Blaz. Manual
Blaz. Manual
Blaz. Manual
«BELORUSSIAN AUTOWORKS»
REPAIR MANUAL
7513-3902080 RM
REPUBLIC OF BELARUS
© PRODUCTION ASSOCIATION «BELoRUSSIAN AUTOWORKS», 2004
Contents
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CONTENTS
1GENERAL INFORMATION................................................................................................................................................. 1-1
2 TECHNICAL SPECIFICATIONS OF DUMP TRUCKS ....................................................................................................... 2-1
3GENEARL DIRECTIONS UNDER REPAIR........................................................................................................................ 3-1
3.1 Dismantling................................................................................................................................................................... 3-1
3.2 Flaw detection ............................................................................................................................................................. 3-1
3.3 Assembling .................................................................................................................................................................. 3-2
4 SAFETY INSTRUCTIONS AND FIRE-FIGHTING REGULATIONS UNDER REPAIR ..................................................... 4-1
4.1Safety instructions ........................................................................................................................................................ 4-1
4.2 Preventive fire-fighting regulations…............................................................................................................................ 4-3
5ENGINE SYSTEMS............................................................................................................................................................. 5-1
5.1 Removal and mounting of the diesel generator............................................................................................................ 5-1
5.2 Engine connection with the traction generator ............................................................................................................. 5-3
5.3 Repair and service of the cooling system................................................................................................................ 5-7
5.4 Fuel systems service ................................................................................................................................................. 5-11
5.5 Air filter cleaning ........................................................................................................................................................ 5-12
5.6 Service and repair of the pneumatic starter engine system ......................................................................................... 5-14
5.7 Service of the engine preheater ................................................................................................................................ 5-16
6 TRACTION ELECTRIC DRIVE .......................................................................................................................................... 6-1
6.1General information about the drive .............................................................................................................................. 6-1
6.2 Description and operation of the drive components ..................................................................................................... 6-2
6.2.1 Electrical machines ............................................................................................................................................. 6.2
6.2.1.1 Traction alternator .................................................................................................................................. 6-2
6.2.1.2 Traction motor ........................................................................................................................................ 6-11
6.2.2 Electric apparatuses............................................................................................................................................ 6-23
6.2.2.1 Control cabinet ....................................................................................................................................... 6-23
6.2.2.2 Contactors ............................................................................................................................................. 6-27
6.2.2.3 Mounting of vented brake resistor .......................................................................................................... 6-31
6.2.2.4 Motion controller ..................................................................................................................................... 6-34
6.2.2.5 Braking controller.................................................................................................................................... 6-34
6.2.2.6 Measuring instruments ........................................................................................................................... 6-35
6.2.3 System of ventilation and cooling of traction drive .............................................................................................. 6-37
6.3 Repair of electrical machines and apparatuses of traction drive .................................................................................. 6-39
6.3.1 Repeair of electric machines............................................................................................................................... 6-39
6.3.1.1 Repeair of traction alternators ................................................................................................................ 6.39
6.3.1.2 Repair of traction motors ........................................................................................................................ 6-47
6.3.2 Repair of electric apparatuses ............................................................................................................................ 6-56
6.3.2.1Repair of motion controlller...................................................................................................................... 6-57
6.3.2.2 Repair of braking controller .................................................................................................................... 6-57
7ELECTRO-MOTOR WHEEL ............................................................................................................................................... 7-1
7.1 General information ..................................................................................................................................................... 7-1
7.2 Repair of electro-motor wheels..................................................................................................................................... 7-1
7.2.1 Removal of electro-motor wheel from the truck ............................................................................................ 7-1
7.2.2 Dismantling of reducer ....................................................................................................................................... 7-5
7.2.3 Checking of the technical state of parts of motor-wheel reducer ................................................................ 7-7
7.2.4 Assembling of motor-wheel ................................................................................................................................ 7-11
7.2.5 Running-in of the motor-wheel reducer.......................................................................................................... 7-19
8 RUNNING GEAR ............................................................................................................................................................... 8-1
8.1 Suspension .................................................................................................................................................................. 8-1
8.1.1 General information ............................................................................................................................................ 8-1
8.1.2 Suspension cylinders troubleshooting................................................................................................................. 8-8
8.1.3 Safety precautions at removal, repair and mounting of suspension cylinders on dump truck .............................. 8-8
8.1.4 Removal of suspension cylinders from dump truck............................................................................................. 8-9
8.1.5 Disassembly of suspension cylinders ................................................................................................................. 8-11
8.1.6 Disassembly of central hinges of front and rear suspension............................................................................... 8-12
8.1.7 Disassembly of pivot unit of front suspension on dump trucks BELAZ-7514-10, BELAZ-75145................................ 8-13
8.1.8 Removal and disassembly of transversal rods of front and rear suspension...................................................... 8-14
I
Contents
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II
Contents
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III
Contents
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14.4.1 Dismantling of dumping mechanism assemblies from BELAZ-7514-10, BELAZ-75145 dump trucks …………..14-8
IV
Contents
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АPPENDIX A Assembly protocol of engine КТА 38С (КТА 50С) with alternator ГС525 ……………………………… 20-1
V
Contents
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VI
General
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1 GENERAL
The given manual sets scope of routine and mid-life repairs and is intended for operators, mechanical
engineers and other personnel working at enterprises operating, servicing and repairing quarry dump trucks
(further – dump trucks) with payload capacity 120 -130 T and their modifications models, produced by Produc-
tion Association «Belarusian Automobile Works».
Manual includes procedure for trouble shooting in units and assemblies mounted into dump truck; pro-
cedure for dismantling of defective units and assemblies from the vehicle and their disassembly; tables stating
design and tolerance limit dimensions for major parts, determining further usage or rejection of the dismantled
article; assembly regulations; technical requirements to repaired units and assemblies and testing procedure
on special stands; procedure for mounting of repaired or brand new units and assemblies into dump truck; list
of activities for integrated testing of the dump truck after repairs.
Manual features list of technical equipment (arbors, extractors, appliances, stands) required for servicing
and repairing, as well as regulations for their application in the process of units and assemblies repair.
1-1
General
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1-2
Technical Specification of Dump Trucks
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Overall dimension of BELAZ-7514-10 and BELAZ-75145 dump truck basic models with payload capacity
120 T are shown in figure 2.1, overall dimensions of basic models of BELAZ-75131 and BELAZ-75132 dump
trucks with payload capacity 130 T are shown in figure 2.2, technical specification of the dump trucks is given
in table 2.1.
2-1
Technical Specification of Dump Trucks
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2-2
Technical Specification of Dump Trucks
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2-3
Technical Specification of Dump Trucks
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Chassis of basic models are used for construction of dump trucks intended for coal and other bulk car-
gos of light specific density transportation, they differ from basic dump trucks in body featuring increased body
volume.
Overall dimensions of BELAZ-75145-0000110 and BELAZ-75138 coal carriers are shown in fig. 2.3 and
2.4, features of technical specification differing from basic dump truck models are given in table 2.2.
2-4
Technical Specification of Dump Trucks
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BELAZ-75145-0000110 BELAZ-75138
Parameters
(on basis of BELAZ-75145) (on basis of BELAZ-75131)
Rated weight of transported load, kg 110000 120000
Vehicle weight, kg:
operation 93600 110000
gross 203600 230000
Overall dimensions, mm:
Length 11840 11500
width 7100 7350
height (empty) 5900 5900
2-5
Technical Specification of Dump Trucks
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2-6
General instructions repairing
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3-1
General instructions repairing
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3.3 Assembling
Assembling sections should be equipped with the work benches, special tools and test benches for dis-
assembling – assembling of units and aggregates. At assembling work cleanness of unit assembling should be
provided and assembling places should eliminate hit of a mud, dust, water, emulsion and abrasives on assem-
bling parts. It is forbidden to dispose places of assembling near to grinders and to use open compressed air dur-
ing assembling.
The details fed on assembly, should not have corrosion, a shavings in ports and deepenings, dents and
nicks on mated and mounting surfaces. The corrosion-resistant coating used at storage of details, should be
deleted. Oil galleries and openings in details should be cleaned, washed out under pressure and blown
throuhg by compressed air.
Before feeding on assembly the internal raw surfaces of cast and forged details should be cleaned of
a calxes, and all blind holes, bins and drillings should be blown through by compressed air.
At assembly it is necessary to use the standard or special instrument. It is allowed to use hammers and
planers of non-ferrous metals and alloys when setting details and gears.
The bearings installed during assembling, should be kept and be delivered on assembling section in
packaging of manufacturer and be unpacked directly before their. In case of damage of packaging, bearings
should be washed out in the petroleum oil heated to temperature 95 – 100 0С. Package is moved of only from
mounting surfaces. Mounting surfaces on bearings are necessary to be washed in kerosene, white spirit, to be
cleaned napless material and to be dried. Before mounting the bearing it is necessary to check conformity of
appearance, identification mark, to be convinced of ease of twirl, absence of gaps.
Surfaces mated to the bearing should be washed by kerosene, white spirit, rubbed, dried and greased
with a thin film of oil ТАП-15В, ТСп-15к or equivalent greases.
During assembling, mated surfaces and technological facets are necessary to smooth out, not disturbing
admissible sizes.
It is necessary to remember, that when setting bearings on the shaft, the pressing force should be ap-
plied through the carrier sleeve on an inner ring, and at mounting into the case – to an outer ring. At setting
bearings simultaneously on the shaft and in the case the simultaneous application of force through carrier
sleeve to external and inner rings. Application of force of a press fitting through solids of revolution and separa-
tors is not admitted. To press bearings use hydraulic, screw and others presses.
When mounting bearings on shafts, their heating in oil till 80-90 0С, for exclusion of closed bearings with
one-time lubricant is admitted.
At execution of fastening operations apply the trig instrument to make a necessary force of torque and in
required cases apply torque spanners. At stopping use only new pin wire and splint pin.
When assembling do not use fasteners (bolts, nuts, splints, rivets, etc.) of non-standard sizes, bolts and
nuts with the worn out edges, screws with the hammered or worn out splines of heads. Fasteners should not
have damages of a thread.
At assembling of units and aggregates of a dump truck it is necessary to use a new package general
mechanical rubber goods (ring gaskets, packing glands, linings).
Collecting the joints having rubber seals (packing glands, sealing ring and cuffs), watch that there were
no undercuts and twistings.
Before setting sealing rubber rings and cuffs should be greased, and in cavities between a working edge
and a duster of a cuff and between the doubled cuffs should be filled approximately on two – third of volume
with lubricant Литол-24 or Фиол-2.
At assembling it is necessary to replace all linings by new ones, preliminary having greased them with
sealant.
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Safety precautions and fire-prevention require-ments when repairing the dump truck
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Besides, observe also the following requirements conditioned by the design of the dump trucks:
4.1.1 Maintenance of the dump truck must be performed by mechanics and electrcians familiar with the
dump truck design, the rules of its operation and the safety and fire precautions to be observed during opera-
tion.
4.1.2 Trailing of a defective dump truck should be carried out by the special recovery tractor. In case of
dump truck trailing when the dump truck is fastened for bumper, it is necessary to unbrake the gear of a park-
ing braking system.
4.1.3 Before a service and repair of a dump truck it is necessary not to allow spontaneous driving of a
dump truck from a place. The service and maintenance are necessary to perform only at the stopped en-
gine, wit the exception of operations on adjustment of the traction electric drive, foreseen in « The Instruc-
tion of regulation of the traction electric drive”.
4.1.4 Before leaving the cab, make sure that the reverser switch and the electric drive control switch
are in OFF “Выключено” position and the dump truck is braked with the parking brake system.
4.1.5 At service and repairing of a dump truck, the raising of a body is required, it is necessary to unload
it and to stop it in the raised position by two towing pivots, having combined openings in links on a body with
openings in brackets on a frame. Operations under the raised and stopped platform are not permitted, if there
are more than 3 t the stuck ground or speed of a fair wind (when repairing outside) is more than 6,5 m/s.
It is impossible to stand near to a dump truck at rise of a platform in avoidance of injury a ground.
It is impossible to go out a cabin at omitting and at rise of a platform.
It is not supposed to begin driving at the lifted platform.
4.1.6 For safety dump truck is equipped with ladders, footboards, handrails and platforms.
When operating without fences and handrails it is necessary to use a safety belt, and also portable ladders
(ladders) and supports. Doing so follow Safety Precautions.
4.1.7 When moving along ladders and upper working flats (fenders, hoods), hold on to the handrails
available on the ladders, fenders, hoods and cab, so that three supporting points are constantly provided for
(with two hands and one leg or two legs and one hand). clean the ladders and flats of dirt, snow and ice. When
moving along ladders be always facing to the dump truck.
4.1.8 When use hydraulic jacks, hoists, and also other elevating means to lift the dump truck, it is nec-
essary to install rigid metal supports under the lifted part of a dump truck. Start maintenance only after the
dump truck is in steady positions on supports.
4.1.9 Rules of an Electric Safety Rules to be observed at an adjustment of traction electric drive are given
in Operation Manual of the traction electric drive.
4.1.10 It is not allowed to dismantle and disassemble elements of braking systems and steering system,
which are under pressure of working fluid.
Release of pressure in front and rear circuits of service brake system, a parking brake system, steering
system is made by unscrewing shutoff needles on the brake valve.
Release of pressure of a working fluid in a hydraulic system of steering and a parking brake of dump
truck BELAZ-75131 and its modifications is made automatically after scheduled shutdown of the engine during
80 s.
4.1.11 Prior to removing the suspension cylinder from a dump truck, it is necessary to release gas from
its space. For complete removal of gas from a space it is necessary to open the charge valve at list three
times, with intervals of 3 - 5 minutes.
4.1.12 Prior to disassembling the suspension cylinder, it is necessary to be convinced that there is no an
excessive pressure of gas in the space for what open charge valves.
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Safety precautions and fire-prevention require-ments when repairing the dump truck
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When check up a level of a working fluid in the suspension cylinder the control fuse should be turned out
slowly to remove an excessive pressure of gas in a space. Do not stay opposite the fuse when doing this op-
eration.
4.1.13 Prior to charging the suspension cylinder with gas make sure that charge accommodating is trig
and that the mark on the compressed gas cylinder is correct. The gas cylinder must bear an inscription
"NITROGEN" and should carry a brown circular marking strip.
4.1.14 Release completely air from the tire before unfastening on a dump truck. For rear double wheels
it is necessary to release air from both tires.
Prior to assemble a wheel, it is necessary to examine carefully condition of rims, bead, landing and lock
rings.
Приступая к сборке колес, необходимо тщательно осмотреть состояние ободьев, бортовых,
посадочных и замочных колец.
Before mounting of a wheel, inflate a tire the up to pressure 0,1 МPа and to be convinced of correctness
of setting of locking ring. To inflate the tire up to required pressure is possible only after fixing a wheel on a
nave. There should be no people near to the inflated tire.
4.1.15 Fuse of expansion vessel of engine cooling system is necessary to screw out cautiously - steam
in the vessel is under pressure.
4.1.16 It is necessary to remember, that low-freezing cooling liquid is toxic and may cause poisoning if
the rules of sanitary are violated.
4.1.17 When servicing and repairing a storage batteries remember, that electrolyt, having got on a body,
can cause strong burns.
4.1.18 Введение конструктивных изменений в схемах электрооборудования без согласования с
заводом-изготовителем категорически запрещается.
4.1.19 Disassembly of the cylinder of a parking braking system should be done in the special accommo-
dating, providing fixing of springs in the compressed condition and smooth their release up to a free state.
4.1.20 It is forbidden to perform repairing, to disassemble an armature, to perform welding jobs in sys-
tem of pneumostart and the pneumatic system of a dump truck which are under pressure.
The pressure release in system of pneumostart is made through the valves of condensate drain, thus
the shut-off cock on air vessels should be opened.
The pressure release in pneumatic system of a dump truck is made through the valves of condensate
drain, installed in a receiver.
4.1.21 Adjustment and operation of system of pneumostart and pneumatic system with out-of-order ma-
nometers and the broken seals on safety valves are forbidden.
4.1.22 Maintenance of airvessels, manometers, safety valves, armatures (including engineering survey
and repair) should beperfofmed according to the requirements and the orders given in “Rules of Arrangement
and Safe Operation of Pressurized Vessels” (ПБ 10-115-96).
4.1.23 Combustive-lubricating materials, working fluids and other operation materials should be applied
only according to recommendations of operation manual. Application of other brands of oils and fuel is forbid-
den.
4.1.24 When carrying out of welding jobs on a dump truck automatic switches SF1, SF2, SF3, SF4, QF2 of
control circuits and auxiliary circuit in the control should be switched off.
It is not admitted to connect the welding unit wire to the wheel hubs, since local heating of parts may
cause damage to the bearings.
The mass wire of the welding apparatus should be connected near to a place of a welding.
4.1.25 It is forbidden to carry out the welding jobs near to the charged pneumohydraulic accumulators
and pipelines, connected to them.
4.1.26 Prior to carry out of welding jobs near to accumulative containers it is necessary to follow neces-
sary precautions.
4.1.27 It is forbidden to fasten electric motorized wheel for the case (housing) in order to prevent its con-
tortion.
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Safety precautions and fire-prevention require-ments when repairing the dump truck
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4-3
Safety precautions and fire-prevention require-ments when repairing the dump truck
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4-4
Engine systems
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5 ENGINE SYSTEMS
Service and repair of the engine systems consists in supporter all external threaded joints, washing of
an integral cooling system and removal of an incrustation, the filter of preliminary of combustible clearing
washing, the dust clearing and inspection of the filter element condition, the tightness inspection and adjust-
ment of the pneumatic drive of management by a fuel feed (dump trucks with the pneumatic drive), inspection
and adjustment of the drive of management by a fuel feed (power-driven dump trucks), washing of the breather
filter of the fuel tank, and also in execution of a maintenance on the engine according to the maintenance en-
gine instruction .
