical equipment.
At actuation of above mentioned safety devices program control unit receives corresponding signal and
unit shuts down circuit of excitation of haul generator and power circuit; on instrumentation panel warning lamp
of safety device actuation is powered up.
For consequent turning on of haul electric drive it is necessary to release motion treadle in zero position
and push button F5 on the display board (seek details in the electric drive manual).
16.4 Braking and shut-down of dump truck

For braking of dump truck or maintenance in defined rate limits of its riding speed on slopes release mo-
tion treadle and press treadle of auxiliary braking system (electric brake).
For motion with constant speed in condition of electric braking it is necessary to turn on switch of braking
mode on instrumentation panel, thus warning lamp on panel of display is powered up.
Speed of motion is set by operator depending on angle of electric brake treadle position.
To increase the efficiency of electric braking while riding in zone of low speeds and ensure braking up to
dump truck full stop it is necessary to press motion treadle repeatedly.
Emergency shut-down of dump truck is realized by service braking system, simultaneously with service
braking system it is allowed to use auxiliary brake.
It is inadmissible to operate dump truck with out-of-order auxiliary braking system as slowing down on
slopes with service braking system will result in excessive heating of disks, intensive wear of linings.
Use braking systems carefully, keeping track of road conditions.
After full stop of dump truck release motion treadle, then treadle of electric braking and brake dump
truck with parking brake.
Disconnect by switch on instrumentation panel control circuit of haul electric drive, and set switch of re-
verser in neutral position.
If dump truck is on parking site, enclose thrust blocks under wheels.
16.5 Engine shut-down

Prior to engine shut-down after operation at full load let engine to operate during three - five minutes at
low idle speed mode. After that shut-down engine, having pressed cutout switch of engine shut-down on in-
strumentation panel.
DO NOT SHUT-DOWN ENGINE UNDER LOAD OR RIGHT AFTER REMOVAL OF LOAD AS THIS CAN CAUSE
ENGINE FAILURE.
16.6 Towing of dump truck

In case of failures arising, which cannot be eliminated at the operation site, the dump truck is to be
towed to the workshop.
For dump truck towing use towing haul truck BELAZ-74242.
Depending on failure tow the dump truck holding its front side or rear side as it is shown in figure 16.1.
In case of towing dump truck when it is hitched to its front side, it is necessary to unbrake the gear of
parking braking system.
16-2
Operation features
75135-3902015 IM
Towing with hitching to rear cross bar of body is made in extreme cases on short distances. In this case
steerable wheels of towed dump truck should be set in position corresponding to forward motion.
Body of towed dump truck should be completely unloaded.
Maximum force to hitch-mechanism of haul truck should not exceed 41000 kg.
AT UNLOADING OF DUMP TRUCK WITH OUT-OF-ORDER DUMPING MECHANISN WITH USE OF HEAVY
HAULER IT IS NECESSARY, AT LOWERING OF THE BODY, TO PERFORM DRAINING OF WORKING FLUID FROM
CYLINDERS INTO HYDRAULIC SYSTEM OF HEAVY HAULER IN ORDER TO EXCLUDE OVERFLOW OF WORKING
FLUID THROUGH BREATHER AT OVERFLOWING OF OIL-TANK OF OUT-OF-ORDER DUMP TRUCK.
Figure 16.1 – Scheme of towing of dump truck with heavy hauler
16.7 Installation of jacks

At maintenance, replacement of wheels, repair it is recommended to use jacks.
Jacks should be installed by end plate on rigid grounding.
After lift of dump truck by jacks and tear of wheels from surface of land it is necessary to put dump truck
on bearing parts (bearing parts should be designed to support corresponding weight).
Before replacing wheels it is necessary to install dump truck on flat horizontal platform to apply parking
brake and to put thrust blocks under wheels.
At lifting of front of dump truck it is necessary to use two jacks with capacity of not less than 25 t.s.
Jacks should be installed symmetrically to direct-axis of dump truck under beam of front axle.
At lifting of rear of dump truck it is necessary to use two jacks with capacity of not less than 40 t.s.
Jacks should be installed symmetrically to direct-axis of dump truck under crankcase of rear axle.
Schemes of jacks installation are shown in figures 16.2 and 16.3.
Figure 16.2 – Installation of jacks for rise of front of dump truck:

1 – grounding of jack; 2 – jack; 3 – bearing part
16-3
Operation features
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Figure 16.3 – Installation of jacks for rise of rear of dump truck:

1 – grounding of jack; 2 – jack; 3 – bearing part
16-4
Technical maintenance
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17 TECHNICAL MAINTENANCE
17.1 Types and periodicity of maintenance

For maintenance of a dump truck in constant technical readiness and prevention of an intensive wear of
details while in operation it is necessary to execute periodically in prescribed terms maintenance operation of
units and systems.
The following types and maintenance rate are recommended:
- daily maintenance (DM);
- maintenance in every 250 hours of the engine operation, but not later than after 4000 - 5000 km of the
dump truck run (Maintenance -1);
- maintenance in every 500 hours of the engine operation, but not later than after 8000 - 10000 km of
the dump truck run (Maintenance -2);
- maintenance in every 1000 hours of the engine operation, but not later than after 16000 - 20000 km of
the dump truck run (Maintenance -3);
- seasonal maintenance (SM), which is performed while preparing of dump truck for spring – summer or
autumn – winter operational conditions. Seasonal maintenance is to be combined and performed with sched-
uled maintenance.
Prior to maintenance performing thoroughly remove dirt and wash dump truck. Before washing protect
tightly the cabinets with power and starting regulating equipment, protect with special shields and screens from
ingress of moisture the air inlets and air vents of electrical machinery, as well as air inlets of air filters.
Perform washing and cleaning operations observing prescribed safety and electrical safety rules.
Perform maintenance avoiding dirt and dust ingression onto the mating surfaces, into units and mecha-
nisms.
Maintenance operations list including control, washing, fastening and adjusting operations is indicated in
table 17.1
Table 17.1 – List of maintenance operations
Gears, tools, and devic-

The operations content and procedure of
N Technical requirements es necessary for opera-
executing
tions execution
DAILY MAINTENANCE
1 Check the level and, if necessary, fill up oil into In accordance with engine operation manual
the engine pan
2 Check the level and, if necessary, fill up coolant Overflow bottle of cooling system on the truck
into the engine cooling system BELAZ-75135 should be filled with coolant up to
the lower pipe butt of filler neck
3 Check the level and, if necessary, fill up fuel in- Pour up to the maximum level
to the tank
4 Drain residue from the tank Residue should be drained in 30-40 minutes af-
ter fueling until pure fuel appears
5 Check the level and, if necessary, fill up opera- The level should not be higher the middle of up-
tion fluid into the oil tank of united hydrosystem per eyelet when pneumatic hydroaccumulators
are discharged, and not lower the middle of low-
er eyelet when, pneumatic hydroaccumulators
are charged (after the engine is started up). See
section “Maintenance of dumping mechanism”
6 Check the level and, if necessary, fill up fluid in- Pour up to the maximum level
to the tank of windshield washer
7 Check the level and, if necessary, add anti- Defroster is primed with antifreeze only when
freeze into the reservoir of pneumatic system the ambient temperature is below 5 0С. See the
defroster section “Pneumatic system maintenance”
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Continuation of the table 17.1