5.1 Removal and mounting of the diesel generator
For the remomal of the diesel generator it is necessary:
- install the dump truck on the even horizontal platform, brake it by parking brake system and lay under
all wheels the stops;
- lift the platform in the extreme upper position and jammed it by special rope, which both end take in
lugs on the axle housing and fixed by tow pivot;
- remove from systems the oil and cooler fluid ;
- remove from dump truck front and rear jakets
- disconnect and remove the radiators block, air filter, control drive of the fuel feed;
- disconnect from the engine the exhaust system
- disconnect and remove cooling pipes of the traction generator and motor- wheels
- disconnect pipelines from the receivers (for dump trucks BELAZ-7514-10, 75132);
- disconnect hoses and pipelines of the engine external system
- disconnect pipeline of the pneumatic system running to the compressor;
- disconnect and remove the engine cable assembly and cable assembly building on the traction gen-
erator;
- disconnect output wires of the traction generator;
- disconnect the box cardan shaft of the power take-off from the hub of the ventilation wheel;
- remove the cross beam and screw off the fastening of underframe to the shock absorber ;
- disconnect diesel generator from the frame;
Figure 5.1 — Fastening diagram diesel generator of the dump truckсs BELAZ-7514-10
and BELAZ-75132 by suspension 7808-7598
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Engine systems
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- fasten diesel generator behind underframe (Figures 5.1 и 5.2) and slowly move forward by dump truck
motion up to contact of the arm rear branches with upper cross frame;
- sink diesel generator and install it the underframe on the bumper and bearing pipes, welded to the-
frame longeron;
- throw the arm rear branches through cross-arm install it in the socket which are located on the end of
the cross-arm. Fasten the lower parts of the rear arm branches behind longeron lug of the underframe.
- lift by crane the diesel generator to give it forward on the dump truck motion and install on the support.
The diesel generator installation on the chassis to make in the return sequence.
Figure 5.2 — Fastening diagram of the diesel generator of the dump truckсs BELAZ-75145
and BELAZ-75131 by suspension 7808-7059
At the installation the upper part of the vibroinsulators rubber pad should be situated near the dump
truck longeron frame. The flatness tolerance of the upper surfaces the four vibroinsulators should be no more
1,5 mm, test to diesel generator installation and adjust by gasket, installed between lower vibroinsulator fittings
and dump truck arm frame. No more than two gaskets is installed under one vibroinsulator. The adjustment it
is possible execute by vibroinsulators selection at the height
In case of the traction generator emergency the dismantling can to make without engine removal.
For the generator removal it is necessary :
- install the dump truck on the plane horizontal ground to brake it by parking brake system and put under
all wheels supports;
- lift the platform in the extreme upper position and to stop it by special rope which the both ends install
in the lugs on the axle crank case and fixing by tow pin
- dismantle pipelines of the exhaust system ;
- disconnect the cardan shaft of the power takeoff drive from the hub of the fan wheel;
- disconnect and removal the cooling pipelines of the traction generator and motorwheels;
- disconnect power cable from the clamps of the traction generator;
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Engine systems
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5-3
Engine systems
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5-4
Engine systems
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At setting adjusting shims the size of the typed package should not exceed the size "É", and this vari-
ance of sizes should be less than 0,5 mm.
Package of layer pads to install on the shaft of the shaft generator and to press the adapter of the rotor.
Bolt eighteen bolts М24х160. Gradually and serially to tighten bolts by the moment (500 + 50) N.m. The bolts
cotter by the plates it installed under the head of bolts.
With the help of device to install the fast-head butt of the rotor of the generator coaxially to the stator
(approximately).
Figure 5.5:
Figure 5.6:
1 – generator body; 2 – generator shaft;
Г1 - size И1, Н - surfaces 1 - generator body; 2 – rotor body; 3 - bolt
М24х160; 4 – generator rotor; 5 - adjustment gasket s;
И1, Ж1, Н1 - flatnesses; F, К, Р, М - sizes
With the help of the levelling rule to measure in 4 points accordingly: 3 and 9, 6 and 12 hours of a hour
dial distance between docking surfaces of the generator body (surface И1) and the rotor adapter (surface Ж1).
To find an average value. It is the size "F". To define size В1=F+1/2Е.
Obtained size В1 necessarily should be less size А1. The maximum difference of these sizes П=А1-В1
should not exceed 1,5mm.
To define an amount of layer pads N installed on an engine flywheel (surface Ж). The amount of layer
pads should be selected with exactitude N=П±0,1.
With the engine, from the left and right sides to remove the covers closing access covers, timbered one
bolt.
To screw in the adapter of the rotor generator two technological studs in points accordingly 3 and 9
hours of a hour dial. To move the generator forward along axle.
To turn an engine flywheel so that two pins on a cushion disk were opposite to bores under pins in the
adapter of the generator rotor, and bores in the fly wheel were opposite to the engine access cover.
Cautiously to give the generator to the engine as it is possible more precisely having combined their ax-
les. Technological studs should enter the corresponding bores of the disk of an elastic clutch.
To install two technological layer pads of equal width (3-5 mm) in points accordingly 3 and 9 hours of a
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hour dial and bolt four bolts from above and from below layer pads from each side between the adapter of a
stator (surface И) and the case of the generator (surface И1) according to Figures 5.4 and 5.6. To tighten four
bolts the moment 10 - 20 N.m, thus displacing the generator in the necessary horizontal direction.
To adjust overlapping generator axles and the engine in a vertical plane, measuring by a probe a spac-
ing between the case of the generator and the adapter of the stator in points accordingly 6 and 12 hours of the
hour dial and establishing adjusting shims under each claw of the generator until the variance in spacings no
more than 0,1 mm will be reached. The spacing in point of 12 hours should differ in the smaller side, than in
point of 6 hours.
To bolt but to not torque, four bolts М30x2-6gx70 with flat and the spring lock washer fastening the
claws of the generator to the underframe.
To remove the lifting tackle of the generator.
To release four fastening bolts in points accordingly 3 and 9 hours of a hour dial and to delete two tech-
nological layer pads. To test a spacing in points accordingly 3 and 9, 6 and 12 hours of the hour dial which
should not vary at removal the lifting device.
To install the bolts fastening the stator adapter to the generator body (16 pieces, four of which are in-
stalled preliminary). Under six bolts to install a visor bracket and to tighten all bolts the moment (220±10) N.m.
The spacing between adjoining planes should not be.
Turn off and to remove technological studs. With the help of the barring gear the installed in engine ac-
0
cess cover to turn an engine flywheel through everyone 30 and tinstall bolts М16-6gx70 (12 pieces with lock-
washers from two sides of the engine in access cover simultaneously. To mark the first torqued bolt and to
tighten bolts the moment (220±10) N.m.
To tighten four bolts М30x2-6gx70, fastening generator claws to the underframe, the moment
(700±50) N.m.
Validation of assembly.
Inspection of engine backlash.
In a place where the starter motor is removed to remove a cover of a manhole of the engine. To move a
bent shaft of the diesel-generator set back against the stop. Ahead of the engine, whenever possible is closer
to a shaft of a bent shaft to install the indicator and to expose it on "zero". To shift a bent shaft forward against
the stop and, keeping to fix the observation on the indi-
cator. To compare an obtained value to a value to the
accompanying documentation on the engine and with
obtained as a result of sampling a size of C. This value
of size C should coincide with a size in the deed on the
engine with an exactitude ±0,13 mm.
Inspection of the generator radial runout.
To fix bar indicator on thread М14х1 executed in
the case of the adapter in a point of 3 or 9 hours of a
hour dial. The indicatorleg to install on surface Т (Figure
5.7) of the rotor adapter. To expose the indicator on
"zero". The barring gear to turn crankshaft of the Diesel-
generator set on 3600, registering an outrun on the indi-
cator.
Preferable magnitude of the runout is 0,08 mm.
The maximum permissible value of the runoutis 0,13
mm. If magnitude of the runout is more than 0,13 mm,
necessary to lead disassembly of the Diesel-generator
set, to turn an engine flywheel on 1800 and again to
manufacture process of assembly.
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To test tightening torque of the bolts fastening the adapter of the stator to the generator body and cotter
of them.
To test tightening torque of the bolts installed through engine access covers, fastening the adapter of the
generator rotor to an elastic clutch of the engine. To install on the place access covers from two sides of the
engine.
Additional indications.
To fix the removed cover of the engine with the layer pad, bracket of the starter motor and bracket of the
oil injected pump by bolts, having tightened the moment (44±3) N.m.
To install the starter motor and to fix three basic bolts to the fly-wheel casing of the engine by the mo-
ment (220±10) N.m. To tighten two bolts, fastening the starter motor to the bracket by the moment (44±3) N.m.
To connect the hoses connected to the starter motor, on the former place. To fix oil injected pump on the
bracket.
To install four covers on the generator, closing air ports in the generator.
5.3 Repair and service of the cooling system
Index of a normal operation of the engine cooling system is maintenance of temperature of a cooling
fluid in nominal limits. The aberration from the specified temperature condition while in service a dump truck
can be caused a series of the reasons.
Most typical of them the following:
- insufficient amount of the cooling fluid;
- big adjournment of an incrustation in an integral cooling system;
- pollution of an external surface of radiators;
- failure of thermostatically controlled chambers;
- failure of a louvers or their drive gear;
- failure of a water pump.
Washing of the cooling system, descaling, substitution of a cooling fluid is necessary for carrying out ac-
cording to the use specification of the engine and indicatings of a maintenance manual of the dump truck.
Remarks - At the filling of the cooling system at cooling fluid it is necessary to turn out dummy
plug on the boiler of the engine starting preheater.
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tubes and through unblocking bores to delete the cooling fluid or to merge it with disassembly thermostat
boxes on the connector.
ATTENTION: IN THE COOLING SYSTEMS INSTEAD CRANES THE PLUG INSTALLATION IS POSSIBLE.
Figure 5.8 - the Stand - turner for assembly - disassembly of the radiators block:
1 - frame; 2 - stopper; 3 - reducer; 4 - fast-head support; 5 - fast-head arm; 6 - back arm; 7 - end support bearing
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Radiators Repair
After disassembly radiators are necessary for examining carefully.
The basic imperfections of radiators are:
- leak in places of the soldering;
- leak of handsets;
- damage tank and cooling plates;
- pipe choking and tanks depositions of the mud and an scale.
Tightness test will be carried out after clearing an outside radiators surface from mud and scale removal
which, filling in pores and flaws, can hide defects.
Radiators tightness is tested by compressed air in water bath (Figure 5.9). Apertures of bringing and as-
signing connecting pipes preliminary should be enclosed by rubber fuses (Figure 5.10), through one of which is
fanned under pressure 0,3 МPа. Tests will be carried out within 5 minutes.
For detection of the defective tube located inside the radiator check up each tube separately. For this
purpose remove upper and lower tanks, place a core of the radiator in water bath, muffle one end of the mus-
tered tube by fuse, to other end by means of accommodating (Figure 5.11) connect the hose for the intake of
compressed air. The radiator leak is eliminated by the tube soldering by tin solder ПОС-40 or ПОС-30. Tubes
which soldering is hampered or impossible, it is necessary to replace new or to solder them from both cleaning
cloth on depth 10 mm. It is supposed to kill no more than 1,5 % tubes.
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The radiators undergoing to repair by means of the soldering, it is necessary to wash out an alkaline so-
lution for neutralization of an acid with consequent washing by hot water for removal of an alkaline solution.
Cooling radiator plates at repair to correct so that they did not touch.
The repaired radiator after corresponding subassembly with tanks should be tested on the contaiment
above within 5 minutes.
Regulation plates louvers position
The louvers plates position is regulated by change of length of the free draft end or its installation in
other aperture in the lever. For regulation to disconnect draft (from one end), turn off the lock nut to turn the
fork on 0,5 - 1 turnover and to stop by nut. To install draft on the place.
To open - enclose the louvers and to test the thickness of plates adjacency.
At the louvers opening the plate should open completely, and at close there the plates should be the
dense adjacency.
Maintenance of the oil-water heat exchangers
The most typical the heat exchanger inaccuracies :
- violation of the soldering at grate;
- oil deposition on outside surfaces of tubes of the heat exchanger;
- big scale deposition in tubes of the heat exchanger.
Washing of water and oil cavities of the heat exchanger is made separately.
Removal of the scale and washing of the water cavity of the heat exchanger is necessary for manufac-
turing on special installation with use of the solution used for removal of an incrustation in radiators.
Test of the section of the water-oil heat exchanger for tightness will be carried out at the removed upper
cover by compressed air pressure 0,5 МPа within 5 minutes in water bath. Air should move through oil chan-
nel. It is necessary to replace defective tubes by new or to damp from both cleaning cloth, but no more than 5
tubes. After the tubes replacement and the block heat exchanger soldering wash out it in an alkaline solution
for acid neutralization, and then in hot water test for tightness.
Pneumoswitch repair
At the tightness violation of the pneumoswitch it is necessary to replace joint rings.
Pneumoswitch disassembly: - to turn off bolts and to remove cover 1 (figure 5.12) to extract from the
case 2 piston 4 together with stock 7 to remove the retaining ring 5 and to disconnect stock and piston, to re-
move joint rings
Figure5.12-Pneumoswitch:
1- cover; 2 - case; 3, 6, 8 - joint rings; 4 - piston; 5 - retaining ring; 7 - stock
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ATTENTION IT IS NOT SUPPOSED PRESENCE THE BOARD BREAKS AND DAMAGE OF SEALING ELE-
MENTS
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In case of need holdings of repair of the pneumatic starter are necessary for executing the following op-
eration.
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- disconnect the pneumatic engine from the reducer, for what turn off four bolts 29;
- cautiously tapping with a hammer from the soft material to separate the pneumatic engine from the
case of the reducer;
- turn off bolts 1 of the cover fastening 2 pneumatic engine, and then the bolt of 5 of the pinions
fastening 7;
- put the pneumatic engine in the verticality position and easily striking on the cover 2 to extract the shaft of
the pneumatic engine;
- for the disconnection of the reducer case 27 from the drive case 9 turn off bolts 21;
- easy percussion on the drive case to disconnect the reducer case ;
- turn off the bolt 25 of the bearings fastening 23 and the bolt 14 pinions fastening 13 then through the hole
in the shaft pinion to remove the retaining ring 24;
- with the help of special accommodating it is cautious turn off two screws of the case fastening 8 with the
drive case 9 as the restitution spring of the piston is strongly compressed;
- cautiously releasing restoring spring 10 to remove the reducer from the drive case ;
- to put the drive case in the verticality position and, tapping with the hammer from soft material on the
shaft end face 18 to beat out it from the bearing 12.
After disassembly all parts at which imperfections detected, it is necessary to replace.
Table 5.1 – Possible inaccuracies of the pneumatic starter and ways their removal
Faultiness Possible cause Remedy
The pneumatic starter does not turn to
the engine crank shaft though the
The engine crank shaft is not turned. The
pneumatic starter pinion has come in Fined reason. The engine blocking is elimi-
engine is blocked.
gearing with the flywheel, and to the nated.
pneumatic engine compressed air is
brought.
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The possible troubleshooting of the starting preheater and the methods their removes are in the
table 5.2.
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Table 5.2 The possible troubleshooting of the starting preheater and the methods their removes
Faultiness Possible cause Remedy
Preheater fails to start because of no fuel de- Electromagnetic valve filter clogged Wash or replace filter, blown down
livery with compressed air before mount-
ing
Electromagnetic valve fails to open (no click Check reliable connection of wire
heard in working position) lugs to terminals and serviceability
of 2A fuse. Replace fuse if needed
Nozzle centre orifice choked Remove and disassemble nozzle,
wash all parts in diesel fuel, clean
chamber hole and casing centre
orifice. Energize preheater and
check spray cone of nozzle not
screwed into burner
Air entrapped into fuel line Unscrew pump fuel supply pipe, let
air locks out, then screw pipe back
into place
Heater electric motor is inoperative Check reliable connection of wire
lugs to terminals and check electric
circuit with the aid of pilot lamp.
Push fuse button on control board
Glow plug does not operate Control board check spiral burnt Replace spiral
Glow plug spiral burnt Replace glow plug
Glow plug spiral heat insufficient Check connection of wire lugs to ter-
minals. Check storage battery
charge. Recharge, if necessary
No contact between wire lug and plug Tighten up wire lug attachment
Preheater is smoky Air delivered by blower insufficient because Charge storage batteries
of low motor speed
Nozzle orifice choked Disassemble nozzle, wash parts in
diesel fuel and clean orifice. Check
assembled nozzle for spray cone
Air intake blower screen or outlet pipe Clean outlet pipe or air intake screen
clogged with dirt
Combustion chamber carbonized Disassemble and decarbonize com-
bustion chamber. Clean chamber and
blow down with compressed air
Engine warming up period is too long Clogging of valve and nozzle filters causes Clean filters of solenoid valve and
insufficient delivery of fuel nozzle. Increase fuel consumption by
turning fuel pump pressure-reducing
valve screw
Fuel pipelines leaky Eliminate leakage
Electromagnetic valve fails to shut off fuel feed Dirt got under check seat Screw valve out of base, wash in die-
sel fuel and blow down with com-
pressed air
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5-18
Traction electric drive
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6-1
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ports of system of automatic regulation and together with lamps signal about turning on of safety devices.
Mechanically power rectifiers, adjusters, power switching equipment, and devices of program and auto-
matic control are integrated in control cabinet.
Operation modes of electric drive can be divided into two groups:
- modes set by operator;
- modes set automatically by means of system of automatic regulation.
In first group it is necessary to divide basic and additional modes.
Basic modes comprise:
- traction mode at forward and backward motion;
- mode of electric braking operation at forward and backward motion, implemented in two alternatives -
mode of standard electric braking operation in all speed range of driving and mode of forced electric braking
operation only in range of low speeds.
Additional operation modes of electric drive comprise:
- traction mode with emergency excitation of traction alternator (at out-of-order system of automatic
regulation or thyristors of adjuster of excitation of traction alternator);
- mode of emergency control (at out-of-order system of program control);
- mode of driving at power supply from external current source in garage;
- mode of manual or automatic control of exciting currents of traction alternator on braked dump truck at
inspection of technical condition of electric drive and regulating of parameters of external characteristic of in-
jection diesel-generator set at imitation of traction mode.
Second group of electric drive operation modes, set by system of automatic regulation, comprise:
- operation mode of traction motors with slackened magnetic stream of excitation (slackened field) in ba-
sic traction mode at forward motion:
- mode of dump truck speed limitation (of maximum rotary speed of traction motors).
Besides in traction electric drive safety of electrical equipment is ensured in case of overflow of accept-
able values of voltage and current of power circuit, shorting of power circuit on body of dump truck, short-circuit
of power rectifier, skidding of electric motorized wheels and others.
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Maintenance and repair of internal components of alternator (slip rings, brush-holders, sweepers and
others) is made through access hatches of board closed by folding covers.
Output leads from outputs of basic stator winding, wire from exciting winding of rotor and from outputs of self-
excitation winding are located in heel of board at left and right of vertical axis.
The end bracket 21 is welded skeleton structure, fixed by bolts to case 30 of stator. In central part of end
bracket demountable hub 11, providing opportunity of replacement of bearing 4 without removal of end bracket
from alternator and without removal of alternator from dump truck, is fixed by bolts.
On brackets of end bracket by means of insulators 15 two suspensions 14 are installed, to each of which
three brush-holders 13 and current carrying wires of sweepers are fixed, and also wire, connecting circuit of excit-
ing winding of rotor with system of automatic regulation, is connected.
In alternator radial one-clip brush-holders (figure 6.2) are applied in which force of pressure is created
and transmitted to sweeper by pressure bar 3 consisting of spring, bar and cock, which is intended for rise of
bar from sweeper.
The construction of brush-holder ensures fixed force of pressure to sweeper irrespective of its wear.
Therefore, while in operation additional readjustment of force of pressure on sweeper is not required.
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Sweepers, installed in cartridge clips of brush-holders, are supplied with shock-absorbing strap.
In alternator spherical roller double-row bearer is applied for support and for free rotation of rotor 4 (see
figure 6.1), closed with covers 1 and 10 from two sides.
Cavities between bearing 4 and covers 1 and 10 form internal and external chambers of lubrication ac-
cordingly. Besides, as result of press fitting of ring 7 in internal bearing cap, backup chamber of lubrication,
which is filled by lubricant at assembly of cover 1 is formed.
Lubricating grease, which brand is specified in certificate of alternator, is applied in bearing.
The construction of bearing mount assembly ensures reset of completed lubrication in special chamber
formed by external cover 10 of bearing, its ring 8 and external sealing ring 6. Reset of debris-contaminated lu-
brication in chamber occurs through spacing between ring 8 of cover 10 and external sealing ring 6.
Labyrinth and groove sealings are applied in order to prevent outflowing of lubrication from bearing out
or in inside of alternator and penetration into bearing of dust and moisture.
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package is selected from pressure washers. On outer diameter of inductor sheets and pressure washers
chases in shape of "dovetail" are made, in which poles of single-block construction are fixed with wedge keys
39. Each of poles consists of core hub and coil.
The core of pole is typed from sheets, pressed and strap with two cheeks and polar rivets, and has spe-
cial protuberances in shape of "dovetail" for fastening in chases of case of rotor.
The single-layer coil of pole is reeled up on rib from copper ribbon of rectangular cross-section. Between
coils of coil layer pads from insulation substance are stamped in shape of coil. Coil in assembly with core of
pole is impregnated in epoxide compound, by which cast-in-place construction eliminating conveyance of coil
concerning core is ensured.
Each coil has two output leads to which interpolar joints are connected.
From eight coils of poles which form exciting winding of rotor, four are executed with intercrossed output
leads, and other four are direct (open). Полюсы with intercrossed and direct output leads of coils are installed
on case of rotor through next nearest one.
The series connection of coils of poles is executed by means of webs 42 fastened with output leads of
coils to case of rotor through pads 24.
The beginning and finishing of winding of excitation 40 are connected by tires to slip rings 12.
Slip rings are produced of antirust steel and pressed on isolated cylinder landed on shaft with tightness.
As contact output, stud, to which corresponding connective tire from exciting winding is connected, is
fixed in each ring.
The surface of rotor (except for working surface of slip rings of shaft and flange) is covered with enamel
Эп-91 GOST 15943-80.
The wiring scheme of joints of windings of alternator is specified in figure 6.3.
Alternators in different climatic modifications differ in brands of used constructive materials, paint and
varnish and metal plating.
Figure 6.3 - Scheme of electric joint of windings of alternator ГС -525A (view from side of slip rings):
F1, F2 - beginning and finishing of winding of rotor excitation; S1, S2 - outputs of self-excitation winding (from third harmonics);
1U, 2U, 1V, 2V, 1W, 2W - outputs of phases of stator winding; 1N, 2N - outputs of origins of stator windings; H, K - beginning and end of
polar coils of rotor
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The beginnings of phases and origins are inferred through bores in heel of board from side opposite to
diesel engine. Lead-out tires are closed by protective demountable housings 4, 17 (figure 6.6).
The stator of alternator is of cylindrical shape and consists of core, windings and case.
The case is welded of sheet steel, consists of sheeting and flanges connected among themselves by ribs.
The core of stator is blended from isolated by varnish segments of electrotechnical steel with width of
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Traction electric drive
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0,5 mm, divided on length into separate packages by glass fiber plastic segments. Core is pressed with pres-
sure flanges, coupling studs and nuts.
In open chases of stator three windings are stacked - two basic three-phase winding and single-phase
self-excitation winding. In chases they are fixed by glass fiber plastic chocks. Frontal parts of windings are fas-
tened to retaining rings.
The rotor consists of shaft, skeleton put it, poles with windings and fan blower.
Cores of poles are burdened. Poles are fastened to skeleton by T-shaped shanks with chocks.
The current supply to rotor winding is carried out through slip rings.
Coils of poles are produced from tire copper bent on rib. Interturn isolation of coils is made of glass rib-
bon or fiber glass on epoxide cementing material.
Interbobbin joints are executed by non-isolated tires, which are timbered with bolts on isolation pads.
In end bracket of alternators СГД and СГД2 on side, opposite to diesel engine, spherical double-row
roller bearing is installed. For protection from emersion of bearing currents, end bracket is executed with iso-
lated cap.
Internal and external bearing caps are produced with grooves for protection of outflowing of lubrica-
tion. In addition from interior of bearing ring is installed, which forms labyrinth device in pair with cover. For
washing of bearing and feeding of lubrication two tubes are screwed in internal cover. Cavities of external
and internal covers are connected by bore in cap.
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Figure 6.6 - Traction alternator СГД (view from side of slip rings):
1 - lock of cover; 2 - cover of access hatch; 3 - greaser; 4, 17 - housings; 5, 6, 7, 8, 13, 14, 15, 16 - output leads; 9, 12 - wires;
10 - pipe duct of lubrication; 11 - plug
7513-3902080 RM
Fanning of electric motor is of forced type. Cooling air moves from side of collector through collector
manhole and goes out from opposite side through bores in rear end bracket. Lead-out wires go out through
bores with rubber inserts in end bracket on side of collector.
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Chases in armature sheets before stacking of coils are covered by film from fiber glass fabric. Armature
coils in chases of armature sheets are fixed by insulation chocks, and frontal parts of them are fixed with bind-
ings from special glass-strip ribbon.
Joint of equalizers and armature coils with collector bars is executed by welding.
The head of coils from side opposite to collector are protected from mechanical damage by winding-
holder. Besides, winding-holder serves for separation of streams of cooling air moving out of electric motor.
Sealing rings of bearings 3, 5, 22 and 24 are set on shaft in heated mode. On their external surface, there
are grooves for setting sealing split collars with expanders.
Magnetic system consists of case 15, brush-holders 11, principal 16 and additional 27 poles, connective
tires and wires.
The case of magnetic system serves for assembly of all electric motor and simultaneously is its mag-
netic conductor.
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Figure 6.9 - Traction electric motor ЭД136 (view from side of collector):
1, 2 - covers of access hatches; 3 - nipple;
Д1, Д2 - outputs of winding of series excitation (Д1 - beginning of circuit, Д2 - end of circuit); А1, В2 - outputs of winding of
armature (А1 - beginning of circuit, В2 - end of circuit)
With purpose of best use of internal space for seating principal and additional poles, case is executed in
lateral section as scalene octahedron that allows to receive least outline dimensions of electric motor at four-pole
modification.
There are welded gusset plates on case from above and from below, which serve for fixing electric mo-
tor on dump truck.
In butts of case borings (necks) are available, through which assembly of magnetic system is executed.
End brackets with armature are installed in borings.
Four brackets are welded to internal face wall of case against principal poles, which serve for fastening
of brush-holders. Case on side of collector has four manholes, on one of which nipple for feeding of cooling air
in electric motor is installed. Other manholes serve for maintenance and repair of internal components of elec-
tric motor. From side opposite to collector, in case there are windows for exit of cooling air.
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The magnetic system has four radial brush-holders. Case 4 of brush-holder (figure 6.10) has two car-
tridge clips in which split brushes 2 are installed.
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Each of coils has two output leads for fastening tires or wire joints between poles. Output leads of coil of
additional pole for toughness are rested on steel insulated plates inserted between coils. From four coils of
principal poles, two are executed with cross output leads, and two others – with direct (open) ones. Coils with
cross and direct output leads are installed in magnetic system through one, what enables to interlace polarity
of poles and to simplify construction of connective tires at series connection of coils of principal poles.
Principal poles are fastened to case of magnetic system by means of bolts rolled in tapped holes of rod.
Additional poles are fastened to case of magnetic system by means of through passage square-head
bolts and nuts. Heads of bolts are placed in special chases of cores on side of armature.
Joints between coils of principal poles are executed from insulated tires and located on side of collector.
Tires are fixed by means of bolts to output leads of coil and by means of steel ribbon and rubber shock-
absorber to clinches welded on case.
The wiring scheme of joints of windings of electric motor is shown in figure 6.11.
Joints between coils of additional poles, between brush-holders of one polarity, between circuits of addi-
tional poles and brush-holders are executed by flexible wires (cables) and located on side of collector. Fixing of
wires is similar to fixing of tires between coils of principal poles.
Magnetic system has four wires for connection of electric motor to power circuits of dump truck. Wires of
winding of armature and winding of series excitation, and also wire of sensors of thermal mode are inferred from
case of magnetic system through bores in its upper part on side of collector. Bores are condensed with rubber in-
serts precluding hit of moisture inside of electric motor and protecting insulation of lead-out wires from fault.
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Collector of electric motor is of arch type, on steel modular grounding. Electric motor is made with four
brush-holders 5. Each brush-holder has three split brushes. Force of pressure to sweepers is regulated by
turning movement of screw. For maintenance of brush device and collector there are windows in end bracket.
In electric motor on side of collector ball bearing is installed, from opposite side - roller bearing. Lubricant
Литол-24 GOST 21150-87 is applied to bearings.
Bearing mount assemblies ensure opportunity of lubrication refill without dismounting of electric motor.
On side of collector on electric motor tubes for feeding lubrication in bearing mount assemblies are located.
Fanning of electric motor is independent. Cooling air moves from side opposite to collector through
bores in rear end bracket, and is rejected on side of collector through bores in front end bracket.
Lead-out wires of windings of electric motor go out from side opposite to collector, and are fastened in
cleats installed on board.
Each electric motor has plate on frame, on which motor’s serial number, extent of safety, operation
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mode, mass of electric motor, class of insulation and other ratings are specified.
The serial number of electric motor is also plotted on flange of frame. Number of armature is plotted at
butt of shaft on side of collector.
The wiring scheme of joints of windings of electric motor is shown in figure 6.13.
Direction of rota-
tion (from side of Joint of lead-out ends
collector)
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- engine is resistant to effect of vibration loads over range frequencies from 1 up to 80 Hz with maximum
speedup of 50 мс2 for degree of stiffness "6" in accordance with GOST 16962.2-90;
- angles of bank and trim are no more than 20 °.
Main parts of engine include: magnetic system, armature, end brackets with covers of bearings, brush-
holders.
The traction electric motor (figure 6.14) is four-pole electric direct-current machine with series excitation
with two running ends of shaft. As support of shaft 1 of armature serves single-row ball-bearing 30 located on
side of collector, and single-row roller bearer 40, located on opposite side. Change of direction of armature
shaft rotation in both sides is carried out by switching exciting winding according to scheme (figure 6.15).
System cooling is of forced-circulation type. On air vent, which is fastened to window of nipple 34 (see
figure 6.14) in case on side of collector, cleared cooled air moves in engine. Blowout of air is carried out
through windows located on face surface of end bracket 8, on side of opposite to collector. At mounting of en-
gine on dump truck, reinstallation of nipple 34 and closing 45 on opposite side face of case is supposed.
Choke tubes located on closing 45 and nipple 34 should be placed on side of butt of frame case.
Magnetic system. In frame, executed by steel welded both being case and magnetic conductor of en-
gine, four principal and four additional poles are fixed by bolts 11, 14. Frame has two basic platforms, with the
help of which engine is fastened on dump truck. For visual inspection and maintenance of collector, brush de-
vice and replacement of sweepers four manholes, enclosed by covers 33, are made in frame.
Cores of principal and additional poles 12, 13 are executed blended of sheet electrotechnical steel. Be-
tween cores of additional poles and frame sets of magnetic and not magnetic gaskets 15 providing operation of
engine in zone of safety commutation are installed. Between cores of principal poles and frame adjusting
shims are installed. Coils of principal 7 and additional 16 poles are executed from copper ribbon of rectangular
cross-section and fixed on cores of poles. Between coils of poles and frame there is air gap that augments
area of convective heat exchange from surface of coils.
Heat, produced by windings of poles, is sinked from surface of coils by cooling air coming through en-
gine.
Windings of poles are interconnected by copper tires according to scheme (see figure 6.15), by means of
hard soldering. Lead-out ends 43 (see figure 6.14), and joint of windings of poles with brackets are executed
from multifilament wire with rubber insulation. Each output consists of two wires, joint in parallel. Lead-out wires
go out through bores in frame and rubber inserts 44, and are fixed by pad 42 to clinch 21. Identification mark of
outputs is executed on cable lugs.
From butts of frame bores for mounting end brackets, tapped holes for fastening working end bracket 8
and body-size holes for fastening collector end bracket 27 are executed. On face surface of case on side of col-
lector brackets with brush-holders 18 are fixed. brackets are installed on neutral on factory-manufacturer. Cases
of brush-holders are executed of brass cast, in each of which two sweepers are installed that are held down to
collector by pressure gears 46 of brush-holders with roll springs.
Armature. Basic components of armature is winding consisting of armature coils 6 and equalizers 17,
armature core 39, shaft 1, collector 37 and winding-holder 5. Simple lap winding of armature is executed from
insulated copper wire of rectangular cross-section and stacked in chases of armature core.
Outputs of armature coils and equalizers are joined to collector bars by argon-arc welding. Armature core
is executed blended of sheet electrotechnical steel. Round bores in sheets form two lines of axial ports for pass
of cooling air.
The collector 37 is of arch construction and ensures current lead through sweepers to winding of armature.
Collector ring 38 and taper collector 23, executed of forged steel, at tie with studs 35 and nuts 32 create neces-
sary arch thrust (pressure) holding collector and insulation plates from offset. Between taper and nuts Belleville
springs 25, providing stability of shape of collector at maintenance, are installed. For insulation of collector bars
from barrel and pressure taper two insulation cuffs 20 are installed. In collector ring there are bores which form
with bores of armature core ports for pass of cooling air.
Heat produced in winding and in armature core is taken away from external cylindrical surface of arma-
ture core and from surface of internal ports by cooling air. Winding-holder is of welded steel, and serves for ar-
rangement and fixation of frontal parts of armature coils and security of solidity of armature core.
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End brackets and covers are of bearing type. End brackets 8 and 27 are steel welded. Supporting bear-
ings 40 and 30 are installed in them, bearing 30 perceives axial loads on shaft. On hubs of end brackets bear-
ing covers 3 and 29, defending together with stop rings 31 bearings from hit of dust and mud and forming
chambers for confinement of lubrication, are fixed. Lubricant moves in bearing chambers through oil pipe 49
located on external surface of case, near to lead-out wires, and connected by system of handsets and bores in
case, end brackets and covers. As matter of convenience access to greasers, their reinstallation with plugs lo-
cated on opposite side of case of engine is supposed. Bearing mount assemblies are filled by lubricant
ЛИТОЛ-24. In nodes of bearings 2,5 kg of lubrication is applied.
Temperature, vibration and rotary speed sensors. Engine is equipped with sensors for monitoring tem-
perature of windings of additional poles, bearings, sensor of rotary speed. Output of sensors of 1 m cables in
length with connectors are inferred from upper part of case.
Temperature sensors - thermistors СТ 14-2А-160 (for additional poles) and СТ 14-2А-105 (for bear-
ings). Sensors are connected in sequence.
The sensor of rotary speed - cutout retract non-contact switch, is installed inside engine on bracket in-
stalled on face part of case of engine. Sensors (designation on scheme BR1 and BR2) are intended for feeding
signal about current values of rotary speed of armatures of traction electric motors on electronic blocks.
The sensor is fastened to case of traction electric motor. On external belt of taper of collector, there are
two diametrically located chases at transmitting of which under sensor pulse will be selected. Spacing between
+1
sensor and belt of taper of collector is 2 mm.
At operation of engine, reinstallation of bracket with sensor of rotary speed on diametrically opposite
side of case is supposed.
As speed sensor non-contact retract switch ЭВИ-151 is used. The switch is electric inductance-type trans-
ducer working on closure.
Appearance of speed sensor and scheme of its connection are shown in figure 6.16.
The technical data of speed sensor ЭВИ-151 is specified in table 6.1.
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The control cabinet 75131-2112010 has frame modification with one-sided maintenance of electrical
equipment located in it, contains four consistent doors with weather strips and locks. On rear wall of cabinet
stuffing boxes for lead of main leads are located. Control cabinet consists of four chambers. Arrangement of
electrical equipment in chambers of control cabinet is shown in figure 6.18.
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6.2.2.2 Contactors
Direct-current electropneumatic contactors ПК-1-02 (figure 6.19) are intended for turning on and cutting
off of power circuits of electric drive.
The contactor consist of following basic units: mobile 4 and motionless 5 contact pieces, pneumatic
drive 12, extinguishing chamber 9 and electric blocking 14. All units and parts of apparatus are built on insula-
tion rod 1. Unit of fixed contact consists of bracket 6, arcing ground suppressor 7, principal contact piece 5 and
arcing contact 8. On bracket 2 of movable contact bar 3, carrier contact clip with principal contact piece 4 and
arcing contact 10 are hingedly installed. Principal contact pieces have straps from composition silver-cadmium
oxide and are intended for long transiting of current through them. Arcing contacts have straps from composi-
tion copper-tungsten and are intended for commutation of power current. Bar 11 is connected by insulation
pull-rod 3 to stock of pneumatic drive 12. Drive gear includes cylinder, cutting off spring, stock, bucket and
electromagnetic valve 13. Piston seal is executed by rubber cuff.
For arc control contactor has one-slotted chamber executed as two premolded side members from arc-
resistant material. On exit of extinguishing chamber arc chutes are installed.
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Electropneumatic contactors ПК-753Б9 connects power circuit of electric motors to traction alternator.
Contactor consists of fixed contact 3 (figure 6.20) with arcing ground suppressor 2 and extinguishing chamber
4, movable contact 5, retaining contacts 8 and pneumatic drive controlled by electropneumatic valve 13. All
units are built on insulation panel 1. Technical data of contactor is shown in table 6.1.