Gears, tools, and devices
N Technical requirements necessary for operations
executing
execution
8 Make sure in the absence of leakages of fuel, Leak and dribble of fuel, coolant, engine oil and
cooling fluid, motor oil. Check by sight the operation fluid of hydrosystem are not admitted
state and fastening of pipes and hoses of
united hydrosystem
9 Check by external examination the lack of flam- If required clean the truck from flammable mate-
mable materials on the external faces of units rials: dribble of combustive-lubricating materials,
and parts coal dust, etc.
10 Check by visual examination the state of Collecting hatch covers and cabinet doors
locks and sealants of collecting hatches, should be closed and tightly fitted along the
sealants of hardware cabinet door, state, lay- whole perimeter. Leading-out wires and cables
ing and hookup of leading-out wires and ca- should be snagged, shouldn’t have insulation
bles of haul electric drives faults and mechanical damages
11 Check by visual examination the state, laying Damage of wires and cables insulation, loosen-
and hookup of wires and cables of low- ing of its fastening is not admitted
voltage installation
12 Check visually condition of electric motor- As the leakage occurrence over cups define the
wheel cups reasons of faults and repair the unit
13 Check the state of air ducts of ventilating sys- Soft hoses of air ducts shouldn’t have tears.
tem and of haul electric drive cooling While motor operating the air should outlet from
the vents of electric motor wheels
14 Check by visual examination the attachment All parts should be snagged. Cracks on parts
of bars, suspension cylinders, arm hinges and welds are not admitted
15 Shiftly, up to tightening torque stabilization, See the tightening torque at the appendix A Kit of wrenches
check the tightening of the most important
threaded joints of suspension
16 Check by visual examination the state of sus- See section “Suspension maintenance”
pension cylinders
17 Check the air pressure in tires See section “Wheels and tires maintenance” Manometer
18 Daily, before departure, check by visual exam- See tightening torques at the appendix B Kit of wrenches
ination the state of wheels fastening and, if
necessary, tighten nuts
19 Check by visual examination the state of fas- Parts should be snagged. Bolts and nuts should Kit of wrenches
tening of turning cylinders, arms and steering be tightened up to stop. See torques at the ap-
link pendix A
20 Check the state of welds and turning cylinder Cracks, bends and other damages are not ad-
brackets, arms and steering link mitted
21 Check by visual examination the fastening of Parts should be snagged. Bolts and nuts should Kit of wrenches
service and parking brake systems mecha- be tightened up to stop. Castellated nuts should
nisms be splinted. See torques at the appendix A.
Brake mechanisms shouldn’t have mechanical
damages, cracks and leakage of working fluid
22 Daily before departure check visually the See section ”Front axle maintenance”
condition of welds of front axle beam end-tips
23 Clean cab windows, headlamps, front and Rag, brushes
rear headlights, side blinkers, rear-view mir-
rors
24 Check the voltage of storage batteries before The voltage should be not lower 24V The voltmeter on the in-
motor start strumentation panel in cab
25 Link up “ground”. Check the serviceability of At pushing button of pilot lamps block all the op-
pilot lamps, inspection tool, illumination ele- erative lamps should light up
ments, light and sound signaling
26 Start up the engine. Make sure engine system The motor should operate stably on the whole
are in order. Check on the move the serviceabil- motor speed. Controls, brake systems, illumina-
ity of steering, brake systems, lighting and sig- tion and signaling systems should be operative
naling systems
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executing
execution
27 Check the serviceability of emergency steering See section “Steering maintenance”
drive
28 Check the operation of windshield wiper and Fluid jet should be hit into the upper section
washer zone circumscribed by windshield wiper brush
29 Check up level of air filter loading by pilot If the pilot lamp lights up, carry out maintenance
lamp on facia of filters
30 Check air-tightness of pneumosystem See section “Pneumatic system maintenance”
31 Check and, if necessary, adjust the pressure See section “Pneumatic system maintenance”
of compressed air in the pneumatic system
32 Daily after the shift drain the condensate from After condensate is completely drained, fill the
receivers of pneumatic starter and from system once more up to the actuation of pres-
pneumatic system receiver sure regulator and only after that stop the motor
33 Shiftly, examine the sprinkler system During the examination check the reliability of
threaded joints of powder duct and presence of
seals on cylinders
34 Carry out visual examination of centralized See section “Maintenance of centralized self-
self-lubrication system lubrication system”
MAINTENANCE 1 (M-1)
1 Carry out all operations of daily maintenance
2 Clean the truck from dirt and wash Carry out washing only having placed protective Washing gadget, shrouds:
shrouds. After the washing take off the shrouds 1. 549-3922010 – protec-
and check the absence of power circuit closing tive shroud of traction al-
to the body. For that start engine and switch on ternator
the power circuit at the braked truck. If the pilot
2. 549-3922030 – protec-
lamp lights up, eliminate the closing. Blow out by tive shroud of exhaust pipe
compressed air the hardware cabinets
3. 7513-3922020 – protec-
tive shroud of air inlet
4. 75211-3922140-10 –
shroud of brake resistors;
5. 7512-3922050 – protec-
tive shroud of synchronous
generator
3 Wash the filter of fuel heater See section “Engine systems maintenance” Kit of wrenches, bath for
washing, hair brush
4 Clean from dust the cyclones and bodies of See section “Engine systems maintenance” Kit of wrenches, lighting
air filters. If necessary replace filter elements device while checking of fil-
ter elements integrity
5 Check the fastening of resistor blocks, the re- Before checking up blow the resistor units by dry
liability of resistor fastening in brake units, the compressed air
reliability of air cooling elements fastening
6 Check the state and operation of the drive of The drive pedal should move free, without jam-
fuel supply control ming. The pedal moving should support the
change of motor speed on the idling from mini-
mum to maximum
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executing
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7 Clean the dust baffles and monocyclones of
air ducts of ventilation system and of haul mo-
tor cooling system, paying attention to that
splits for dust fall are not clogged
8 Clean magnets, mounted in drain pipes of See section “Electric motor-wheel maintenance”
motor-wheels reducers, of metal dust. Check
oil level in the reducers
9 Take a sample of oil from reducers of motor See the order of analysis realization at the ap-
wheels for analysis pendix B
10 Disassemble the thrust-breathers of motor wheel Kit of wrenches, bath for
reducers and wash filter packing washing
11 Clean from dirt the drain ports at the lower
part of the rear axle casing
12 Check up the integrity of hoses and hose Hoses and hose pipes, which have leaks, swell- Kit of wrenches
pipes of united hydrosystem, as well as their ing, bursting and loss of elasticity, are to be
fastening. Tighten the loosened hose fas- changed
tening and the bolts of flange attachment to
the pumps
13 Check cardan shafts fastening and backlash- While cardan shaft shaking by hand any back- Kit of wrenches
es in hinges lash is not to be felt
14 Check up the nitrogen pressure at the pneu- See the order of pressure checking and nitrogen Kit of wrenches, survey de-
matic hydroaccumulators of steering and charging “Maintenance of brake systems” vice 540-3830390-10, nitro-
brake system, if necessary bring up to norm gen cylinder, charge device
531-3924370-10
15 Tighten the fastening joints of suspension: See the tightening torques at the appendix A Kit of wrenches
1. bolts and nuts of lugs fastening of central
hinges o front and rear suspension to the
arms;
2. bolts of finger fastening of front suspension
central hinge;
3. nut of finger fastening of rear suspension
central hinge;
4. bolts of bearing cups fastening of central
hinges of front and rear suspension;
5. bolts of fastening of front suspension rod
pins;
6. bolts of fastening of pressure plates to the
pin of cross bars of suspension
16 Tighten the fastening joints of steering: See the tightening torques at the appendix A Kit of wrenches
1. nuts on the conic pins of turning cylinders;
2. bolts of fastening of steering trapezium link
fingers;
3. nuts of clamping joints of turning cylinder
tips and steering trapezium link ;
4. nuts of fastening studs of steering link arms
17 Check the free running of steering wheel, Free running of the steering wheel should be not Kit of wrenches, manometer
gaps at the hinges of link and turning cylin- more 25о. If the free wheeling is more, eliminate , gap gauge 8704-6005
ders of steering trapezium the gaps at the steering hinges and tighten the
weakened fastening
18 Tighten the fastening nuts of front and rear See the tightening torques at the appendix A Kit of wrenches
wheels .The nut weakening is not permitted
19 Check the wear-out of the brake mechanism The change of brake linings is carried out under the
linings of front and rear wheels, and if neces- wear-out of friction material up to the retained thick-
sary replace the linings ness less 10 mm
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executing
execution
20 Check the gap between brake disk and linings See section “Maintenance of brake systems”
of service and parking brake systems, if neces-
sary tune
21 Check electrolyte level in storage batteries Prior to inspection, clean storage batteries by 10% liquid ammonia solu-
and if necessary bring it to normal one. Clean rags, wet in 10% liquid ammonia solution. Elec- tion, glass tube with 3 - 5
ventilation holes in the batteries plugs trolyte level should be by 10 - 15 mm higher than mm diameter, rubber sy-
level of safety ledge ringe
22 Carry out the haul motor maintenance opera- See the documentation on haul drive
tions
23 Carry out the engine maintenance operations According to the motor operation manual
24 Carry out lubrication operations See section “Lubrication of the truck” and chap- Lubrication equipment
ter “Operational materials“
MAINTENANCE 2 (M-2)
1 Perform all operations maintenance 1
2 Check the state of fastening of all aggregates All aggregates should be snagged Kit of wrenches
to the motor, of diesel generator to the frame.
If required tighten the fastening joints
3 Check the fastening of cooling system radia- Radiators should be snagged Kit of wrenches
tors to the frame and if required tighten, clean
the external radiator faces
4 Extract the torsion shaft as assembly with sun Under the detection of pitting, wear-out marks Kit of wrenches
gear and check by sight their state measure the controlled variables of parts accord-
ing to the repair manual
5 Check and if required tune the gap between See section “Electric motor-wheel maintenance” Kit of wrenches
the torsion shaft and rest
6 Examine by sight the cracks presence at the In case of cracks detection on the reducer body
zone of: of electromotor wheel – replace body, on the
1. joint of the back axle housing with the re- back axle housing – dress the cracks and weld
ducer of motor wheel;
2. welding of the arm flange of back axle
housing;
3. welding of the lower bracket of torque arm
7 Tighten the fastening joints: See the tightening torques at the appendix A Kit of wrenches
1. the bolts of fastening of upper and lower
cylinder foot of front suspension;
2. the nuts of spherical bearings of front and
rear suspension;
3. the bolts of traction motors fastening to the
reducers of electro motor wheels;
4. the bolts of motor wheels fastening to the
back axle housing
8 Examine the state of welds of suspension There shouldn’t be cracks. Weld discovered
bracket and check the state of welded joints cracks
of frame and platform
9 Check the oil level at the casings of suspen- See section “Suspension maintenance”
sion cylinder. If necessary pour up to the level
of control plug
10 Check the suspension cylinder charging by See section “Suspension maintenance” Characteristic line
gas and if necessary charge 7513-3924130, balloon with
nitrogen, adaptation
531-3924370-10
11 Wash the filter element of filters of steering, Under the detection of faulted filter elements re- Kit of wrenches
brake and dumping gear mounted at the place them
pressure line of impeller pump
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executing
execution
12 Replace the filter elements at the oil tank, at the Kit of wrenches
tank breather of united hydrosystem, the filter
element of steering filter mounted at the pres-
sure line of axial-plunger pump
13 Check the compactness of pedal roller abutment Under the lifted up to stop into the adjusting screw Kit of wrenches, probe
to the pusher of control tap of service brake sys- pedal, the roller should abutted on pusher, at that
tem not causing its moving
14 Check the electrolyte density at the storage bat- See section “Maintenance of electric equip- Areometer
teries. If necessary, restore the electrolyte den- ment”
sity and charge batteries
15 Tighten the tips fastening to clamps and fas- Kit of wrenches
tening of storage batteries
16 Check the accuracy of headlamp lights control See section “Maintenance of electric equip- Screwdriver, kit of wrench-
and fastening of lighting devices and warning ment” es, shield
lights
17 Tighten the cabin and empennage fastening All elements should be safely fastened Kit of wrenches
18 Clean filter of cabin air intake
19 Carry out the operations of haul electric drive See documentation on haul motor
maintenance
20 Carry out the operations of engine maintenance According to the engine operation manual
21 Perform lubrication operations See section “Lubrication of the truck “ and Lubrication equipment
chapter “Operation materials”
MAINTENANCE 3 (M-3)
1 Carry out all operations maintenance 2
2 Check the fastening of traverse and brake con- Tighten the loosened joints
trollers
3 Check the state of rubber shock absorbers of Shock absorbers, which have rubber peeling Kit of wrenches
diesel generator or its delamination from metal, should be
changed
4 Check the rotation speed of steering wheel at the See section “Steering maintenance” Stop watch or watch with
extreme positions of steering wheels (“sliding”) second hand
5 Tighten the bolts of fastening of front wheels The tightening torques are given at the appendix Kit of wrenches
brake mechanisms and fastening nuts of rear B
wheels brake mechanisms
6 Carry out the operations of engine maintenance In accordance with engine operation manual
7 Carry out the operations of haul electric drive See the documentation on tractive drive
maintenance
8 Carry out lubrication operations See section “Lubrication of the trucks”, chapter Lubrication equipment
“Operation materials”
9 Adjust the toe-in of steerable wheels after dump See section “Steering”
truck reaches the haul of 40 - 50 thousands km
10 Perform the scheduled change of metal-plastic After dump truck reaches the haul of 60 - 70
bushes of suspension cylinders after dump thousands km the probability of operation of
truck reaches the haul of 60 - 70 thousands km suspension cylinder spherical bearing at the
mode “Steel along steel”
11 Perform the scheduled replacement of bearings See repair manual 7513-3902080
of motor wheel first row satellites after dump
truck reaches the haul of 150000 km
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executing
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SEASONAL MAINTENANCE (SM)
1 Check the serviceability of ball hinges of gas In case of jamming remove the ball hinges, Kit of wrenches, hog, fluid
exhaust system (the hinges should be rotated dismantle and clean the hinge parts faces from for scale eliminating
by hand) scale
2 Check abutment of spring bay of exhaust sys- In case of bay loss of mobility or its play on
tem sealing device to body exhaust gas intake springs it is necessary to disassemble sealing
device and to clean its friction surfaces
3 Wash the fuel tank, fuel pipes and the filter el- Dismantle the fuel tank from the truck. There Kit of wrenches, bath, hair
ement of fuel tank breather shouldn’t be tankage on the bottom and walls brush, washing fluid
of the tank. The filter element should be clear
4 Carry out the maintenance of engine pre-start Clean from the scale glow plug, sprayer and Kit of wrenches, bath, hair
heating system burner, wash the filter of electromagnetic brush, washing fluid, de-
valve, clean the drain port of fuel pump scaling fluid, hog
5 Check the necessity of bearings adjustment of See section “Electric motor-wheel mainte-
electro motor wheels hubs nance”
6 Carry out the adjustment of cone bearings of See section “Front axle maintenance” Kit of wrenches
front wheel hubs
7 Perform the maintenance of moisture separator See section “Pneumatic system maintenance”
8 Wash the tank of united hydrosystem Internal tank face should be clear without
sludgy deposits
9 Carry out the maintenance of storage batteries Lead the electrolyte density in accordance with Areometer, charging unit
and if necessary charge season and charge batteries
10 Remove soot from soot collectors through side Under the uncuped hatches, start motor and Kit of wrenches
hatch operate 5 – 10 minutes up to the soot removal
under the rotation speed 1000 – 1200 min-1
11 Carry out the operations of haul drive mainte- See the documentation on haul electric drive
nance
12 Carry out the operations of engine maintenance In accordance with engine operation manual
13 Carry out the operations of fire-fighting system See section “Maintenance of fire-fighting sys-
tem”
14 Perform the lubrication operations See section “Lubrication of the trucks”, chapter Lubrication equipment
“Operation materials”
15 Once a year under the seasonal maintenance
remove, disassemble, wash the parts and ad-
just the safety valve of pressure regulator of
pneumatic system
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17.2 Lubrication of the truck

Reliability of dump truck units depends on periodicity of rubbing pairs lubrication, grade and quality of
lubricating materials. Using lubricating materials not specified in the “List of used lubricating materials” and ig-
noring of lubricating materials replacement periodicity adversely affects serviceability of units and systems.
Lubricating materials substitutes are allowed for using only at lack of basic brands. When brand
changing remove the previous brand remains completely. Mixing of different lubricating materials brands is not
admitted.
While checking the oil level in units and systems, and while their refilling place the dump truck on hori-
zontal ground surface.
When lubricate through greasers avoid dirt ingression along with grease on mating surfaces. For this
purpose clean place of grease ingression and thoroughly wipe greasers.
Prior to fill tanks with oil clean thoroughly plugs of dust and dirt. Fill tanks from oil-dispensing pumps. If
there is no oil-dispensing pump, use funnel with filtering gauze and clean oil-dispensing reservoirs. Fill dump
truck units with warmed up oil.
Drain waste oil from units being heated. After oil being drained, clean magnets of drain holes plugs.
Lubrication points layout scheme is shown in the figure 17.1, and the list of lubricants for being used is
specified in Table 17.2; the list of service materials for being used depending on ambient temperature is given
in table 18.1; the list of lubricants fit as substitutes is given in table 18.2.
Figure 17.1 – Layout of lubrication points
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75135-3902015 IM
Table 17.2 – List of used lubrication materials