At energizing on coil of valve core of electromagnet displaces and connects drive gear of contactor to
pneumatic drive of parking braking system. Compressed air moves in cylinder 12 of drive gear, effects on bucket
and sets in stock 10 which displaces bar 7 with movable contact 5, which completes circuit. At stress relief from
coil of valve turnpike of pneumatic drive is
unhooked from drive gear of parking braking
system, compressed air goes out in aero-
sphere, and contact pieces under operation
of restoring spring are unlocked. Electric arc
originating at contact breaking is blown off
from them by magnetic field formed by arc-
ing ground suppressor, and dies away in
extinguishing chamber.
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The electromagnetic contactor SU-610 Ts – dry open contactors with electromagnetic DC-drive. Con-
tactors of this type can be used instead of electropneumatic contactors. Technical data of contactor is shown in
table 6.2.
The contactor consists of fixed contact 11 (figure 6.21) with arcing ground suppressor 9, arc-
suppressing groove chamber 10 arranged with pole shoes, movable contact 13, forcing circuitor 3, magnetic
system (core 17, armature 4, coil of drive gear 2 and forcing resistance 1) and block of free contact pieces.
The movable contact is connected to lead-out tire 14 by flexible connection 15. System of principal con-
tact pieces is built on plastic grounding 6. Contactor is installed in horizontal position on claws 5.
At maintenance it is enough to remove only arc-suppressing chamber for inspection of its condition and
condition of principal contact pieces.
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The electromagnetic contactor МК-6 is intended for commutation of resistors shunting windings of se-
ries excitation of traction electric motors and for connection of exciting winding of traction alternator. Contactors
are installed in control package of control cabinet.
Construction of contactors is of single-block type. All parts are installed on clinch 5 (figure 6.22). Mag-
netic system is of two-bobbin type. Twirl of armatures 2 and 8 occurs on shafts 4 fixed in pads, shock absorb-
ing is performed by springs 3.
The contact system of principal circuit consists of terminal block 7 on which motionless base rings 1 are
installed. In pad 7 there are snapping clinches 9, intended for confinement extinguishing chamber 10. Contact
system of auxiliary circuit consists of two interlock contacts 6 which are fastened motionlessly on clinch 5.
The technical data of contactor is shown in table 6.3.
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The stream of cooling air from fan 5 acts in zone of arrangement of resistors through air vent 6. In front
and rear parts of framework are installed guiding 2 for regulating streamline of cooling air.
On side of exit of air framework is enclosed by protective lattice for prevention of hit in zone of blocks of
resistors of mud and ectogenic subjects.
Accumulation of mud and dust on resistors at continu-
ous exploitation call aggravation of fanning that can serve as
reason of excessive heating. Besides adhesion of mud and
dust to insulators results in aggravation of electrical insula-
tion.
In case of pollution remove cover, put forward blocks
of resistors and delete mud and dust by wood putty knife or
other wood tool.
The axial fan 9 (figure 6.26) is driven by electric motor
of 4 direct-current series excitations. Power supply of electric
motor is carried out from interior of brake mounting. For
power supply power failure on side of brake resistance is
used at leakage of current flow through it, therefore air sup-
ply is made only at connection of mounting in circuit, that is
at braking operation of dump truck.
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Each traction electric motor in mode of electric braking operation is connected to one bank of resistors.
The frame of electric motor has mounting surfaces to pinion point for fastening in housing 5 of fan. For
access to collector and to brush device in frame there are windows enclosed by housing.
The end of motor shaft is cylindrical, with tab and thread part for landing and fastening of axial fan. On
frame, coils of principal and additional poles are fixed.
The electric motor has four brush fingers, mica-insulated by plastic. Fingers are chucked in beam, which
has opportunity to be pivoted on surface of front end bracket.
Lubrication of frictionless bearings is carried out through tubes brought to end brackets.
Mounting of ventilated brake resistors УВТР2х600 (figure 6.27) consists of two banks of resistors 1
and motor-fan 8. Each bank of resistors consists of four elements. Each element represents fechral ribbon
curved in sinuous shape and timbered between insulators. Technical data of mounting is shown in table 6.4.
The axial fan is driven by direct-current electric motor of series excitation. Power supply of electric motor is
carried out from interior of resistor. For power supply power failure on side of brake resistance is used at leakage
of current flow through it, therefore air supply is made only at connection of mounting in circuit.
The frame of electric motor has mounting surfaces to pinion point for mounting in fan casing. For access
to collector and brush device there are windows enclosed by housing in frame.
The end of motor shaft is cylindrical, with tab and thread part for landing and fastening of axial fan. On
frame coils of principal and additional poles are fixed.
The electric motor has four brush fingers, mica-insulated by plastic. Fingers are chucked in beam, which
has opportunity to be pivoted on surface of front end bracket. Technical data of fan is shown in table 6.5.
Lubrication of frictionless bearings is carried out through tubes brought to end brackets.
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System of fanning and cooling is intended for maintenance of optimum temperature operation mode of
components of traction electric drive.
The system of input of cooling air ensures input of air from least dusty zone of dump truck and through
air-slaked cyclonic filter built on power cabinet and cyclone separators, built on front wall of power cabinet (for
dump trucks BELAZ-7514-10/75145), through cyclone separators built on front wall of power cabinet (for dump
trucks BELAZ-75131/75132), air cleared of ectogenic admixtures on suction air duct acts in upstream end of
traction alternator on side of slip rings.
The part of air is used on cooling of traction alternator, passing through air channels (through vent holes
in stator sheets, spacing between poles of rotor, poles of rotor and stator). Passing through spacing air goes
out of alternator through windows protected by grids in case of stator, from side opposite to slip rings.
Other air acts in cooling fan of traction engines and through forcing air vent moves in crankcase of rear
axle and on ports in cases of reducers of electric motorized wheels acts for cooling traction electric motors. Air
goes out through air-vent windows of traction electric motors and bores in cover of manhole of crankcase of
rear axle.
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- clear surfaces of windings, slip rings, brush device of pollution and dust. For removal of stuck mud it is
necessary to use rigid hair sweeper, and also dulled wood or fibre scratcher. If pollution is easily cleared me-
chanically, insulation surfaces should not be sprayed and washed out with any fluid. During clearing or flushing
out it is necessary to ensure sufficient aeration.
If pollution is not cleared mechanically, clearing of alternator, which has arrived on repair, and its com-
ponents from operation pollution is to be performed in washing mounting by washing fluid for which dilute solu-
tions of one of following washing-up liquids are to be applied:
- 0,1-percent solution of МЛ-80 ТУ 84.509-1-82;
- 0,5-percent solution of waste products of "Синтамида 5" ТУ6-02-09-04-82;
- 0,5-percent solution of "Термос" ТУ6-0,2-15325-80;
- 0,1-percent solution of "Термос" ТУ6-02-15325-80 with 0,2-percent solution sodium tripoliphosphate of
GOST 13493-86.
0
Clearing is to be produced at temperature of 70 С for washing fluid with solution of MЛ-80 and waste
0
products of "Синтамида 5" and at 50 - 60 С with solutions of " Термос".
It is supposed to apply to flushing out of alternator in assembly cleaning solution "Лабомид-101" or
"Лабомид-102";
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- after clearing or flushing out produce drying at temperature of 130 - 150 0С before restoring required
values of insulance of units. Thus from moment of termination of clearing or flushing out prior to beginning of
drying should pass not less than 0,5 h.
Insulance of circuits of alternator regarding to case and between windings is to be measured with me-
gohm meter by voltage on 1000 V.
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- put against stop in bearing external sealing ring 6 (only in case of its removal), preliminary picked up
and heated up to temperature of 120 - 160 0С (before installation of sealing ring corresponding mounting sur-
face of shaft is to be greased with thin stratum of petroleum oil, excluding cases when heat is made in lubri-
cated bath);
- wrap up working surface of slip rings with board or other dense material for protection from mechanical
damages during assembly of alternator;
- grease thread surfaces of bolts and bores, and also mounting surface of case of stator 30 under end
bracket with lubricant ЖРО ТУ32 ЦТ520-83;
- install sweepers in brush-holders so that they did not appear from cartridge clips aside slip rings (bar
on sweepers is not to be installed, but sweeper from side should be propped up by them).
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ТГМ-3 ТУ6-16-2010-82, hundred thirty parts of talc GOST 19729-74 or hundred sixty parts of quartz sand.
Damaged insulation of tires between slip ring and exciting winding should be restored similarly to restor-
ing of insulation of tires of stator. Thus each stratum of insulation should be covered with glueing air-drying
varnish. At insulance in cold condition less than 10 MOm produce drying of insulation by external heating. After
drying it is necessary to enamel surface of rotor.
At detection of breakdown of insulation on case, and also if insulance gauged at temperature of 100 -
110 0С (after drying), less than 0,5 MOm, deliver rotor on major repair. Before sending on repair remove bear-
ing, internal sealing ring and internal bearing cap from shaft;
- test by visual inspection and tap test condition of bolt contact joints of rotor and if necessary tighten
them. At burning of nosepieces of tires of webs and output leads of poles replace them. At impossibility of re-
placement of poles under operating conditions deliver rotor to major repair. After replacement of poles pierce
and balance rotor;
- test by visual inspection, ruler and probe condition of slip rings. Slip rings should have smooth working
surface without traces of flashing off, burnings and pollution. Development under sweepers is to be defined by
measuring by probe light slot between ruler and slip ring. Development under sweepers should be no more
than 0,25 mm.
At radial development more than 0,25 mm pierce and ground working surface of slip rings. There should
not be traces of blanking on surface of barrel between slip rings. After propoint and grinding work of slip rings
blow rotor with compressed air.
Enamel surface of rotor (except for surface of shaft, flange and working surface of slip rings). Surface
covered with enamel, should be equal (without rolls and smudges);
- test by external examination condition output leads and wires of alternator. Restore damaged insulation.
Replace wires and tires at burning of nosepieces, abruption of more than 10 %;
- test by visual inspection condition of brush-holders. Replace out-of-order (damaged) details. Remove
file rolls disturbing free conveyance of sweepers in cartridge clips;
- test retorque fastening of brush-holders to suspenders, suspenders to insulators, insulators to brackets
of end bracket. Slackening of fastening is not supposed;
- enamel internal and external surfaces of end bracket (except for tapped holes, mounting surfaces to
pinion point, suspenders, brush-holders). Surfaces covered with enamel, should be equal (without smudges
and rolls).
For internal surface it is necessary to apply enamels ГФ-92ХС or ГФ-92ГС GOST 9151-75, to external
surface – enamel ПФ-115 GOST 6455-76 or enamel of МЛ-12 of GOST 9754-76;
- install package of new sweepers. Again installed sweepers preliminary should be reseated on special
drum (with diameter equal to diameter of slip rings) on which surface emery paper by speckle of 8 - 10 pres-
sure face to sweepers is installed. Install only sweepers of brand, which is specified in certificate of alternator.
Sweepers should not have chopped off crimps at contact area of more than 10 % of cross-section and should
displace freely in brush-holders. Current carrying wires of sweepers should be braid on 2,5 revolutions;
- wash out and blow with air tube for adding lubrication. Test by visual inspection condition of tube and
greaser for adding lubrication. Tube having cracks, fault of thread and others failures should be replaced;
- test by visual inspection condition of housing, covers of lower housings. Weld cracks in details of hous-
ings, and also in weld seams with consequent square-wave stripping. Smooth out weld seams flush with par-
ent metal. Remove warping of details by editing on plate;
- replace components of board at presence of cracks not permitting reparation and warping;
- enamel internal and external surfaces of housings, covers of lower housings. Restore color image of
warning sign of safety on covers of lower housings. Surfaces covered with enamel, should be equal (without
smudges and rolls).
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Where U for stator windings is equal to greatest voltage of alternator at durating condition of power, for
exciting windings and autoexcitation U is equal to rated voltage of these windings.
After trial cover external surface of alternator with enamel ПФ-115 GOST 6465-76 (modification УХЛ) or
enamel MЛ-12 GOST 9754-76 (modification Т), and also cover greaser and screw of external bearing cap with
red enamel ГФ-92ХС GOST 9151-75.
In case of storage necessity produce rust-preventive treatment of alternator.
After rheostatic trials of dump truck alternator should meet following requirements:
- slip rings should have smooth working surface without traces of flashing off, without burnings and mud;
- radial runout of working surface of slip rings in hot condition should be not more than 0,08 mm;
- sweepers should not have one-sided development of edges, traces of burning, fault and traces of ex-
cessive heating of current carrying wires;
- stator should not have traces of violation of brazing;
- insulation of windings should not have traces of mechanical or electric faults;
- bolted joints should be tightened and have no slackenings.
After rheostatic trials of dump truck apply 0,05 kg of fresh lubrication in each tube for adding lubrication.
Replacement of bearing of alternator ГС-525А without removal of alternator from dump truck
At replacement of bearing it is necessary to wash out bearing mount assembly and to replace lubricant.
Type of lubrication and amount is specified in Operation manual or lubrication charts.
Replacement of bearing should be performed in following sequence:
- clear alternator outside of dust and mud;
- remove from conic end of shaft hub of fan wheel;
- disconnect from end bracket 21 (see figure 6.1) and turn out tube of input of lubrication 20;
- lift sweepers;
- swept shaft of rotor 5 between bearing and slip rings with rope of necessary length with hempen armor
and hinge strains on ends;
- put on hinge strains of rope on hook of hoisting crane;
- stretch rope with help of crane and suspend rotor for removal of loading from its mass on details of end
bracket mated to bearing;
- unscrew bolts and remove external bearing cap 10 by means of bolts screwed in its squeezing bores;
- unscrew bolts, squeeze hub 11 of boring end bracket by means of bolts screwed in squeezing bores
and remove it;
- press bearing 4 and sealing rings by means of mechanical remover (bolts of remover should be screwed in
bores of internal bearing cap), wash out bearing mount assembly;
- test by visual inspection absence of cracks of sealing rings and covers of bearings, absence of burrs,
nicks, agnails on them, absence of burrs on mounting surfaces of shaft (it is supposed no more than three lon-
gitudinal marks by depth up to 0,1 mm);
- measure diameters of corresponding mounting surfaces of shaft of rotor and pick up on them (or use
removed) internal 3 and external 6 sealing rings, and also pick up new bearing. At selection provide tightness
no more than 0,035 mm (or spacing no more than 0,03 mm) for internal sealing ring, 0,013 - 0,055 mm for in-
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The principal reasons for violation of serviceability of traction electric motors are: drop of insulance of
windings, breakdown of insulation of windings on case, spring coil closure in windings, transfer on collector of
electric arc, violation of commutation (heavy sparking under sweepers, violation of glossy surface of collector,
burning of crimps of sweepers), rupture and drum-out glass-tread of winding of armature, excessive heating or
collapse of bearings, heightened outrun of collector.
For elimination of majority of listed failures and faults removal of electric motor from dump truck, disas-
sembly and replacement or repair of its components is required.
Repair of electric motors is executed by highly skilled mechanics in special locations equipped with nec-
essary equipment for holding of maintenance functions.
At detection of insignificant burnings of collector bars which are not eliminated by wiping by cleaning
cloth, it is necessary to grind collector. Grinding work should be performed by abrasive sticks specially in-
tended for this purpose. For deriving greater exactitude and tall surface smoothness it is necessary to fix sticks
in caliper. It is forbidden to apply to grinding work sand or carborundum paper.
In case of failure detection and faults which elimination needs disassembly of electric motor before its
repair perform following operations:
- clear external surface of electric motor removed from dump truck of dust and pollution, blow electric
motor outside and inside with dry clean air, clear external surface of assembly unit and details of pollution.
Air for blowdown of separate parts and as whole of traction electric motor should be dry, cleared of ec-
togenic admixtures and move under pressure of 0,18 - 0,2 MPa, hose for blowing should not have metal nose-
piece.
Clearing of contact or other metal and insulated surfaces of electric motor should be performed by clean
dry pileless napkins (if necessary moistened in benzine or spirit) at powered exhaust ventilation.
For removal of mud, densely stuck to components of electric motor, use rigid hair sweepers, and also
wood or fibre scratchers.
Clearing and drying of electric motor which has arrived on repair and its components from operation pol-
lution is to be carried out in washing mounting by washing fluid according to recommendations, specified in
Operation manual;
- measure insulance of circuits with purpose of detection of sections with reduced insulance (the insu-
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- measure by probe radial clearance in bearings (between upper roller and outer ring of bearing) which
should be not less than 0,09 mm for bearing from drive end and not less than 0,05 mm for bearing on side of
collector;
- measure axial take-off run of armature, which should be 0,6 - 0,9 mm;
- measure face runout of outer rings of bearings which should be not more than 0,12 mm;
- mount split collars with expanders in external sealing rings 5 and 22, preliminary having lubricant in
bores, and expose junctions of split collars of sealing in each sealing ring on 1800 and their common shaft ap-
proximately in midposition;
- install and fix bolts of cover 6 and 21. Through body-size holes in board on side of collector turn, not
torquing, bolts to internal cover to fix bolts of external cover and after that fix internal bearing cap;
- remove board from collector;
- test and expose distance between brush-holder and working surface of collector (the distance should
match to the one specified in assembly drawing);
- reseat sweepers on collector, for that envelop collector with emery paper in length of 1,3 of length of
round of collector and in width that is equal to length of working surface of collector. Lower sweepers on collec-
tor and, twirling armature produce abrading of sweepers. After abrading of sweepers blow electric motor with
dry compressed air;
- test by dynamometer force of pressure of springs to sweepers. It should be 42 - 46 N;
- measure radial runout of working surface of collector in heated condition. Radial runout should be not
more than 0,04 mm at variance between outrun in cold and hot conditions no more than 0,02 mm;
- test absence of contingence of current carrying wires of sweepers to metal parts of electric motor;
- measure insulance of windings of electric motor in practically cold condition. Insulance should be not
less than 10 MOm.
At assembly of electric motor bolts of fastening of end brackets and covers of bearings should be tight-
ened by a little serial screwing of diametrically opposite bolts.
After assembly of electric motor perform visual inspection of condition of working surface of collector,
sweepers and brush-holders, correctness of identification mark and arrangement of wires, and also make sure
(by rotation of hand) of free rotation of armature and in absence of ectogenic subjects in electric motor.