Number of po-
Quantity of lu-
sition at the
Periodicity
figure 17.1
brication
points
Name of the lubrication point Maintenance operation
Lubricant type and brand
(unit, joint, capacity) guidelines
15 Engine КТА 50С In accordance with the engine operation manual
4 Oil tank of united hydraulic sys-

Usage of oils at the hydrosystem and frequency of
tem 1
operations performance can be seen at the section 14 “Dumping gear”
10 Reducers of electro motor Mobilube GX 85W/90A (Mobil) M-1 Check the oil level
wheels 2 Mobilube SHC 75W/90LS Change oil
2500 ч
(Mobil)
– Cups of reducer case of electro Lubricant Литол-24 Add through lubricators in
motor wheel 4 Lubricant Лита M-1 150 g of lubrication into
each cup hole
Substitute: lubricant Фиол-2
8 Suspension cylinders Damping fluid Add fluid under the each
ЛУКОЙЛ-АЖ charging if necessary
Substitutes :
4 Damping fluid M-2
МГП-12;
Damping fluid
ГРЖ-12
–* Spherical bearings of suspen- Lubricant Литол-24 Lubricate through lubrica-
sion cylinders Lubricant Лита tors up to the fresh lubrica-
8 M-2
tion appearance from the
safety valves
–* Central hinges of the front axle Lubricant Литол-24 Lubricate through lubrica-
and back axle suspensions Lubricant Лита tors up to the fresh lubrica-
2 M-1
tion appearance from un-
der compactors
–* Cross bar hinges of front axle Lubricant Литол-24 Lubricate through lubrica-
and back axle suspensions Lubricant Лита tors up to the fresh lubrica-
4 TM-2
der compactors
1 Bearings of front wheels hubs Lubricant Литол-24 Take off hubs, wash bear-
Once a ings and fill lubrication
2 Lubricant Лита
year
2* Bushings of front axle pivot Lubricant Литол-24 Lubricate through lubrica-
4 Lubricant Лита M-2 tors in amount of 0,2 – 0,3
kg for each knuckle lug
12 Cardan shaft hinges of the pump Lubricant № 158М Lubricate through lubrica-
drive of united hydrosystem tors up to the fresh lubrica-
2 M-1
der compactors
11 Spline joint of the cardan shaft of Lubricant Литол-24 Lubricate through lubrica-
united hydrosystem pump drive Lubricant Лита tors up to the fresh lubrica-
1 M-2
tion appearance from the
hole in plug
– Spline joint of the cardan shaft of 1 Lubricant Литол-24 Once a Lubricate by lamina under
steering Lubricant Лита year the assemblage
– Hinges of the steering cardan Lubricant № 158М Once a Dismantle units and fill lu-
2
shaft year brication
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servicing imple-
Number of po-
Quantity of lu-
Frequency of
sition at the
figure 17.1
mentation
brication
points
Designation of lubrication Directions on servicing
Name and grade of lubrication
points (unit, joint, capacity) implementation
3* Hinges of the steering link Lubricant Литол-24 Lubricate through lubrica-

Lubricant Лита tors up to the fresh lubrica-
2 M-2
Substitute: lubricant Фиол-2 tion appearance from un-
der compactors
–* Hinge of turning cylinders of Lubricant Литол-24 Lubricate through lubrica-
steering Lubricant Лита tors up to the fresh lubrica-
4 M-2
Substitute: lubricant Фиол-2 tion appearance from un-
der compactors
– Bearings of steering column Lubricant Литол-24 Once dur- Dismantle the bearings
shaft 2 Lubricant Лита ing 2 components, wash and fill
Substitute: lubricant Фиол-2 years the fresh lubrication
Rests of dumping gear cylinders: Lubricant Литол-24 Lubricate through lubrica-
5* – lower 4 Lubricant Лита M-1 tors up to the fresh lubrica-
Substitute: lubricant Фиол-2 tion appearance from gaps
5 – upper
7* Axles of platform rear props Lubricant Литол-24 Lubricate through lubrica-
2 Lubricant Лита M-1 tors up to the fresh lubrica-
Substitute: lubricant Фиол-2 tion appearance from gaps
– Bearings of electric motor of Lubricant Литол-24 Lubricate through lubrica-
cooling fan of brake plant УВТР 1000 tors. Dismantle and wash
2
hours the bearings components
and fill the fresh lubrication
– Bearings of moving and brake Lubricant Литол-24 – Lubricate under the dis-
controllers 4 Lubricant Лита mantling
13 Bearings of haul generator СГД Lubricant Литол-24 Add through lubricator up
89/38-8 (see the generator op- 1000 to the fresh lubrication out-
eration manual) hours let in the hole on the lower
1 part of bearing cap
12000 hours Change lubrication
or repair
9 Bearings of haul electromotor Lubricant Литол-24 1000
Add through lubricator
ЭК-420 (see the electromotor hours
operation manual) Disassemble bearings,
70-80 thou-
sands of wash and add fresh
2 haul at grease (0.45 kg into each
planned and unit)
out of plan
disassem-
bling
– Defroster Lubricant Литол-24 Dismantle defroster, wash
1 SM parts, dry and lubricate
wear faces
– Plug shoes and connecting pan- Lubricant Литол-24 Lubricate metallic faces by
els of leads of low-voltage instal- 20 – lamina under each disas-
lation sembling
14 Terminal posts of the storage Lubrication Литол-24 – Lubricate by lamina under
batteries Lubrication Лита the batteries installation
Substitute : Фиол-2
4
17-10
75135-3902015 IM
servicing imple-
Number of po-
Quantity of lu-
Frequency of
sition at the
figure 17.1
mentation
brication
points
Designation of lubrication Directions on servic-
Name and grade of lubrication
points (unit, joint, capacity) ing implementation
– Electric motor of priming pumps Lubricant Литол-24 Once a year Dismantle the bearing
2 components, wash and fill
the fresh lubrication
– Bearings of low-voltage genera- See operation manual on generator
2
tor
– Bearings of pneumatic starter 6 See operation manual on pneumatic starter
– Shock-absorber of operator seat Damping fluid – Change fluid after dis-

ЛУКОЙЛ-АЖ mantling or repair of the
1 Substitute : shock absorber
Damping fluid
ГРЖ-12
– Heater cock Lubrication Литол-24 SM (once a Previously having
1 Lubrication Лита year) cleaned lubricate (in au-
Substitute : Фиол-2 tumn)
– Cab door lock Lubrication Литол-24 – Lubricate if necessary
2 Lubrication Лита
– Drive of cab door lock Lubrication Литол-24 – Lubricate if necessary
2 Lubrication Лита
Pins of cab door hinges Lubrications Литол-24, Лита – Lubricate if required
– 6
– Races of balls and rollers of Lubrication Литол-24 – Lubricate if required
the runners of operator seat 2 Lubrication Лита
shifting mechanisms Substitute : Фиол-2
– Roller pins and seat lever runners Lubrications Литол-24, Лита – Lubricate under the dis-
16 Substitute : Фиол-2 mantling and repair of
component
Notes:
1 Sign «*» marks units that are lubricated by centralized automatic lubrication system. If units are lubricated by centralized automatic
lubrication system use lubrication brands, specified in the table 17.3
2 Lubricating materials substitutes are allowed for using only at lack of basic brands. When brand changing remove the previous
brand remains completely. Mixing of different lubricating materials brands is not admitted.
17-11
75135-3902015 IM
17.3 Centralized automatic lubrication system

The centralized automatic lubrication system is intended for lubricating suspension and steering units,
supports of dumping mechanism cylinders, body supports, hinge pivot bushings.
Lubrication systems “LINCOLN” or “VOGEL” are mounted on the dump trucks. Both systems ensure au-
tomatic lubrication of dump truck units and have only slight constructive differences in system units.
17.3.1 Lubrication system technical data

Lubrication systems performances are shown in table 17.3
Table 17.3 – Features of lubrication systems

Parameter value
Parameter, dimensionality
«Lincoln» «Vogel»
Pump:
Operating voltage, V 24 24
Volume of refill capacity, l 8 10
Maximum operating pressure, МPa 35 30
Amount of lubrication outlets 2 2
3
Volume pumping of one pump element, cm /min 2,8 2,5
Control unit:
Set time of pump operation, min 4 4
Set pause time at the pump operation, min 60 60
Used laminar lubrications of type NLGI 2:
Фиол-2, the lubrications indicated at the
Up to the temperature - 25 0С manuals on «Lincoln» or «Vogel»
Лита, the lubrications indicated at the manu-
Under the temperature below - 25 0С
als on «Lincoln» or «Vogel»
Note – it ‘s allowed within spring and summer period to use lubrication Литол-24 of type NLGI 3 with change
of it under the seasonal servicing
17.3.2 Lubrication system arrangement and its principle of operation

The lubrication system consists of the pump (figure 17.2) with reservoir for lubricant and control unit,
safety valves, dosing units, pipelines, button with backlighting on the instrument panel. Dosing units II, III, IV, V
are located on dump truck front axle beam; dosing units I, VI, VIII are located on dump truck frame left spar.
The pump VII is powered up automatically at engine start. From the tank of the pump lubricant passes
through pipe lines to main dosing units IV and VI, from main dosing units it passes to additional dosing units I,
II, III, V, VIII and then to lubrication points. During the pump operation each lubrication point gets certain
amount of lubricant, proceeding from volume filled by lubricant in unit of friction and periodicity of its change. At
the working pump the button signal lamp lights up constantly.
The filling of the tank is performed through a cover or through the priming valve on a pump body. The
filling through the priming valve is more preferable, as the possibility of lubricant contamination is excluded.
The pump driving is carried out from the electromotor located in one case with the pump. Lubricant is supplied
by means of two pumping elements. There are safety valves mounted on pumping elements. They reduce sys-
tem pressure and start working at pressure of 30 – 35 MPa. If lubricant escapes from the valve it means that
the system is blocked. The pump operation time and pause are set by switches based on the pump. There is a
button on the pump to perform additional cycle of lubrication. The additional cycle of lubrication can be effected
by switching on of special button located on instrument panel. To effect the additional cycle of lubrication push
the button on the pump or on instrument panel and hold it pushed during two seconds. The direction of pump
blade rotation is shown by the arrow on the pump tank.
During lubrication system operating and maintenance use attached to systems “Lincoln” or “Vogel” Op-
erational Manuals.
17-12
75135-3902015 IM
Figure 17.2 – Centralized lubrication system chart:

1, 12 – spherical supports of front and rear suspension cylinders; 2 – hinges of turn cylinders; 3, 8 – central hinges of front axle
and rear axle suspensions; 4, 5 –bushings of front axle pivots; 6, 11 – hinges of cross bars of front and rear axle suspensions; 7 – hinges
of steering link; 9 – lower bearings of dumping mechanism cylinders; 10 – axles of the platform back supports
IV, VI –main dosing units; I, II, III, V, VIII –additional dosing units; VII – electric pump with tank;
———— pipes between pump and main dosing units;
– – – – – pipes between additional, main dosing units and lubrication points;
17.3.3 Centralized automatic lubrication system maintenance