Disassembly of engine
Disassembly of engine is to be carried out as follows:
- disconnect output 43 (see figure 6.14), dismantle working half-coupling, brake and brake plate;
- open collector manholes 33 and extract sweepers from nests of brush-holders 18. Dismantle thermistor
located in external bearing cover 3;
- install engine in horizontal position, turn out bolts 9, 4, remove end brackets, having screwed bolts 9 in
thread squeezing bores of working end bracket 8;
- install engine on special jamb with collector downwards. Output end bracket 8 of lock, having screwed
bolts 9 in thread squeezing bores in bracket. Armature outputs together with bearing mount assemblies. Arma-
ture should be put on special rack storage or jamb with felt or rubber gasket;
- disconnect connecting leads from brackets, remove brackets 18. Delete putty, arresting head of bolts
11 and 14. Blow magnetic system with compressed air, delete accumulated mud and dust. Wipe internal sur-
face of magnetic system with cleaning cloth moistened in benzine;
- examine condition and security of attachment of coils of principal and additional poles, their outputs
and connective tires. Insulation of outputs, external surfaces of coils of principal and additional poles should be
clean, without mechanical damages and burnings. Veins of wires at nosepieces should not have abruptions.
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and separator with lubricant ЛИТОЛ-24. Bearing chambers of end brackets and bearing covers, and also oil
tubes carefully should be washed out with benzine and blown with compressed air;
- ports of feeding of lubrication, sealing grooves and bearings to fill completely with lubricant ЛИТОЛ-24,
and fill chambers of boards and covers on 50 % of their volume. Expenditure of lubrication on unit of bearing
40 - 2,5 kg, on unit of bearing 30 - 2,5 kg;
- at mounting of bearing covers combine its oil-drain chases with bores in end brackets;
- before wiring internal bearing rings heat them in lubricated bath up to 100 0С. Contingence of rings
about walls and bottom of metal bath at heat is not supposed;
- at wiring do not admit sidesways and strong impacts on rings of bearings;
- test conformity of bearings to nameplate data of engine. Pay attention to absence of visible faults of
bearings (quality of separator), absence of ectogenic turnings on in lubricant;
- in case of detection of specified imperfections, and also cracks and shells in details, bearings should
be replaced.
Assembly of engine
Before assembly clear of dust and mud all details and units of engine. Delete nicks and rust on mounting
surfaces.
Assembly of engine should be performed only after heat of magnetic system to temperature from 70 up
to 100 °С, in connection with execution of installation of end brackets with tightness.
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Disassembly of engine
Disassembly of engine is to be carried out as follows:
- install engine vertically with collector up, on jamb defending rear end of shaft and providing support of
electric motor on rear end bracket 22 (see figure 6.7);
- unscrew bolts 13 fastening end bracket 11 to frame 14. Insert these bolts into squeezing bores of
board and, uniformly twirling them, to squeeze board. Turn out squeezing bolts;
- cautiously, preserving against impacts take out armature shaft 1 together with board, drawing through
outputs through rubber inserts. Put armature on special rack for storage or jamb with felt or rubber gasket, ar-
mature should not be rested on end bracket;
- for disassembly of bearing mount assemblies unscrew nuts 6, bolts 23 and remove covers 5 and 25.
If on collector there are burrs, outcome of separate plates, under sweepers 9 or outrun of surface more
than on 0,08 mm collector should be notched and grinded. Before propoint armature should be heated in fur-
0
nace to temperature 120 - 140 С and collector bolts should be tightened.
The outrun of collector in heated condition should not exceed 0,04 mm while in operation. Variance be-
tween outrun in cold and heated condition - no more than 0,02 mm. Minimum diameter of collector at wear or
turning - 327 mm.
In traction electric motor sweepers of brand ЭГ-84 by cross-section 2х12,5х32 mm are applied. Allow-
able wear of sweepers on altitude - 25 mm.
The force of pressure of finger to sweeper should make 28 - 32 N. Testing of force is made by dyna-
mometer ДПУ-0-2. Adjusting of force of pressure of finger on sweeper is carried out by adjusting screw.
Damaged sections of insulation of windings insulate with glass-calico ribbon, and cover with insulation
enamel ПКЭ-19 and dry.
Inspection of insulance concerning case of electric motor and between windings is made by megaohm
meter on 1000 V serially for every circuit having separate outputs, at electric joint of all other circuits with case.
After measurement of insulance of every circuit unload its electric joint with grounded case.
Insulance of windings of electric motor concerning its case and between windings should be not less
than 7,0 MOm in cold condition, 1,0 MOm in heated condition (after trial on heating up in control condition).
Maximum deviation of resistance of all windings of electric motor in cold condition should be + 6 %.
If resistance between winding and case is less than above-stated dry electric motor with hot air with
temperature of 100 - 120 0С or current flow 270 - 310 A. At drying by current every two minute turn armature
on some angle. Manholes of collector chamber and output air-vent windows in rear end bracket should be
open.
At drying by current flow each hour measure temperature and insulance. First two-three hours tempera-
ture of windings should not be raised above 50 - 60 0С, and through 6 - 8 hours after beginning of drying – not
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Assembly of engine
Assembly of engine is to be carried out as follows:
- wipe gudgeons of armature shaft 1 by cleaning cloth moistened in benzine;
- wash out bearings, labyrinth grooves and internal surfaces of end brackets;
- heat ball bearing 4 and inner ring of roller bearing 26 in motor oil to temperature 80 - 90 0С and keep it
during 10 - 15 minutes;
- install on armature shaft 1 internal cover 7, ball bearing 4 and slit barrel 3;
- install inner ring of roller bearing 26 on armature shaft;
- install outer ring of roller bearing 26 in end bracket 22 from drive end;
- put lubricant in bearing and cover 25. Type and amount of lubrication is specified in lubrication chart
and Operation manual. Grease mounting faces with lead oxide red. Tighten cover with bolts 23, having laid
washers;
- install inductor on jamb collector manholes downwards;
- wipe mounting faces of end bracket 22 by cleaning cloth moistened in benzine;
- install end bracket 22 and tighten bolts, having laid washers under it;
- install board 11 on armature shaft with ball bearing 4, preliminary having put lubricant in internal cover
7 and bearing 4;
- grease mounting surfaces of external cover 5 and board with 11 lead oxide red;
- put lubricant in cover 5 of bearing;
- install cover on board and tighten its nuts 6, having laid washers under it;
- install engine vertically with collector up on jamb providing support of electric motor on rear end
bracket 22;
- cautiously, preserving against impacts insert armature shaft 1 together with board 11, drawing through
lead-out wires through bores in board;
- turn bolts 13 fastening end bracket 11 to frame 14;
- connect waste of lead-out cable to brackets of brush-holders;
- install on collector 8 package of brush-holders 10;
- put sweepers 9 in brush-holder;
- install engine horizontally;
- install slit barrel 3 on armature shaft 1 on side of end bracket 22;
- through press-greaser apply 50 g of lubrication in each bearing mount assembly.
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Assembly of engine
Assembly of engine is to be carried out as follows:
- wipe gudgeons of armature shaft 13 with cleaning cloth moistened in benzine;
- wash out bearings, labyrinth grooves and internal surfaces of end brackets;
- heat ball bearing and inner ring of roller bearing in motor oil to temperature 80 - 90 0С and keep it dur-
ing 10 - 15 minutes;
- install on armature shaft 13 internal cover, ball bearing and barrel;
- install inner ring of roller bearing on armature shaft 13;
- install outer ring of roller bearing in end bracket 9 from drive;
- put lubricant in roller bearing and cover 12. Type and amount of lubrication is specified in lubrication
chart and Operation manual. Tighten cover by bolts 10;
- wipe mounting faces of end bracket 9 by cleaning cloth moistened in benzine;
- install end bracket 9 and tighten bolts, having laid washers under it;
- install board 6 on armature shaft with ball bearing, preliminary having put lubricant in internal cover and
bearing;
- To put lubricant in external cover 2 of bearing;
- install cover on board and tighten its nuts 3, having laid washers under it;
- install fastening device on end of shaft 13 and fix it;
- cautiously, preserving against impacts insert armature shaft 13 together with board 6;
- turn bolts 7 fastening end bracket 6 to frame 8;
- connect wire connecting brush-holder with tire, transiting through coil of additional pole to output Я1;
- connect wire connecting brush-holder with additional pole;
- install sweepers 4 in brush-holders 5, install covers of collector manholes 1.
6-53
Traction electric drive
7513-3902080 RM
Uисп. = 2U + 1000, V
- inspection of commutation, rotary speed and reversing should be carried out only at replacement of
poles or armatures, pay attention to presence of necessary gaskets in straps of brush-holders intended for
mounting of neutral.
At trial of electric motor there should not be circular fire and mechanical damages. Collector and brush-
holders after trial should be suitable to further operation without clearing and any reparation.
Assembly and mounting of running control unit should be carried out observing following requirements:
- at assembly of drum locating holes of cams 17 and keyway of shaft place in one plane, and identifica-
tion mark of cams should be directed aside keyway;
- before mounting of cam drum in case of cavity of ball-bearings 20 fill lubricant Литол-24;
6-54
Traction electric drive
7513-3902080 RM
- install spacing between contact pieces in open condition conveyance of lath 3 together with brackets
22 in longitudinal bores of case;
- overlapping rollers of cam elements 1 with cams is made by offset of lath 3 in axial direction concern-
ing bracket 22;
- test spacing between contact pieces of cam elements which should be 2 - 3 mm at neutral (vertical)
position of bar 13. Clearance adjustment is ensured with editing of cross-section of cam.
6-55
Traction electric drive
7513-3902080 RM
6-56
Electro-motor-wheel
7513-3902080 RM
7 ELECTRO-MOTOR-WHEEL
7.1 General information
Electro-motor –wheel is fastened to casing of back axle and switches on traction motor 2 (figures 7.1 or
7.2), reducer 8, back wheel hub 4, brake gears of service 3 and parking 1 brake systems and induction sensor
of speed limit.
Brake gears of electro-motor –wheels of trucks BELAZ -7514-10/75145 (payload capacity 120 t) – block,
service brake gears are fitted on the body of motor-wheel reducer, parking ones – on the end bracket of trac-
tion motor (from the side of collector), brake gears of electro-motor wheels of trucks BELAZ -75131/75132
(payload capacity 130 t) – disk, service and parking brake gears are fitted on end bracket or frame of traction
motor.
Reducer of motor wheel – double-row, differential, with spurs, is mounted in the hub of rear wheel. Reducer of
the trucks BELAZ -7514-10/75145 is differ from reducer of trucks BELAZ-75131/75132 by gear ratio, dimensions of
parts and their embodiment.
7-1
Electro-motor-wheel
7513-3902080 RM
7-2
Electro-motor-wheel
7513-3902080 RM
Figure 7.3 –Suspension 7808-7263 for fastening of motor-wheel reducer of the truck BELAZ-7514-10/75145:
1 – reducer of motor-wheel; 2 – mooring
Figure7.4 –Support 360-007 for removal and mounting of electro-motor wheel of the trucks BELAZ-75131/75132:
1 –cross-beam; 2 – lengthwise beam; 3 – chain; 4 – rear rest; 5 –front rest; 6 – hook; 7 – rest; 8 –inner beam; 9 – roller
7-3
Electro-motor-wheel
7513-3902080 RM
Figure7.5 –Suspension 7808-7061 for fastening and transportation of motor-wheel of trucks BELAZ-7514-10/75145:
1 – lug; 2 – thimble; 3 – rope; 4 – ring; 5 – cramp; 6 – finger; 7 – electric motor-wheel
7-4
Electro-motor-wheel
7513-3902080 RM
7-5
Electro-motor-wheel
7513-3902080 RM
7-6
Electro-motor-wheel
7513-3902080 RM
–squeeze from hub 7 the external ring – at first of external bearing 8, making effort to the crown gear
9,and then – internal bearing;
– unlock and unwrench bolts 36 of fastening of tightening plates of second row satellite axes, take off
tightening plates 37 and squeeze satellite axes 42;
– take out satellites 41, squeeze from them bearings 38, extract tightening plates 39;
–squeeze inner ring of the internal bearing 8;
–in case of need to remove undercollar ring 2 (for trucks BELAZ-7514-10/75145), cut off from the body
and remove undercollar ring 2, having unwrenched bolts 47 through vent holes in the body (for reducer of the
truck BELAZ -75131/75132).
75191-2405210-01/211-01
Right (left) reducer body:
Diameter of landing journals for taper − 0 ,024
roller bearing 710 709,8
− 0 ,074
Steel 40Л
Hole diameter for satellite axes
+ 0 ,087
100 100,15
7-7
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
75132-2405342
+0,063
Casing cap 440 440,12 Steel 40Л
Diameter of holes for bearing
7519-2405372
Solar gear of the second row −0,165
Length of the common tooth normal
81,74 81,00
Steel 20Х2Н4А
Tooth and spline faces
−0,245
Substitute: 58 - 62 HRCэ
−0,75 18ХГН2МФБ
Spline size (по роликам ∅9±0,002) 207,83 206,00
−0,85
7519-2405434 Steel 20Х2Н4А
−0,19 Tooth and spline faces
Satellite of the second row 111,969 111,40 Substitute:
−0,31 58 - 62 HRCэ
Length of the common normal 18ХГН2МФБ
75191-2405492
Axe of the second row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
7-8
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
7519-2405496
Crown gear of the second row
Tooth size +1,4
(by rollers ∅18±0,002) 809,984 812,00 Steel 38Х2МЮА
Tooth and spline faces
+1,1 >550HV5
7512-2405526
Torsion shaft −0,10 Steel
86,3 85,2 375 - 444 НВ
Spline size −0,21 45ХН2МФА
(by rollers ∅6,212±0,002)
75191-2405532
Flange of torsion shaft
Spline size +0,063 Spline face and faces
(by rollers ∅6,212±0,002) 67,143 68,2 Steel 20Х for collar
54 - 60 HRCэ
Wear of surface under the working 0.3 mm of side
edges of collars
75191-3104114-20
Undercollar ring Face for collar>52
0.5 mm of side Steel 45
Wear of surface under the working HRCэ
edges of collars
7512-3104015
Motor-wheel hub +0,26
922,2 923,5 Steel 40Л
Spline size + 0,09
(by rollers ∅9±0,002)
Table 7.2 – Nominal and maximum dimensions of the main parts of motor-wheel reducer
of the truck BELAZ -75131/75132
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
75132-2405210-01
Reducer body:
Diameter of landing journals for taper −0,024
roller bearings 710 709,8 Steel 40Л
−0,074
+0,087
Hole diameter for satellite axes 100 100,15
7-9
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
+0,063
Diameter of the hole for bearing 440 440,12
75132-2405342
+0,063
Casing cap 440 440,12 Steel 40Л
Diameter of the hole for bearing
7519-2405372
Solar gear of the second row
−0,165 Steel 20Х2Н4А
Length of the general tooth normal 81,74 81,00 Tooth and spline faces
−0,245 Substitute: 58 - 62 HRCэ
18ХГН2МФБ
Spline size −0,75
207,83 206,00
(by rollers∅9±0,002) −0,85
7519-2405434 Steel 20Х2Н4А
−0,19 Tooth and spline faces
Satellite of second row 111,969 111,40 Substitute:
−0,31 58 - 62 HRCэ
Length of the common normal 18ХГН2МФБ
75191-2405492
Axe of the second row satellite 100 99,93 Steel 40Х Face >50HRCэ
−0,022
Diameter
7-10
Electro-motor-wheel
7513-3902080 RM
Dimensions, mm
Number, part designation and
Material Hardness
controlled variables
nominal maximum
7519-2405496
Crown gear of the second row
Tooth size +1,4
(by rollers ∅18±0,002)
809,984 812,00 Steel 38Х2МЮА
Tooth and spline faces
+1,1 >550HV5
−1,5
Spline size 948,26 945,5
−1,7
(by rollers ∅9±0,002)
75132-2405522
Solar gear of the first row −0,165
Length of the common tooth normal
57,312 56,40 Steel 20Х2Н4А
−0,285 Tooth and spline faces
Substitute:
58 - 62 HRCэ
+0,180 18ХГН2МФБ
Spline size 86 87,2
+ 0,073
(by rollers ∅6,5±0,002)
75132-2405526
Torsion shaft −0,10 Steel
106,42 105,3 375 - 444 НВ
Spline size −0,20 45ХН2МФА
(by rollers ∅6,5±0,002)
7520-2405532
Flange of the torsion shaft
Spline size +0,180 Spline face and faces
(by rollers ∅6,212±0,002)
86 87,2 Steel 20Х for collar
+ 0,073
54 - 60 HRCэ
Wear of surface under the working 0.3 mm on
edges of collars side
75191-3104114-20
Undercollar ring 0.5 mm on Face for collar>52
Steel 45
Wear of surface under the working side HRCэ
edges of collars
75132-3104015
Motor-wheel hub +0,26
922,2 923,5 Steel 40Л
Spline size + 0,09
(by rollers∅9±0,002)
7-11
Electro-motor-wheel
7513-3902080 RM
– install on the body of reducer the internal bearing ring and squeeze up to the stop (figure7.12). The
probe of 0,03mm thickness should not pass between thrust end of internal bearing ring and body. In case of
0
bearing mounting with heating the heat temperature should not exceed 120 С;
7-12
Electro-motor-wheel
7513-3902080 RM
– assemble satellites of the second row(figure 7.13), have mounted into the satellite 1 locking ring 2 and
having squeezed bearings 3 up to the stop into the ring, previously having lubricated by oil the conjugated
faces of satellite;
– install satellites into the body of the reducer 1 (see figures 7.7 or 7.8), squeeze the satellite axes 42,
previously having lubricated by lubricating grease conjugated holes of the body and bearings, mount tightening
plates 37 of satellite axes and fasten them to the body by bolts 36, having stopped bolts 3 (figure7.14) by pin
wire 2.
– squeeze into the wheel hub 7 (see figures 7.7 or 7.8) the external ring of the inner bearing 8, collar 6,
previously having lubricated by lubricating grease the conjugated faces of hub. Mount spacer ring 4 and fasten
clamping 3 by bolts 5 to the hub, mount and fasten by bolts the brake drum 47 (for electro-motor wheels of
trucks BELAZ -7514-10/75145), mount the crown gear 40 and squeeze the external ring of external bearing 8,
previously having lubricated by lubricating grease the conjugated faces of hub. The probe of 0.03 mm thickness
shouldn’t pass between thrust ends of external bearing rings and hub. The cavity between collars should be
7-13
Electro-motor-wheel
7513-3902080 RM
7-14
Electro-motor-wheel
7513-3902080 RM
Check by probe the gap between roller faces and bearing board 4 (figure7.18). If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 near located rollers, at which gap exceed 0,4
mm), pass to the carrying out of the next point. Otherwise repeat bolt tightening in the same order up to estab-
lishment of torque 60 Н.м in all 8 bolts.