At daily maintenance carry out visual inspection of the system
While inspecting, make sure there is no any damage of pump, dosing units, pipelines and lubricants
egress out of joints. Check the lubricant availability in the pump tank and whether lubricant egress out safety
valves. Don’t allow pump tank emptying; fill the tank with lubricant in time. Lubricant level is to be maintained
not lower than mark indicating minimal level in tank. Lubricant is to be clean, without admixtures and bulbs of
air. Otherwise the locking of system can occur. Apply only recommended brands of lubricants. Check regularly
the lubricants supplying to friction units. Lubricant egress out of the valves and backlashes should be visible.
17-13
75135-3902015 IM
IF DURING DUMP TRUCK OPERATION THE UNIT LUBRICATED BY LUBRICATION SYSTEM WAS DISAS-
SEMBLED THEN AFTER ASSEMBLING IT SHOULD BE FILLED WITH GREASE BY MEANS OF GREASING GUN UP
TO LUBRICANT EGRESS OUT OF VALVES OR CLEARANCES
WHILE PERFORMING OF DUMP TRUCK MAINTENANCE, REPAIR, WELDING WORKS ENSURE PROTEC-
TION OF LUBRICATION SYSTEM PIPELINES
NEVER REST ON DOSING UNITS, PIPELINES, KNEEPIECES AND NIPPLES OF LUBRICATION SYSTEM
WHILE MOVING ALONG THE CHASSIS
17.3.4 Lubrication system troubleshooting

Lubrication system troubleshooting is specified in the table 17.4
Table 17.4 – Lubrication system troubleshooting

Trouble and its symptom Possible reason Troubleshooting
The pump electromotor does The voltage is not supplied Check the power supply, fuses and wires. Eliminate the fault, change
not work fuses
The electromotor is out of or- Change electromotor
der
The control unit is out of order Change control unit
The pump does not supply The tank of the pump is empty Fill in the tank with clean lubricant. Start the pump actuating an addi-
lubricant tional cycle of lubrication by pressing the button with backlighting on
the instrument panel or on the pump and hold it in such position dur-
ing 2 sec. Carry out some additional cycles of lubrication until lubri-
cant reaches all lubrication points.
Air bulbs in lubricant Loosen the pipelines fastening from pump to main dosing units. Ac-
tuate additional cycle of lubrication. When the lubricant escapes
without bulbs connect pipelines
The not recommended type of Change lubricant for specified one
lubricant is used
Suction port of the pump ele- Clean suction port
ment is clogged
The pump element piston is Change pump element
worn out
Inoperative check valve or Change check valve or pump element
pump element
The system blockage – lub- Dosing units, pipelines or lu- Find the place of blockage and eliminate it performing the follow-
ricant escapes from safety brication points are clogged ing:
valve 1 Check safety valve. In order to perform that connect the ma-
nometer to the safety valve and, actuating an additional cycle of lu-
brication, check at what pressure the valve gets opened. It is possi-
ble to perform this check by hand pump with manometer. The safety
valve is to be opened at pressure of 35 MPa for Lincoln system, and
30 MPa for Vogеl system. Change the valve if necessary
2 Disconnect the pipeline leading from pump to the main dosing
unit. Start the pump and check whether the lubricant escapes from
the pipeline. Connect the pipeline to main dosing unit.
3 Disconnect the pipelines leading from the main dosing unit to
additional dosing units. If lubricant escapes from the dosing unit port
the blockage is to be sought in additional dosing unit circuit.
4 Connect pipelines to the main dosing unit and disconnect se-
quentially the pipelines leading from additional dosing units to lubri-
cation points. If lubricant escapes from the dosing unit port the
blockage is to be sought in the pipe line or in the lubrication point.
17-14
75135-3902015 IM

Trouble and its symptom Possible reason Troubleshooting
The system blockage – lub- Dosing units, pipelines or lu- 5 Connect pipelines to additional dosing unit and disconnect sequen-
ricant escapes from safety brication points are clogged tially the pipe lines leading from lubrication points. If lubricant es-
valve capes from the pipeline then the lubrication point is blocked.
6 Screw the greaser into the blocked lubrication point and squirt it
until the fresh lubricant appears. After that connect the pipeline to the
lubrication point and make sure that blockage is eliminated and the
system operates properly. If the pipeline is blocked, pump it with
hand pump.
7 If during the check-up it is found out, that the lubricant does not
egress from dosing unit port it means that the dosing unit is blocked.
8 Disconnect all pipelines from the dosing unit. Unscrew dosing
unit piston plugs, extract pistons with the help of elastic drawbar in
order to exclude damage to working surfaces. Wash the pistons and
dosing unit ports with fat-splitting cleaning solution and vent by com-
pressed air. Assemble dosing unit, fill it with lubricant with the help of
hand pump, prior to connecting of the pipe lines. The pressure in
dosing unit should not exceed 2,5 MPa. If pressure is higher then
this specified value the dosing unit is to be changed.
ATTENTION :
Pistons are not interchangeable. It’s necessary to mark the pistons
and holes, at which they placed.
Irregular (redundant or insuf- Incorrect time of pump opera- Check the pump time set-up
ficient) lubrication of lubrication and pause
tion points. Some friction
units emit more lubricant
through the valve or clear-
ances than others
17-15
75135-3902015 IM
17-16
Operational materials
75135-3902015 IM
18 OPERATIONAL MATERIALS
During operation of dump trucks use only recommended brands of service materials which quality is to
be certified.
18.1 Fuel
Fuel for the engine is to be applied in accordance with recommendations, stated in the Engine Operation
Manual
Depending on the ambient temperature fuel of following grades according to ГОСТ 305-82 (Standard) is
to be applied:
0
- Л-40 (summer) - at ambient temperature 0 С and higher;
0
- З – minus 35 (winter) - at ambient temperature minus 20 С and higher;
0
- З – minus 45 (winter) - at ambient temperature minus 35 С and higher;
0
- A (arctic) - at ambient temperature minus 50 С and higher.
To prevent fuel system failure because of water availability in fuel, it is recommended to refuel the tank
with fuel been settled for 10 days.
18.2 Lubricants
Motor oils are necessary for applying according to recommendations of firms – manufacturers of the mo-
tors, stated in corresponding instructions on their operation.
Transmission oils, working fluid for hydraulic systems (hydraulic oils) and plastic greasing it is necessary
to apply according to a season and climatic conditions of dump trucks operation.
The list of lubricants and recommendations for their applying depending on ambient temperature are
given in table 18.1.
List of lubricants and their substitutes are given in the table 18.2.
Table 18.1 – Use of lubricants depending on ambient temperature

Temperature range of lubri-
Lubricant grade ГОСТ, ТУ (Standard
cant using
Damping fluid ЛУКОЙЛ-AЖ TU 0253-025-00148599-2001 Above minus 50 0С
Damping fluid МГП-12 TU 0253-052-00148843-98 Above minus 40 0С
Damping fluid ГРЖ-12 TU 0253-048-05767924-96 Above minus 50 0С
Greasing № 158М TU 38.301-40-25-94 Above minus 30 0С
Greasing Литол-24 GOST 21150-87 Above minus 40 0С
Greasing Лита TU 38.101808-90 Above minus 50 0С
Greasing Фиол-2 THAT 38 УССР 201188-79 Above minus 40 0С
The note: Oils application of in hydrosystem depending on ambient temperature look in the chapter “Dumping mechanism ”
Table 18.2 – List of lubricants substitutes
Lubricants substitutes
Lubricants brand Classification,
Manufacturer Substitutes brand
specification
Mobilube GX 85W/90A API: GL-4, SAE-90 Shell Dentax G 80W-90

BP Energear EP 90
Mobilube SHC 75W/90LS API: GL-5, SAE-75W Shell Spirax GSX 75W80
BP Energear EP 80W/90
18-1
Operational materials
75135-3902015 IM
Lubricants substitutes
Lubricants brand Classification,
Manufacturer Substitutes brand
specification
Литол-24 MIL-G-18709A Shell Alvania EP 2;

MIL-G-10924C Retinax EP 2
Mobil Mobilux EP 2,
Mobilux EP 3
BP Energrease L2
Лита SM-1C-4515A Shell AeroShell Grease 6
(Ford) Mobil Mobilux EP 2
BP Energrease LT2
Фиол-2 MIL-G-18709A Shell Alvania RL 2
Mobil Mobilux EP 2
BP Energrease LS2
ЖРО MIL-G-10924C Shell Alvania RL 3
Mobil Mobilux EP 3
BP Energrease LS2
158М – Shell Alvania RL 1
BP Energrease LS-EP2
Note: Oils substitutes for hydrosystem look in the chapter “Dumping mechanism”
18.3 Coolant
It is recommended to apply to the cooling system all-the-year-round special antifreeze coolants in ac-
cordance with Engine Operation Manual.
COOLING LIQUIDS ARE POISONOUS!
18.4 Nitrogen
For charging of the suspension cylinders as well as pneumatic hydroaccumulators of service brake sys-
tem and steering gaseous technical nitrogen (GOST 9293-74 «Nitrogen gaseous and liquid ») is applied.
Gaseous technical nitrogen is delivered in steel seamless cylinders under pressure (15.0±0.5) МPа. Cyl-
inders are painted in black color. On the upper part of the cylinder the inscription "NITROGEN" of yellow color
and circular marking stripe of brown color are put down.
18.5 Technical ethanol

To refill of pneumatic system defroster and for washing details of electric machines and devices rectified
ethanol is applied in accordance with GOST 18300-87.
RECOMMENDED ETHANOL IS MADE FROM NONFOOD VEGETAL RAW MATERIAL. ON EFFECT ON THE
HUMAN ORGANISM IT BELONGS TO SUBSTANCES OF 4-TH GRADE OF DANGER ACCORDING TO GOST
12.1.007-76.
18-2
Dump trucks storage rules. Transportation
7513-3902015 IM
19 DUMP TRUCK STORAGE RULES.

TRANSPORTATION
Preservation is made at station of dump trucks on storage with the purpose of prevention from corrosion
of internal and external surfaces of units and mechanisms to keep a dump truck in a serviceable condition.
Operations on preservation are to be executed at temperature of air not below 15 ºС to exclude penetra-
tion of aggressive gases and the liquids causing corrosion.
It is supposed to carry out preservation of dump trucks on the open areas only in dry weather at temper-
ature of air not below 5 ºС.
Technically serviceable, completed and preserved dump trucks, which operation is not planned for more
than two months, are subjected to station on storage.
There are two types of dump trucks storage: short-term (till one year) or long-term (more than year).
As protective grease ПВК GOST 19537-83, fluid K-17 GOST 10877-76 and also АКОР-1
GOST 15171-78 to regular lubricant oils are applied.
Grease K-17 is applied at long-term preservation of products. Units of dump trucks are preserved with-
out disassembly: regular oil is to be drained, protective grease is pumped and surplus of it goes for drain. For
input of the unit in operation it is enough to fill it with regular oil.
At preservation of the units having filters, they are required to be disconnected.
Grease ПВК is applied to preservation of external and easily accessible internal surfaces.
Additive АКОР-1 is entered into regular lubricant oils for improvement of their protective properties at the
rate of 10 % from prepared quantity working-conservative grease. For input of the unit in operation working-
conservative grease is used as operational till its first replacement.
19.1 Storage preparation

Operations list:
– perform cleaning-washing operations;
– carry out the scheduled maintenance service;
– remove rust from the damaged surfaces, degrease them and restore a covering;
– protect by grease ПВК unpainted external metal surfaces (open chrome-plated cylinders surfaces of
the dumping mechanism and turn cylinders rods);
– fill a fuel tank up to a maximum level;
– drain water from cooling system, blow with compressed air, close plugs of overflow bottles and drain
cocks. The low freezing liquid from system is not to be drained;
– seal engine breathers, oil tank of dumping mechanism, reducers of motor-wheels, having wrapped up
them by polyethylene film and having tied with a rope;
– seal ventilation windows of haul generator, having put in linings under a grid and wrap up by polyeth-
ylene film and tie by rope cyclones of an air intake;
– seal engine air cleaners by gluing linings under covers of an air intake;
– seal exhaust system by placing of plug in the tee of reception pipe;
– place protective linings from paraffin papers in two layers between brushes and rings of haul generator
and between brushes and collectors of haul electric motors;
– paste over the cab from the inside with light-proof paper;
– remove storage batteries and prepare them for storage according to Manufacturer’s instructions;
– place the dump truck on supports, lift wheels on height 80 – 100 mm from ground;
– preserve the engine according to the operation manual on the engine.
19.2 Maintenance service of the dump trucks which are on storage

Once a month:
– check the position of dump truck on supports;
– clean the dump truck of dust, moisture or snow;
– check units and mechanisms for proper condition of their external surfaces;
– check condition of sealing materials;
– check storage batteries condition.
19-1
Dump trucks storage rules. Transportation
7513-3902015 IM
Twice a year:
– charge storage batteries;
– grease all points according to the scheme of greasing;
– check up impermeability of units and systems.
In a year of storage:
– depreserve the dump truck;
– start up the engine, warm it up to operational temperature and listen to its work on different modes;
– check up work of systems and units by instrumentations;
– check up work of the haul electric drive;
– make repeated preservation.
19.3 Depreservation of the dump truck