Check by probe the gap between faces of rollers and operation board of bearing. If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in which gap exceeds
0,4 mm), pass to the performance of the next point. Otherwise repeat the bolt tightening in the same order up
to the establishment of torque 80 N.m on 8 bolts.
Check by probe the gap between faces of rollers and operation board of bearing. If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in whiches gap ex-
ceeds 0,4 mm), pass to the performance of the next point. Otherwise repeat the bolt tightening in the same or-
der up to the establishment of torque 100 N.m on 8 bolts .
Check by probe the gap between faces of rollers and operation board of bearing. If for 70% of rollers the
gap don’t exceed 0,3 mm (at that there shouldn’t be more than 3 closely located rollers in whiches gap ex-
ceeds 0,4 mm), pass to the performance of the next point . Otherwise disassemble and realize parts detection.
Realize the adjustment of hub tapered bearings of motor wheel reducers of truck BELAZ-7514-10/75145
further in the following way:
– wrench the rest adjusting bolts by torque 20 N.m. Release bolts 3 (see figure7.16) and tighten them by
torque 20 N.m.
– wrench stop bolts 2 (12 pieces) against stop. Tighten by turns all diametrical stop bolts by torque
600 – 640 N.m. Repeat bolt tightening in the same order up to establishment of torque 600 – 640 N.m on all
bolts;
– tighten regulating bolts 1 and 3 (24pieces) by turns per 2 diametrical ones by torque 400 – 440 N.m;
– check by the probe the gap between roller faces and operaion bearing board. For 70% of rollers the
gap shouldn’t exceed 0,4 mm. Here there shouldn’t be more than 3 closely located rollers in whiches the gap
exceeds 0,5 мм (see figure7.18);
– check the hub torque through the second row. It can be encreased in comparison with earlier measured
torque (not more 500 N.m) not more than on 400 N.m (on the technological gear of second row as compared
with earlier measured torque (not more135N.m) not more than on 108 N.m;
– stop bolts by pin-wire (see figure7.16);
– if necessary under performance of adjustment the change of inner bearing ring is permitted.
Attention: there were changes at the design of motor-wheel reducers of trucks BELAZ-7514-10/75145,
produced from 2003 : the stop bolts 2 were canceled, and for regulating of hub bearings the adjusting washers
are installed under adjusting bolts (design is similar to the reducer of motor-wheels of trucks BELAZ -
75131/75132). Realize the regulating of tapered bearings of hubs of motor wheels reducers of truck BELAZ-
7514-10/75145 with above changes analogously to the considered further regulating of tapered bearings of
hubs of motor wheels reducers of truck BELAZ -75131/75132.
7-15
Electro-motor-wheel
7513-3902080 RM
Realize the adjustment of tapered bearings of motor-wheel reducer hub of BELAZ-75131/75132 further
in the following way:
– check up hub operating torque through the second row. It can be encreased in comparison with earlier
measured torque (not more 500 N.m) not more than in 400 N.m (on technological gear of the second row in
comparison with earlier measured torque (not more135 N.m) not more than in 108 N.m;
– in four equilocated places against bolts 3 (see figure7.16) measure gap Б (see figure7.18), Б1, Б2, Б3,
Б4 with accuracy to +0,02 mm;
– grind spacing washers 33 (24pieces) (see figures7.8) in size С=(((Б1+Б2+Б3+Б4):4)+0,2) with accu-
racy 0,015;
– unwrench 8 adjusting bolts 3 (see figure7.16);
– wrench adjusting bolts 1 and 3 (24 pieces) putting onto it per spacing washer out of ground kit in order
to spacing washers will be in gap Б (see figure 7.18);
– tighten diametrical adjusting bolts by turn by torque 400 – 440 N.m;
– cotter bolts in pairs by pin wire;
–if necessary under adjustment the replacement of inner bearing ring is permitted.
Realize assemblage of the first reducer row of electro-motor wheel in the following way:
– install into the satellite of first row 3 (figure 7.19) retaining ring 2;
– insert into the satellite the bearings 1 against stop into the retaining ring, previously having lubricated
by oil the conjugated satellite faces;
– put satellites into the carrier 17 (see figures 7.7 or 7.8) of the first row, insert axles26, previously hav-
ing lubricated by lubricating grease the conjugated faces of body and bearings, mount and fix by bolts the lock-
ing plates 4 (figure 7.20), stop bolts 3 by pin -wire 2;
– built up onto the cage 17 (see figures 7.7 or 7.8) the bearings 19, here apply force only to the internal
bearing rings (under application of force to the external rings of bearings the surfaces and solids of revolution
are damaged);
– mount into the drive cap14 the crown gear of the first row 15, the cage of first row with satellites, hav-
ing united teething of the first row crown gear and of first row satellites, the cap of first row cage 16 with
packing ring 31, previously having lubricated the ring by lubricating grease, and tightening by bolts 32
assemble the first row of reducer;
– mount the crown gear of second row 23, fasten two locking plates 2 (semirings) (figure7.21) by bolts 1
to the cage of first row and stop bolts by pin wire 3;
7-16
Electro-motor-wheel
7513-3902080 RM
– fasten the first row to the hub 7 (see figures7.7 or 7.8) by bolts 12, having mounted packing ring 35,
previously having lubricated the ring by lubricating grease (be careful under introduction of solar gear of the
second row 23 into the satellites of the second row 41);
– wrench into the hub threaded holes the return tubes. Put the return tubes on joint sealant
«Унигерм 9»;
For mechanization of adjustment of second row tapered bearing of motor wheel reducer of truck
BELAZ-7514-10/75145 and hub turning under measurement of gap between brake drum and linings of motor
wheel reducer brake the stand 281-30 (figure7.22) is intended.
The stand consists of the following main parts: frame 7, actuator 4, ground 3 and control console fixed
on the supports 2 on site 1 at the electrical cabinet.
Frame 7 is intended for mounting and fixation on it of adjustable unit and placement of actuator inside
the frame. Base plate, in which 8 fingers are mounted for fixation of adjustable unit body, is fixed to the lower
part of frame.
Actuator 4 is intended for crank through torsion shafts 6 and sun gears 5 of reducer second row under
tapered bearings regulating and for reducer hub crank under measurement of gap between brake drum and
linings. Actuator consists of worm-and-wheel reducer and electric motor. Spline clutch for mounting of change
torsion shafts is fixed on outlet reducer end.
For gap adjustment in tapered bearings and under gap measurement between brake drum and linings –
install the second reducer row to the stand base plate, fix unit against turning along cage holes, install change
torsion shaft 6 introducing into engagement with clutch of actuator. Install to the shaft the sun gear 5 introduc-
ing into engagement with satellites of second row. Turning the hub through satellites, tune gap at the tapered
bearings, as mentioned above. After gap regulating at the tapered bearings, turning the hub measure the gap
between brake drum and linings and if necessary tune.
7-17
Electro-motor-wheel
7513-3902080 RM
Under measurement of the gap between brake drum and linings under fully assembled reducer of the
motor wheel it’s necessary to install reducer onto stand, remove cap 11 (see figure7.1) and install the change
crown gear of first row. Turning the hub measure the gap between brake drum and linings and if necessary
tune.
For regulating of gap of tapered bearings of motor wheel reducer of truck BELAZ-75131/75132 the stand
ЧРЦ 1.00, which is similar to stand 281-30 described above, is intended.
Realize assemblage of electro-motor wheel in the following way:
– fasten the reducer of motor-wheel by device (see figures 7.3 or 7.5) and install it onto the support (fig-
ures7.4);
– install into body 1 the collar 45 (see figures7.7 or 7.8), previously having lubricated by lubricating
grease the conjugated body face, wrench into the body studs (see figures 7.8) (for the reducer of motor-wheel
of truck BELAZ-75131/75132), mount guard ring 44 (see figures 7.7 or 7.8), wrench nuts or bolts 43;
– mount flange 14 (see figures 7.1 or7.2) onto the shaft of traction motor and fasten it by bolt with elastic
washers (tighten by torque 260 – 320 N. m). Put bolts on sealant «Унигерм 9»;
– fasten by bolts to the flange of traction motor the flange of torsion shaft 13 (tighten by torque 270 –
315 N.m);
– fill up labyrinth grooves of packing 46 (see figures 7.8) by lubricant Литол-24 and lubricate the opera-
tion edges of collar 45 (see figures 7.7 or 7.8);
– fasten traction motor by ring bolts (for the electro-motor wheel of the truck BELAZ -7514-10/75145), by
adaptation (figure 7.6) (for electro-motor wheel of the truck BELAZ-75131/75132) and install it into reducer
body, having tightened by bolts 15 (see figures 7.1 or7.2) (tighten by torque 800 – 1000 N.m). Before installa-
tion lubricate the landing face of electric engine by lubricant Литол-24;
– mount on to torsion shaft 12 the inner retaining ring (2 rings for electro-motor wheel of the truck BE-
LAZ-7514-10/75145);
– mount torsion shaft into the spline cavity of flange 13 up to stop;
– mount onto torsion shaft the crown gear 9 of the first row and outer retainer ring 10;
– mount cap 11with packing ring, previously having lubricated the ring by lubricating grease, and fasten
it by bolts 7;
– mount into the cap 4 (figure 7.23) the rest 2 up to the stop in to the torsion shaft 7. Measure gap be-
tween faces of cap and rest. Collect the kit of shims 1 in width for amount of clearance plus (1 – 2) mm and
mount it between cap 4 faces and rest 2 faces. Fix the rest in cap by bolts;
– fasten electro-motor wheel of the truck BELAZ-7514-10/75145 by adoption (see figure 7.3), on the
support for truck BELAZ-75131/75132 by loader and bring it to the back axle housing, unite the holes by turn of
motor-wheel and fasten the motor-wheel to the back axle housing, having tightened bolts by torque 1300 –
1500 N.m for the truck BELAZ -7514-10/75145 и 500 – 550 N.m for truck BELAZ -75131/75132;
– join to the gauge of speed limitation the hoses for lubrication of traction motor bearings, leadings-out of
traction motors to the power cables. Join hoses of high pressure to the cylinders of brake system, connect cyl-
inder rod extender clevis of parking brake system with regulating lever (for the truck BELAZ-7514-10/75145).
Mount and fix by clamps the elastic nipple for supply of cooling air to the traction motor (for the truck BELAZ -
75131/75132).
7-18
Electro-motor-wheel
7513-3902080 RM
7-19
Electro-motor-wheel
7513-3902080 RM
During the running-in on each of above modes of electric engine operation define the waste of idling
which should not exceed loss, indicated on the diagram of idling waste (figure7.25).
During the running-in watch the rise of unwanted sounds and knocks. After the running-in control the
heat of brake on the external face of drum, the heat of reducer on the face of external cap at the zone of loca-
tion of check and filter plugs. The heat shouldn’t exceed 70 0С. Under occurrence of elevated heat tempera-
ture, idle loss, leakages, unwanted sounds and knocks at the reducer of motor-wheel you need to clarify and
eliminate the reasons of malfunctions, after that to perform running-in once more. Noise level shouldn’t exceed
95 dB on the distance (1000 + 100) mm under the general noise level not more 85 dB;
After the running-in pour the oil out of reducer.
7-20
Running gear
7513-3902080 RM
8 RUNNING GEAR
8.1 Suspension
8.1.1 General data
Suspension of dump trucks BELAZ-7514-10 and BELAZ-75145.
Front suspension is independent, from each side of dump truck pneumohydraulic cylinder 4 (figure
8.1.1), pivot 5, swivel member 8 with hub of front wheel 7 and bracket of pivot 6 are installed.
8-1
Running gear
7513-3902080 RM
The pneumohydraulic cylinder is fastened with self-locking nuts 2 to upper 3 and to lower brackets 28.
Lower bracket is fastened with bolts 33 to upper butt of pivot.
The pivot 5 is rigidly connected to swivel member 8 and can displace together with wheel in bracket of
pivot 6 in axial and angular directions. Bracket of pivot is fixed on frame by means of barrels 10 and bolts 11
with nuts 12.
As plain bearings of pivot metal-plastic barrels 20 inserted in boring of bracket of pivot are used. From
conveyance in axial direction barrels are secured by pimples. Barrels from both sides of eyelets of bracket of
pivot 6 are sealed with cuffs 24 which are protected from damage by wiper rings 25 and scratchers 26.
The buffer 29 restricts conveyance of pivot at maximum stroke of release and softens impacts.
Rear suspension is dependent and consists of two pneumohydraulic cylinders 3 (figure 8.1.2), trans-
versal rod of suspension 4, central lever 2 of rear axle and eyelet 6 with hinge.
The loads operating on wheels of rear axle, are transmitted to frame through cylinders of suspension,
transversal rod and central hinge. Cylinders of suspension react only vertical loads, rod reacts only transversal
loads, and central hinge reacts vertical, transversal and longitudinal loads.
Pneumohydraulic suspension cylinders are fastened to brackets on frame and crankcase of rear axle by
self-locking nuts 32.
The transversal rod 4 is fixed to brackets on frame and crankcase of rear axle with help hinged bearings
23 that are fixed on fingers of rod 26 through distance barrel 29, pinch plates 21 and bolts 20 and 28.
The eyelet 6 of central hinge is fixed to central lever with help of bolts 16 and nuts 17, and is also
hingedly fixed to bracket of frame by finger 9.
8-2
Running gear
7513-3902080 RM
8-3
Running gear
7513-3902080 RM
The rear suspension is dependent and consists of two pneumohydraulic cylinders 2 and 4 (figure
8.1.4), transversal rod of suspension 3, lever of rear axle and eyelet 7 with central hinge.
The loads operating on wheels of rear axle are transmitted to frame through suspension cylinders,
transversal rod and central hinge. Cylinders of suspension react only vertical loads, rod reacts only transversal
loads, and central hinge reacts vertical, transversal and longitudinal loads.
Pneumohydraulic suspension cylinders are fastened to brackets on frame and crankcase of rear axle
with self-locking nuts 29.
The transversal rod of suspension 3 is fixed to brackets on frame and crankcase of rear axle with the
help of hinged bearings 23 timbered on fingers of rod 20 through distance barrels 17, pinch plates 25 and bolts
18 and 26.
The eyelet 7 of central hinge is installed on barrels 11 and fixed to central lever with the help of bolts 15
and nuts 14 and is also hingedly fixed to bracket of frame by finger 9.
8-4
Running gear
7513-3902080 RM
The suspension cylinder (figure 8.1.5) represents piston-type air spring in combination with hydraulic
shock absorber. Working element in cylinder is engineering gaseous nitrogen. In suspension cylinder damping
fluid ЛУКОЙЛ - АЖ is applied as working fluid.
Front and rear suspension cylinders of dump trucks BELAZ-7514-10, BELAZ-75145, BELAZ-75131 and
BELAZ-75132 are analogous in construction and differ only in sizes of parts, configuration of chase on rod of
absorber and amount of filled oil and gas pressure level.
The suspension cylinder consists of tube of basic cylinder 13 and rod 34 with piston and partition of ab-
sorber welded on it. Lower cover 25, which fastens housing 11 to butt of rod, is fastened to lower part of rod, and
to upper part of tube of major cylinder upper cover 38 is fastened by bolts. In upper and lower cover trunnion balls
40, timbered by covers 39, are installed. Between upper 38 and lower 25 covers and cover 39 adjusting gaskets
24 are installed.
Between spherical surfaces of covers and trunnion balls liners 2 of metal-polymeric ribbon are installed.
Trunnion balls are greased through push-type lubricating fitting.
Two compression valves 33 and valve of release 29 are located on partition of absorber. In body of re-
lease valve rod of absorber 36 displaces The rod comprises two long slots of variable section executing func-
tion of throttle of variable resistance of valve of release of absorber. Rod of absorber is also the drive gear for
pump 28.
The housing 11 forms cavity И in which working fluid is filled up to level of check plug 15. Working fluid
is intended for refilling of cavity Л and K and for lubrication of housing sealing. Leakproofness of movable joint
of tube of major cylinder 13 and housing 11 is ensured with sealing ring 53 and safety ring 54. Protective boot
9, timbered between ring 30 and sealant 31, serves for protection of external surface of cylinder from dust and
mud.
Leakproofness of fixed joints is ensured with rubber sealing rings of round cross-section. For prevention of
working fluid escape from suspension cylinder movable joint “rod – tube” of major cylinder is sealed with fluoro-
plastic cuff 57, which working crimps are unclenched by rubber spacing ring 56. Cuff is installed with tightness that
is regulated by set of adjusting gaskets 61 and supported by spring 60. Sealing of junction “tube of major cylinder –
piston” is ensured with fluoroplastic washers 52 on piston of rod 34.
Pressure-relief valve 10 serves for protection of housing 11 from overcharges, at pressure boost in its
cavity due to decrease of volume at squeeze of cylinder and because of possible escape of working fluid
through cuff and other joints. In order to set cylinder back in operation condition it is to be filled by nitrogen
through priming valve 3.
For maintenance of fixed level of working fluid in cavity Л ram-type pump 28 is installed in boring of
lower cover 25 and timbered by flange 19 with bolts 26 and washers.
External fault symptom of suspension cylinders is change of their altitude relatively to normal running
order.
At abnormal operation of suspension cylinders (roll of dump truck, strong leak of oil) test their service-
ability by defining size C (see figure 8.1.1) for cylinders of front suspension of dump trucks BELAZ-7514-10,
BELAZ-75145, size Н1 (see figure 8.1.5) for cylinders of front suspension of dump trucks BELAZ-75131 and
BELAZ-75132 and size Н for cylinders of rear suspension. These sizes are defined by special (characteristic)
ruler (figure 8.1.6) on which two scales are marked: charge and working. Points on scales indicate level of gas
pressure in cylinder of given size at correct charging of cylinders. Besides, zones of admissible scatter of size
at operation of cylinders are marked on working scale of ruler.
The charge scale located on ruler at right side is intended for monitoring charged cylinder or when gas
pressure in cylinder is absent completely. Working scale located on ruler at left serves for inspection charging of
suspension cylinders in operation.
For performing check of dimensions install unloaded dump truck on equal horizontal platform. At cor-
rectly charged front suspension cylinder of dump trucks BELAZ-7514-10, BELAZ-75145 upper crimp of swivel
member 8 (see figure 8.1.1) should be placed against zone of admissible scatter of size of cylinder. At per-
forming measurement butt of ruler should rest against lower butt of bracket. Front suspension cylinder of dump
trucks BELAZ-75131 and BELAZ-75132 is considered normally charged if center of check plug 15 (see figure
8.1.5) is placed against zone of admissible scatter of size of cylinder.
8-5
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8-6
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8-7
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Pressure in all cylinders does not corre- Incorrect charging Adjust charging:
spond to pressure on characteristic ruler – test oil level and gas pressure in all cylinders according to
Operation manual;
– charge cylinders with oil and gas on characteristic ruler
In one cylinder according to characteristic Incorrect charging of cyl- Adjust charging of cylinder according to Operation manual
ruler pressure differs from required level inder
most of all
One or several cylinders constantly do not Nonhermetic priming Check condition of copper gasket under valve. If it is solid or
hold sizes "H" or "Н1" (there are no leak- valve damaged on planes replace it and charge cylinder with gas
age of oil)
After charging cylinder abruptly runs down Cuff is worn out. Non- Remove and disassemble cylinder observing safety precau-
and oil escapes through pressure-relief hermetic pump tions, test condition of cuff and pump. Replace worn out and
valve or safety ring damaged parts
On release strokes knocks in cylinder are Fluoroplastic wasers on Remove and disassemble the cylinder. Replace washers on
heard piston rod are worn out piston of rod
8.1.3 Safety precautions at removal, repair and mounting of suspension cylinders on dump truck
At disassembly and assembly of suspension cylinders be careful, as gas in them is under high pressure.
At filling and charging of cylinders, at repair, disassembly and assembly, boost charge on dump truck «Rules
for Construction and Safe Operation of bulbs working under pressure» should be strictly observed.
At removal of suspension cylinders from dump truck and their repair observe the following rules:
- before removal of cylinder from dump truck release gas through priming valve. For release of gas re-
move cap from priming valve and turn special sleeve on valve before opening it. After release of gas unscrew
special sleeve a little so that priming valve is closed, and then turn special sleeve on valve in three minutes
again. Operation on opening and close of priming valve with an interval in three minutes is to be carried out not
less than three times as nitrogen dissolved in oil evaporates fast, and right after unscrewing special sleeve the
pressure in cylinder is recreated;
8-8
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- starting disassembly of cylinder be convinced of absence of gas pressure in it. It is forbidden to disas-
semble cylinder (wrench fastening bolts of upper and lower covers, wrench priming valve, wrench pinch nut) if the
cylinder is under pressure;
- housing plug or safety valve are to be unscrewed only after release of gas from housing, that is per-
formed lifting the rod with sealing taper above valve body;
- it is forbidden to remove lower cover of cylinder and housing at presence of working fluid in cavities of
cylinder and housing. Oil from housing should be merged through bores for plug or for safety valve, and from
cylinder – through bore under priming valve;
- storage and transportation of charged cylinders is to be performed in vertical position only in order to
prevent gas leaks through mobile rod seal. Aberration of cylinder from vertical position should not be more
than on 300;
- before connection of reducer to new bulb at gas charging of cylinder be convinced that on bulb with
compressed gas inscription "NITROGEN" of yellow color and ring marking strip of brown color is present;
ATTENTION: IT IS FORBIDDEN TO PERFORM CHARGING OF SUSPENSION CYLINDERS WITH OXYGEN! IT
CAN CAUSE EXPLOSION!
- install bulb with gas to the prescribed place equipped with devices for fixing of bulb. At change of bulb -
fix it;
- unscrew valves and connecting nuts only with corresponding wrenches, trying not to hit them;
- gas to suspension cylinders is to be supplied smoothly through reducer;
- observe common safety precautions on working place.
8-9
Running gear
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Figure 8.1.8 – Device 360-014 for removal and mounting of suspension cylinder (used as attached implements to loader):
а) - removal and mounting of rear suspension cylinder; b) - removal and mounting of front suspension cylinder;
1 - fork of loader; 2 - cross bar; 3 - bracket of support; 4 - suspension cylinder; 5 - bracket; 6 - shaft; 7 - trunnion ball; 8 - transver-
sal bracket; 9 - longitudinal bracket; 10 - finger; 11 - nut; 12 - handle; 13, 14 - jaws
8-10
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Figure 8.1.10 – Stand ЭСБ 10 for disassembly and assembly of cylinders of pneumohydraulic suspension:
1 - grounding; 2 - clamper; 3 - hand lever of drive gear; 4 - worm reducer; 5 - bearing mount assembly; 6 - hand lever of clamper;
7 - capture
8-11
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8-12
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8.1.7 Disassembly of pivot unit of front suspension on dump trucks BELAZ-7514-10, BELAZ-75145
While in operation pivot, pivot barrels and pivot sealing are exposed to wear out. In case of wear of
chromic coverage of pivot or exit of lubrication through sealing at gun-greasing of pivot joint it is necessary to
replace worn-out parts.
Removal and disassembly pivot joint of front suspension on dump trucks BELAZ-7514-10, BELAZ-
75145 is to be performed as follows:
- install thrust blocks under wheels of rear axle of dump truck;
- release gas from cylinder of front suspension through priming valve, observing rules specified in sub-
section 8.1.3;
- unscrew bolts 33 (see figure 8.1.1) of lower bracket 28 of suspension cylinder fastening to pivot 5;
- close priming valve on suspension cylinder;
- hang out frame of dump truck, with help of crane (jacks) in its front part until free hanging of lower part
of cylinder of front suspension;
8-13
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8.1.8 Removal and disassembly of transversal rods of front and rear suspension
While in operation fingers and hinged bearings of transversal rod are exposed to wear out. Repair is car-
ried out by substitution of worn out and damaged parts.
Removal and disassembly of transversal rod of front suspension on dump trucks BELAZ-75131, BELAZ-
75132 is to be performed as follows:
- unscrew fastening bolts 12 (see figure 8.1.3) of hinged bearing 10 on one side of rod 2;
- remove cover 11;
- remove rod together with bearing 10 from finger 7 with the help of puller device;
- perform analogous operations on other side of rod;
- extract stuffing boxes 8 of rod;
- remove locking rings 9;
- squeeze hinged bearings 10 from rod with the help of arbor.
Removal and disassembly of transversal rod of rear suspension on dump trucks BELAZ-75131, BELAZ-
75132 is to be performed as follows:
- unscrew bolts 18 and 26 (see figure 8.1.4) and remove pinch plates 25;
- extract distance barrel 17;
- beat out finger 20, applying force from the side of taper barrel 24;
- extract liberated end of transversal rod from bracket;
- remove sealing rings 16 from barrels 21 and 24;
- perform analogous operations on other side of rod;
- extract stuffing boxes 27 of rod;
– remove locking rings 22;
– squeeze hinged bearings 23 from rod with the help of arbor.
Removal and disassembly of transversal rod of rear suspension on dump trucks BELAZ-7514-10, BE-
8-14
Running gear
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LAZ-75145 is to be performed analogous to procedures mentioned above for dump trucks BELAZ-75131, BE-
LAZ-75132.
8-15
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After disassembly of suspension cylinders all general mechanical rubber work-pieces and cuffs are sub-
ject to obligatory substitution.
Rated and maximum permissible dimensions of suspension parts on dump trucks BELAZ-75131, BE-
LAZ-75132 are specified in table 8.1.2, and on dump trucks BELAZ-7514-10, BELAZ-75145 – in table 8.1.3.
Table 8.1.2 — Rated and maximum permissible dimensions of major suspension parts on dump
trucks BELAZ–75131, BELAZ–75132
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
549А – 2907036
Tube of major cylinder:
Inner diameter +0,09
260 +0,21
260 241 – 285 НВ
Outer diameter Steel 45 ТВЧ h 1 – 4 mm
(coverage Хтв.30) НRС 53 min
290 There should not
− 0,13 be places with
wear of chromic
coverage
549Б – 2907126-01
549Б – 2907127-01
Upper and lower covers: Steel 45 167 – 217 НВ
Diameter of sphere 124,1 There should not
− 0,07 be faults
8-16
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Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
549Б – 2907056-11
Rod:
−0,100
Outer diameter 220 219,7 – 219,8 Steel 45 ТВЧ h 1,5 – 3,0 mm
− 0,172
549Б – 2907178
Body of contraction valve of shock-
+0, 2 Steel 35 229 – 285 НВ
absorber: 8 7
Diameter of inner hole
549Б – 2907186
Plug of compression valve: ТВЧ h 2,0 – 3,0 mm
Steel 35
Condition of butt from the side of di- There should not be chips and cracks 42 – 49 НRCэ
ameter 10
7513 – 2907327 241 – 285 НВ
Rod: Steel 45 ТВЧ h1 mm
Condition of surface on diameter 25 There should not be burrs and faults НRCэ50
549А – 2907330 There should not be faults of working sur-
Plunger of pump faces (on diameters 16, 20 and 30 mm). Steel 45
Back-pressure valve should be hermetic
7519 – 2907036
Tube of major cylinder:
+0,13 +0,21
Inner diameter 280 280 241 – 285 НВ
Steel 45 ТВЧ h1,5 mm
There should not be НRCэ53
Outer diameter
(coverage Хтв.30) 330 places with wear of
− 0,14 chromic coverage
7519 – 2907076 Strip
Guiding of rod with axle box: ДПРНТ3,0
+0,115 +0,29
Inner diameter on bronze 250 250 НД Бр.ОФ
6,5-0,15
8-17
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7513-3902080 RM
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7519 – 2907056-11
Rod:
Outer diameter −0,100
250 249,7 – 249,8 Steel 45 ТВЧ h1,5 mm
− 0,172 НRC53
7519 – 2907427
Ribbon of
Collar step There should not be places with wear of plastic
brand «С»
stratum
2,05х130
7513 – 2909016-10
Normalization
Rod of suspension: +0,063 Steel 35 ТВЧ h 3 - 5 mm
Inner diameter under bearing
130 130
− 0,04 НRCэ42
7513 – 2909078
Finger: Carbonize
−0,036
Diameter under bearing 90 89,85 – 89,90 Steel h 1,6 – 2,0 mm
− 0,090 20ХН3А 58 – 64 НRCэ
Cores НRCэ32
Conic surface (1:10) There should not
be faults
7513 – 2909118
Barrel:
−0,085 There should not
Outer diameter (up to cutting) 132
− 0,148 be faults Steel 45 241 – 285 НВ
8-18
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Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
75131 – 2909188
Tall barrel (length of barrel 84-0,54):
Outer diameter +0,125 There should not
241 – 285 НВ
148 be faults
+ 0,100
75131 – 2919230
Normalization
Eyelet with grounding: −0,014 215 – 215,02 Steel 35 ТВЧ h 1,5 – 5,0 mm
Inner diameter
215 35 – 50 НRCэ
− 0,060
7513 – 2909230
Normalization
Eyelet with grounding: Steel 35 ТВЧ h 1,5 – 5,0 mm
180 180,01 – 180,03
Inner diameter − 0,04 35 – 50 НRCэ
75131 – 2919016:
Normalization
Rod of suspension: +0,030 +0,072
200 Steel 35 ТВЧ h3 mm
Inner diameter under bearing (length − 0,016
200 НRCэ42
of rod on shafts is 1050 mm)
7513 – 2919016
Normalization
Rod of suspension: +0,063 Steel 35 ТВЧ h3 mm
Inner diameter under bearing
180 180
− 0,04 НRCэ42
7513 – 2909426
Finger (length of finger - 312 mm):
First outer diameter −0,145 241 – 285 НВ
134 134
− 0,245 − 0, 4
8-19
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7513-3902080 RM
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
75131 – 2909426
Finger (length of finger - 320 mm):
First outer diameter −0,145 241 – 285 НВ
134 134
− 0,245 − 0, 4
7521 – 2919078
Finger of rod: Carbonize
−0,043
Outer diameter 130 129,85 – 129,9 Steel h 1,4 – 1,8 mm
− 0,083 20ХН3А 59 – 63 НRCэ
Core НRCэ32
Conic surface (1:3) There should not
be faults
75211 – 2909078
Finger of rod: Carbonize
−0,05
Diameter under bearing 120 119,78 – 119,8 Steel h 1,6 – 2,0 mm
− 0,14 20ХН3А 59 – 63 НRCэ
Core НRCэ32
Conic surface (1:10) There should not
be faults
7513 – 2919186
Tall barrel:
Outer diameter +0,125 There should not 241 – 285 НВ
150 be faults
+ 0,100
75132 – 2919230
Eyelet with grounding: ТВЧ h 1,5 – 5,0 mm
−0,014 Steel 35
215 215 – 215,02 40 – 50 НRCэ
Inner diameter − 0,060
7513 – 2919426-10
Finger (length of finger - 447 mm):
First outer diameter −0,145 241 – 285 НВ
134 134
− 0,245 − 0, 4
8-20
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7513-3902080 RM
Table 8.1.3 — Rated and maximum permissible dimensions of major suspension parts on dump
trucks BELAZ–7514-10, BELAZ–75145
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7519 – 3001018-01
Pivot of swivel member: There should not be ТВЧ h 3 - 5 mm
−0,056 Steel 45
Outer diameter 260 places with wear of 47 – 53 НRCэ
−0,186
(coverage Хтв.60) chromic coverage
7519 – 3001016-11 There should not be places with wear of Ribbon of brand
Barrel of pivot plastic stratum «С» 2,56х100
7519 – 3001060
Bracket of pivot:
+0,13 Steel 40Л 146 – 229 НВ
Inner diameter 265,25 265,5
7521 – 2919016-01:
Normalization
Rod of suspension: +0,030 +0,072
200 Steel 35 ТВЧ h3 mm
Inner diameter − 0,016
200 НRCэ42
(length of rod on shafts is 1220 mm)
75211 – 2909426
Finger (length of finger - 387 mm):
First outer diameter −0,145 241 – 285 НВ
134 134
− 0,245 − 0, 4
7519 – 2919230-10
Normalization
Eyelet with grounding: −0,014 Steel 35 ТВЧ h 1,5 – 3,0 mm
215 215 – 215,02
Inner diameter − 0,060 40 – 50 НRCэ
7519 – 2919186
Tall barrel:
+0,125 There should not
Outer diameter 150 241 – 285 НВ
+ 0,100 be faults
7521 – 2919155
Conic barrel:
+0,11 There should not
Outer diameter 150
+ 0,08 be faults Steel 40Х 241 – 285 НВ
8-21
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7513-3902080 RM
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7521 – 2919158
Distance barrel:
−0,085 There should not
Outer diameter (up to cutting) 132
− 0,148 be faults Steel 45 241 – 285 НВ
8-22
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Figure 8.1.16 - Rod of absorber of suspension cylinder of dump truck BELAZ-7514-10, BELAZ-75145:
1 - cylinder rod of front suspension; 2 - cylinder rod of rear suspension
Figure 8.1.17 - Rod of absorber of suspension cylinder of dump truck BELAZ-75131, BELAZ-75132:
1 - cylinder rod of front suspension; 2 - cylinder rod of rear suspension
8-23
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8-24
Running gear
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Table 8.1.4 - Sizes of cuffs of suspension cylinders after tightening of pinch nut
Place of Recommended size, Recommended Torque of pinch nut,
Name
measuring mm tightness, mm N.m
Cuff of rod of the front
217,7 — 218,0
cylinder
Inner diameter 2,0 — 2,3 9000 — 10000
Cuff of rod of the rear
247,7 — 248,0
cylinder
Sampling of tightness of cuffs (inner diameter) is to be executed by measuring tool eliminating strain and
fault of working crimps of cuffs. For sampling tightness of cuffs it is recommended to use special caliper which
jaws have big length and width as contrasted to usual calipers (figure 8.1.19).
Such caliper is easy to make using usual caliper having soldered to it specially produced jaws, as it is
shown in figure. Jaws are to be soldered with copper-zinc solder. After that perform test of caliper on exacti-
tude of measurement as prescribed by instruction on inspection of probing devices.
After adjusting tightness of cuff (deriving of required inner diameter size) unscrew pinch nut 6 (see figure
8.1.18), take out ring 10 cuff. Put sealing ring 11 on ring of cuff and insert it into tube of major cylinder 1.
Special device (figure 8.1.20) is designed for mechanization of process of tightness adjustment of cuff of
cylinder sealing package. Device consists of adjustment stand (280-55-6), hydraulic equipment and electrical
equipment.
The adjustment stand consists of bed 3, hydraulic cylinder 2 and squeezing mechanism 1. Hydraulic
equipment consists of pump 4, hydraulic distributor 5 and hydraulic reservoir 6.
For adjusting tightness install package of sealing in guidings of squeezing mechanism 1, set upper rod 7
into working position and contract package of sealing. Measure inner diameter of cuff and change amount of
adjusting gaskets at misfit of size.
8-25
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7513-3902080 RM
After mounting sealing package in tube of major cylinder turn pinch nut 6 (preliminary having greased
thread with lubricant Литол-24) not turning approx 1,5 revolutions till compression of package of sealing parts
(against stop);
- install rod 34 (see figure 8.1.5) in assembly with valves in tube of major cylinder 13 so that butt of pis-
ton was on distance of 25 mm from butt of tube of major cylinder of front suspension and on distance of 55 mm
up to butt of tube of major cylinder of rear suspension;
- tighten pinch nut 14 with torque (see table 8.1.5);
- ihrough tapped holes in pinch nut prick-punch ring of cuff 58, having made deepening with angle taper
0
of 90 and depth of not less than 1,5 mm;
- in tapped holes of pinch nut install and turn locking screws 27;
- prick-punch locking screws in two points aside from slot on screw.
The further assembly of suspension cylinders is to be performed as follows:
- put ring 30 in assembly with rod 34 on tube of major cylinder 13;
- install sealing ring 53, safety ring 54 and ring 17 in housing 11;
- put housing 11 on rod 34;
- install assembled lower cover 25 in rod 34 and fix it by bolts 4 with washers;
- unscrew plugs 35 of compression valves and fill oil in cavities of cylinder up to level of upper butt of
piston of rod (filling of cylinder is to be performed in vertical position);
- tighten plugs of compression valves;
- install assembled upper cover 38 in tube of major cylinder and fix it by bolts 4 with washers;
- refuel cylinder with oil through bores under priming valves up to level of bores;
- screw priming valve 3 and valve of sensor 37, having installed sealing gaskets 46under them;
- screw safety valves 21 in upper 38 and lower 25 covers;
- install insert 2 of trunnion balls 40 in upper and lower cover, having greased spherical surface of insert
with lubricant Литол-24;
- install adjusting gaskets 24 on upper and lower covers;
- insert trunnion balls into upper and lower covers, preliminary having greased spherical surface with lu-
bricant Литол-24;
- install sealing rings 22 in covers 39;
- fix by bolts covers 39 to upper 38 and to lower 25 covers so that trunnion balls 40 had no longitudinal
backlash and were twirled in any direction with torque of no more than 60 N.m for front cylinder and torque of
8-26
Running gear
7513-3902080 RM
Dump truck designation Suspension cylinder Cylinder designation Gas pressure, МPа
- fill oil in cavity of housing up to level of plug 15 thread (see figure 8.1.5). Cylinder should be in vertical
8-27
Running gear
7513-3902080 RM
position;
- turn plugs 15 and pressure-relief valve 10, preliminary having installed sealing gaskets;
- remove suspension cylinder from device for assembly;
- install protective boot 9 and put sealant 31.
IN ORDER TO AVOIDE GAS LEAKS THROUGH MOBILE ROD SEAL STORAGE AND TRANSPORTATION OF
CHARGED SUSPENSION CYLINDERS IS TO BE PERFORMED IN VERTICAL POSITION, ABERRATION FROM VER-
TICAL POSITION SHOULD NOT EXCEED 300.
8-28
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AFTER MOUNTING SUSPENSION CYLINDERS ON ALL DUMP TRUCKS TRUNNION BALLS ARE TO BE
GREASED WITH LUBRICANT ЛИТОЛ-24 THROUGH GREASERS TILL EMERSION OF LUBRICATION FROM
SAFETY VALVES.
8-29
Running gear
7513-3902080 RM
The axial clearance in joint butt of finger 9, bearing and butt of barrel is not permitted;
- losk nut 10 from unscrewing with two bolts 11, splint them in turn with splint - wire 12;
- install protective boot 1.
Assembly of central hinge of front suspension of dump trucks BELAZ-75131, BELAZ-75132 is to be per-
formed as follows:
- press stuffing boxes 24 in covers 27 (see figure 8.1.3);
- install cover with stuffing box in eyelet with grounding 28 and fix it with bolts 23;
- press hinged bearing 26 against stop in cover. Before mounting hinged bearing is to be greased with
blend of 90 % of lubrication Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75. Outer ring of hinged
bearing is to be installed on sealer "УГ-9" TУ 6-01-1326-86;
0 0
The jointing plane of outer ring of hinged bearing should be under an angle 90 + 5 to shaft Ж, thus
identification mark at butts of both semi-rings should be on one hand of bearing, and semi-ring should be of
one serial number. Inner ring of bearing after mounting should be turned on angle of not less than 150 by hand
without jams or under force (20 + 5) Н affixed on distance (200 + 50) mm from butt of inner ring;
- install cover 27 with stuffing box in eyelet with grounding 28 and fix it with bolts 23;
- lock bolts 23 from both sides of eyelet with splint-wire 37;
- fix eyelet 28 in assembly with bearing to central lever bolt 29 with torque of 910-1020 N.m;
- install central lever with eyelet 28 inside bracket of frame and, having combined bores in bearing and
bracket, press finger 25 against stop;
- install and fix by bolts 36 with washers lock plate 35. Spacing in junctions of lock plate is not permitted,
it can be eliminated by turning movement of finger 25;
- install disk 30 and fix finger by bolts 31 with torque of 1100 – 1250 N.m with washers. Axial clearance in
joint butt of finger 25, bearing and butt of barrel is not permitted.
Assembly of central hinge of rear suspension of dump trucks BELAZ-75131, BELAZ-75132 is to be per-
formed as follows:
- press stuffing boxes 13 in covers 8 (see figure 8.1.4);
- install cover with stuffing box in eyelet with grounding 7 and fix it with bolts 6. Before assembly external
surfaces of bolts and bores mated to it are to be greased with two - three drops of sealer "Анатерм-8К" TУ - 6-
02-6-88;
- press hinged bearing 12 against stop in cover. Before mounting hinged bearing is to be greased with
blend of 90 % of lubrication Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75. Outer ring of hinged
bearing is to be installed on sealer "УГ-9" TУ 6-01-1326-86;
The jointing plane of outer ring of hinged bearing should be installed on shaft И, thus identification mark
at butts of both semi-rings should be on one hand bearing, and semi-ring should be of one serial number.
0
The inner ring of bearing after mounting should be turned on angle not less than 15 under force (20 + 5)
Н, affixed on distance (200 + 50) mm from butt of inner ring;
- install cover 8 with stuffing box in eyelet with grounding 7 and fix it with bolts 6, having installed them
on sealer "Анатерм-8К";
- fix eyelet 7 in assembly with bearing to central lever bolted joint, nut 14 torque is 1200 - 1500 N.m;
- install central lever with eyelet 7 inside bracket of frame and, having combined bores in bearing and
bracket, press finger 9 against stop;
- install and fix by bolts 32 with washers lock plate 5. Spacing in junctions of lock plate is not permitted,
and can be eliminated by turning movement of finger 9;
- place and tighten with torque of 1800 - 2000 N.m split nut 10 (on factory-manufacturer torquering is
carried out by pneumobox wrench ИП 31-15 GOST 10210-83, Мкр maх 3150 N.m).
After torquering nut is to be tightened on angle of 600 (one edge). Torquering should be performed by
wrench with booster of torque that is sufficient for tightening or other equipment, observing safety precautions.
8-30
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7513-3902080 RM
- lock nut 10 from unscrewing by two bolts, Splint them in turn by splint-wire. Axial clearance in joint butt of
finger 9, bearing and butt of barrel is not permitted.
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ-24 TILL EMERSION OF LUBRICATION FROM UNDER STUFFING BOXES.
8.1.13 Assembly and mounting of transversal rods of front and rear suspension
Assembly and mounting of transversal rod of rear suspension of dump trucks BELAZ-7514-10, BELAZ-
75145 is to be performed as follows:
- install locking ring 24 in head of rod 4 (see figure 8.1.2) and press hinged bearing 23 against stop in
locking ring.
The jointing plane of outer ring of hinged bearing should be installed under angle of 900 + 50 to direct-
axis of rod, thus identification mark at butts of both semi-rings should be on one hand of bearing, and semi-
rings should be of one serial number.
The inner ring of bearing after mounting in greased condition should be turned on full angle (against stop
in ring) by hand without jams or under force (20 + 5) Н, affixed on distance (100 + 50) mm from butt of inner
ring. Before mounting hinged bearings and finger of rod are to be greased with blend of 90 % of lubrication
Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75;
- install second locking ring, having fixed hinged bearing in head of rod;
- press stuffing boxes 19 in head of rod on one from each side of bearing and install sealing rings 30;
- carry out above mentioned operations on second head of rod;
- install head of transversal rod inside of brackets of frame and rear axle, having combined bores in rod
and bracket, install fingers 26;
- install plate pinch 21 on part of conic barrel 22 and fix by bolts with 20 torque of 360 - 440 N.m with
washers;
- install distance barrel 29, pinch plate 21 and fix them with bolts 20 and 28 with washers.
Assembly and mounting of transversal rod of front suspension of dump trucks BELAZ-75131, BELAZ-
75132 is to be performed as follows:
- install locking ring 9 in head of rod 2 (see figure 8.1.3) and press hinged bearing 10 against stop in
locking ring.
0 0
At mounting of hinged bearings 10 jointing plane of outer ring should be installed under angle 90 + 5 to
direct-axis of rod 2, thus identification mark at butts of both semi-rings should be on one hand of bearing, and
semi-rings should be of one serial number.
The inner ring of bearing after mounting should be turned in outer ring on angle of 70 by hand without
jams or under load of no more than 20 Н, affixed on distance of100 mm from butt of inner ring;
- install second locking ring, having fixed hinged bearing in head of rod;
- grease spherical surfaces of bearing with lubricant Литол-24 and put it in cavity of stuffing boxes 8;
- press stuffing boxes 8 in head of rod on one from each side of bearing;
- carry out above mentioned operations on second head of rod;
- install fingers 7 in bores of inner ring of hinged bearings 10, and fingers from both sides of rod should
be unrolled on angle 1800 relative to each other;
- install covers 11 on butts of hinged bearings and fix them with bolts 12 with washers;
- install barrels 6 and disks 5 in bores of brackets of frame and front axle;
- install transversal rod 2 with fingers 7 in bores of brackets of frame and front axle and to tighten bolts 4
with torque of 2400 - 3000 N.m. Bolts 4 are to be installed on sealer "Анатерм-8К" TУ - 6-02-6-88.
Assembly and mounting of transversal rod of rear suspension of dump trucks BELAZ-75131, BELAZ-
75132 is to be performed as follows:
- install locking ring 22 in head of rod 3 (see figure 8.1.4) and press hinged bearing 23 against stop in
locking ring.
The jointing plane of outer ring of hinged bearing should be installed under angle of 900 + 50 to shaft of
rod Ж, thus identification mark at butts of both semi-rings should be on one side of bearing, and semi-rings
should be of one serial number. Inner ring of bearing after mounting should be turned in outer ring on angle of
not less than 70 from force (10 + 5) Н, affixed on distance (100 + 50) mm from butt of inner ring.
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Before mounting of hinged bearing plane of plug of outer ring is to be greased with blend of 90 % of lu-
brication Литол-24 and 10 % of copper dust ПМС-2 GOST 4960-75, outer ring of hinged bearing is to be
greased with sealer "УГ-9" TУ 6-01-1326-86;
- install second locking ring, having fixed hinged bearing in head of rod;
- press stuffing boxes 27 in head of rod on one from each side of bearing and install sealing rings 16;
- carry out above mentioned operations on second head of rod;
- install head of transversal rod inside of brackets of frame and rear axle, having combined bores in rod
and bracket, install fingers 20;
- install pinch plate 25 on part of conic barrel 24 and tighten bolts 26 with washers;
- install distance barrel 17, pinch plate 25 and fix them with bolts 26 and 18 with washers. External sur-
faces of bolts and bores mated to them are to be greased with two - three drops of sealer "Анатерм-8К".
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ-24 TILL EMERSION OF LUBRICATION FROM UNDER STUFFING BOXES.
8.1.14 Assembly and mounting of pivot unit of front suspension on dump trucks BELAZ-7514-10,
BELAZ-75145
Assembly and mounting of pivot unit is to be performed as follows:
- install in eyelets of bracket 6 (see figure 8.1.1) barrels of pivot 20 and sealings: scratcher 26, wiper ring
25, cuff 24 with support ring 23.
Before mounting of bracket of pivot 6, barrels pivot 20, pivot 5 and sealings 23, 24, 25, 26 are to be
carefully cleared till full removal from their surface of dust, mud and preserving lubrication, and are to be dried
by wiping with soft paper or textile fabric napkins. Grease internal surface of bracket 6, swivel member 8, bar-
rels pivot with lubricant Литол-24;
- install and fix bracket 13 of pivot on mobile table 11 of stand (see figure 8.1.14 а);
- fix beam on wheel hub 1;
- install wheel hub with swivel member on support brackets 2;
- with the help of hoisting gear of table and screws perform centering of bores of swivel member and
bracket pivot shafts;
- lock mobile table and basic swinging arms with screws from moving;
- connect worm reducer 4 and swivel member with the help of turnbuckle 3;
- put pivot 12 on table of roll-table;
- perform centering of shaft of pivot regarding shafts of swivel member 1 and bracket of pivot 13. Lock
table of roll-table;
- turn connective head 9 in tapped hole of pivot tail;
- switch on electromotor, bring power-transmission screw 6 against stop in connective head, lock screw
in connective head and press pivot in bores of mated units;
- turn studs 13 and 17 in tapped holes of swivel member and pivot (see figure 8.1.1);
- install lever 18 of steering trapezoids on swivel member, fix it by nuts 14 with torque of 800-1000 N.m,
preliminary having installed expanding barrels 15;
- fix pivot 5 to lever of steering trapezoid 18 by nut 16 with torque of 1600 - 2000 N.m with washer;
- install pivot unit on dump truck, tighten nut 12 with torque of 1800 - 2000 N.m;
- connect to pivot lower bracket of suspension cylinder 28, having fixed bolts 33 with torque of 700 - 900
N.m with washers;
- connect with lever 18 of steering trapezoid the cylinder of turning movement and pull-rod of steering
trapezoid, hose of service brake system;
- install front wheel on hub;
- remove dump truck from jamb and charge suspension cylinder with gas according to characteristic ruler.
AFTER ASSEMBLY GREASE BARRELS OF PIVOT WITH LUBRICANT ЛИТОЛ-24 THROUGH GREASERS 22
TILL EMERSION OF LUBRICATION FROM PRESSURE-RELIEF VALVES 21.
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8.2.1.2 Removal of front axle from dump trucks BELAZ-75131 and BELAZ-75132
Front axle in assembly with hubs and brakes, pull-rod of steering trapezoid and cylinders of turning
movement are removed from dump truck in following sequence:
- apply parking brake and install thrust blocks under rear wheels;
- hang out front part of dump truck up to full disengagement of wheels from floor of platform, release gas
from cylinders of front suspension and install special jambs under frame behind front axle;
- remove wheels from hubs of dump truck front wheels (see «Wheels and tires» section). Before unfastening
of wheels release air from tires;
- disconnect sleeves of high pressure of steering from cylinders of turning movement, hoses of brakes,
lubrication lines of centralized automatic lubricating system. Before unhooking of sleeves and hoses remove
pressure of working fluid in hydraulic drive of braking systems;
- install special carriage-hoist under front axle and jack beam of front axle against stop in lower shelf;
- unscrew bolts 20 (see figure 8.3) of lower brackets 21 suspension cylinder fastening attached to swivel
members;
- unscrew bolt 4, disconnect transversal rod 2 of suspension from beam of front axle;
- lead out brackets of suspension cylinder up to exit of flanges from propoints of landing nests of swivel
members by smooth omitting of shaft on carriage-hoist;
- disassemble central hinge of front suspension and squeeze finger of central hinge (see section 8.1.6);
- make sure of reliable position of shaft on carriage-hoist and roll out front axle from under dump truck
installed on jambs;
- moor front axle with the help of fastening device and deliver shaft to section of repair (weight of front
axle is about 7760 kg).
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8-34
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Figure 8.2.2 – Swivel member with hub, brake and swivel gear of dump trucks BELAZ-75131 and BELAZ-75132:
1 - arrester; 2 - left rotary lever; 3 - barrel of pivot; 4 - expanding barrel; 5 - nut; 6, 22 - studs; 7 - left swivel member; 8 - brake
drisk; 9, 11 - bearings; 10 - arrester of volume; 12, 15, 19, 24, 34 - bolts; 13 - hub of front wheel; 14 - pinch ring; 16 - adjusting barrel;
17 - drive gear of speedometer sensor; 18 - sealing gasket; 20 - external cover of front hub; 21 - stuffing box; 23 - wheel; 25 - cuff; 26 - in-
ternal cover of front hub; 27 - choke; 28 - wiring harness of speedometer; 29 - beam of front axle; 30 - ring; 31 - case of brake; 32 - splint;
33 - adometer; 35 - washer; 36 - strap
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Figure 8.2.3 - Device 360-013 for removal and mounting of front hub on dump trucks BELAZ-75131 and BELAZ-75132:
1 - claw of loader; 2 - wheel hub; 3 - jamb; 4 - nut; 5 - hold-down tool; 6 - bolt; 7 - hand lever; 8, 10 - screws; 9 - insert;
11 - bracket; 12 - support
- disconnect and remove from front axle pull-rod of steering trapezoid and cylinders of turning movement
(see "Steering" chapter);
- unscrew nuts 5 (see figure 8.2.2) of pivot rods 2 of steering trapezoid fastening to swivel members;
- extract expanding barrels 4 and remove pivot rods;
- extract from upper eyelet of swivel members adjusting washers 14 (see figure 8.1.3), ring 18 with
buffer 16 and liners 17;
- unscrew bolts 12 (see figure 8.2.1) and remove cover 13 of pivot and liners 11;
- moor swivel member 7 with the help of load-lifting device (see figure 8.2.2) and hang it out;
- turn two eye bolts M14 in opposite tapped holes of pivot 20 (see figure 8.2.1) and moor pivot;
- turn out locking member 16 of pivot;
- squeeze pivot 20 by means of special device (figure 8.2.4). If squeezing of pivot is hampered due to
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At disassembly of hub 13 (see figure 8.2.2) of front wheel apply device shown in figure 8.2.5 for squeez-
ing of outer ring of external bearing 11, apply device shown in figure 8.2.6 for squeezing of outer ring of inner
bearing 9 (see figure 8.2.2).
Figure 8.2.5 - Device 360-006 for squeezing of outer ring of external bearing (2007156А)
of hub of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - nut; 2 - screw; 3 - washer; 4 - beam; 5 - cover; 6 - stud; 7 - outer ring of bearing; 8 - hub
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Figure 8.2.6 - Device 360-009 for squeezing of outer ring of inner bearing (2007164А)
of hubs of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - hub; 2 - outer ring of bearing; 3 - remover; 4 - washer; 5, 7 - nuts; 6 - screw; 8 - insert; 9 - beam; 10 - stud; 11 - adapter
connector
At disassembly of swivel member 7 (see figure 8.2.2) for squeezing of inner ring of inner bearing 9 and
internal cover 26 of hub of front wheel apply device shown in figure 8.2.7.
Figure 8.2.7 - Device 360-005 for squeezing of inner ring of inner bearing (2007164А)
of hub of front wheel on dump trucks BELAZ-75131 and BELAZ-75132:
1 - remover; 2 - cover; 3 - insert; 4 - wrench; 5 - inner ring of bearing; 6 - internal cover of front hub; 7 - hook; 8 - swivel member
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8.2.2 Swivel member with hub of dump trucks BELAZ-7514-10 and BELAZ-75145
The hub of front wheel is removed from dump truck in following sequence:
- apply parking brake and install thrust blocks under rear wheels;
- hang out frame of dump truck, with the help of crane (jacks) in its front part up to full disengagement of
wheels from floor of platform and install special jambs under spars of frame instead of jacks;
- remove wheel from hub 25 (see figure 8.2.8) of dump truck (see «Wheels and tires» section). Before unfas-
tening of wheels release air from tire;
- unscrew bolts 45 and remove external cover 3 of front wheel hub;
- unscrew bolts 6 and remove drive gear of speedometer sensor 4, having disconnected wiring harness
of speedometer 18 and sealing gaskets 5 (only for left wheel);
- unsplint and unscrew bolts 43 and remove pinch ring 1;
- extract stuffing box 44 out of boring of front wheel hub;
- moor hub with fastening or lifting device for simplification of squeezing and exclusion of falling of hub
after squeezing;
- fix device (figure 8.2.9) on hub 6 and press hub is assembly with brake drum and outer rings of bear-
ings;
- install hub on special jamb and fix hub in order to exclude of its falling;
- extract stuffing box 44 out of boring on other side of hub;
- unscrew bolts 51 (see figure 8.2.8) and disconnect brake drum 9 from hub (only if repair or replace-
ment of brake drum is necessary