For depreservation remove the dump truck from supports, remove from external surfaces protective
grease and sealing means. Check up whether systems and units are refilled properly.
Mount storage batteries, start up the engine and check a technical condition of the dump truck by control run.
19.4 Transportation
Dump trucks can be transported by railway, water and air transport.
The dump trucks are shipped from the manufacturing plant being partially disassembled.
At transportation by railway it is necessary to be guided by instruction ДЧ-1835 on transportation of
oversized and heavy cargoes on railways with a track of 1520 mm.
Accommodation and fastening of dump trucks in partially disassembled condition on an open railway
rolling stock should be carried out within the limits of bulkiness: lower – third, side – fourth, upper – second
grade.
At transportation of the dump truck in the cab, in plain view the label should be set with instructions on:
– water removing from systems or refilling them with antifreeze coolant;
– disconnection and state of storage batteries (with or without electrolyte);
– grease information in units and mechanisms.
19-2
Appendices
75135-3902015 IM
APPENDIX A
(information)
Tightening torques of the most responsible threaded connections
Tightening torques of the most responsible threaded connections are resulted in the Table A.
Table A – Tightening torques of the most responsible threaded connections
Tightening torque
№ The name of the threaded connection
N.m
1 Fastening nut of the fan wheel on shaft of the traction generator 882 – 980
2 Fastening bolts of the traction electric motor to reducer of the motor - wheel 800 – 1000
3 Fastening bolts of the electric motor-wheel to housing of the rear axle 500 – 550
4 Fastening bolts of the thrust ring of a motor - wheel reducer 400 – 440
5 Spherical support nuts of the cylinder fastening of the front suspension 1600 – 2000
6 Spherical support nuts of the cylinder fastening of the rear suspension 1800 – 2000
7 Clamping nut of the suspension cylinder 9000 – 10000
8 Fastening bolts of the upper arm of the front suspension cylinder to steering knuckle 910 – 1020
and upper arm and to arm frame
9 Eye fastening bolts of the front suspension central hinge to the central lever 910 – 1020
10 Finger fastening bolts of the central hinge of front suspension 1100 – 1250
11 Eye fastening nuts of the rear suspension central hinge to the central lever 1200 – 1500
12 Finger fastening nut of the rear suspension central hinge (after tightening the nut to 1800 – 2000
0
tighten on angle 60 (one side))
13 Fingers fastening bolts of front suspension the cross-section bar 2400 – 3000
14 Fastening bolts of pressure plates to the finger of rear suspension a cross-section 360 – 440
15 Fastening bolts of the pressure ring to a steering knuckle 100 – 140
16 Adjusting bushes (for adjustment of conic bearings of the front wheel hub ) 100 – 140
17 Fastening bolts of the case of the front wheels to a steering knuckle 1500 – 1800
18 Fastening nuts of the steering trapeze lever to steering knuckle 800 – 1000
19 Terminal connections nuts of a traction steering trapeze 110 – 140
20 Nuts on conical pin of turning cylinders 500 – 700
21 Fastening bolts of the brake mechanisms internal cheeks of rear wheels 550 – 700
22 Fastening nuts of the brake mechanisms internal cheeks of rear wheels 370 – 450
23 Fastening nuts of front wheels 1150 – 1300
24 Fastening nuts of rear wheels 800 – 900
20-1
Appendices
75135-3902015 IM
APPENDIX B
(information)
Procedure oil analysis from motorized wheels reducers
Periodicity of tests removal:
– during regular checks at every technical maintenance 1 (ТM–1);

– before oil change;
– more frequently if abnormal deterioration is suspected.
Procedure of removal of tests:
– oil selection to make through 10 – 15 minutes after dump truck stop, and before stop the dump truck
should fulfil not less than hour;
– screw fuse of priming hole from an external cover;
– through the hole at sampler to take from each reducer on 150 – 200 ml. oil from depth of 50 mm from
the bottom point of oil cavity, tests from each reducer should be in separate utensils and are marked;
– oil analysis and the results analysis should be carried out immediately, that is execute:
а) spectral analysis on content of iron, chromium and silicon;
b) measure kinematic viscosity;
c) content of insoluble impurity.
– measured on content of iron, chromium, nickel, copper and silicon to compare to results of the previ-
ous check.
If substantial growth of any element is observed, to execute check of cogwheels, spline connections and
bearings. If the silicon contents has considerably changed, then oil should be replaced. The oil replacement to
fulfil in case of gradual accumulation in oil of metal particles with concentration their exceeding 5 g/l (0,5 %).
Presence the copper in oil is caused by use of bearings of the first lines with brass separators. Thus
concentration of copper in oil up to 0,1 g/l (0,001 %) corresponds to normal wear process. Concentration of
copper is higher than the specified size testifies to intensive wear process of a separator, thus particles of a
brass are looked through visually in a glass test tube as golden shine. In similar cases it is necessary to exe-
cute replacement of oil and to examine bearings and if necessary them to replace.
The oil replacement should be carried out in case of change of oil viscosity on 30 % in comparison with
viscosity of new oil and at the contents of insoluble impurity more than 1 %.
All specified oil replacements do not release from performance of oil replacement according to proce-
dural works on maintenance service of motorized wheels reducers.
20-2
Appendices
75135-3902015 IM
20-3
Appendices
75135-3902015 IM
RUPE “Belarusian Autoworks”

Dump truck BELAZ-75135
Operation Manual
Made in Belarus
20-4

Uputstvo Za Rukovanje I Odrz. 131 ENG

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RUPE “BELARUSIAN AUTOWORKS”

OPERATION AND MAINTENACE MANUAL

Manufacturer is constantly busy on modernization of design of trucks and re-

We request to send all opinions on design and operation qualities of trucks as

© RUPE “BELARUSIAN AUTOWORKS”, 2006

12 LOW-VOLTAGE ELECTRICAL EQUIPMENT ............................................................................................................ 12-1

Figure 1.1 – Dump truck BELAZ-75131. Overall dimensions

Location of basic identification, identification tags, tags of devices “FOPS”, “ROPS”.

Table 1.1 — Designation of production year

Year Designation Year Designation

2 SAFETY REQUIREMENTS AND WARNINGS

2.1 Safety requirements

IT IS PROHIBITED TO SINK BODY FORCEDLY, WHEN IT IS LOCKED UP.

IT IS STRONGLY PROHIBITED TO CHARGE THE SUSPENSION CYLINDERS AND PNEUMOHYDRAULIC AC-

IT IS FORBIDDEN TO UNFASTEN AND MOUNT WHEELS IF THERE IS AN OVERPRESSURE IN TIRES.

Slope, % Speed, km/h Slope, % Speed, km/h

Table 2.2 – Controlled operational parameters of dump truck systems

Table 3.1 – Specification

Parameters BELAZ -75131

Continuation of table 3.1

Parameters BELAZ -75131

Tires Tubeless, pneumatic

CAB AND BODY

Continuation of table 3.1

Parameters BELAZ -75131

4 CONTROLS, INSTRUMENTATION AND CAB EQUIPMENT

4.1 Controls and cab equipment

Figure 4.1 – Controls and cab equipment:

4.2 Control panel

Figure 4.2 – Location of controls on main control panel:

Additional dash control panel.

Figure 4.3 – Additional dash control panel :

Figure 4.4 – Display panel:

4.3 Control panel of starting preheater

Figure 4.5— Starting preheater control panel:

Figure 5.1 – Diesel-generator:

5.2 Engine fuel supply system

Adjustment of fuel supply drive:

Figure 5.2 – Control drive of fuel supply and run controller:

Fuel heater with filter.

Figure 5.3 – Fuel heater with filter:

Figure 5.4 – Fuel tank:

Fuel priming pump.

Figure 5.5 – Fuel priming pump:

5.3 Engine air supply system

Figure 5.6 __ Air filter:

5.4 Cooling system

5.5 Engine preheating system

Figure 5.7 – Starting preheater:

5.6 Engine air starter system

Figure 5.8 – Schematic circuit of engine air starter system:

Figure 5.9 – Safety valve:

Figure 5.10 – Single safety valve:

5.7 Exhaust system

5.8 Engine systems maintenance

Figure 5.11 – Exhaust system:

Sequence of air filter maintenance operations:

6 TRACTION ELECTRIC DRIVE

7.1 Electric motor-wheel

Figure 7.1 – Electric motor-wheel:

7.2 Electric motor-wheel reduction gear

Figure 7.2 – Reduction gear of electric motor-wheel: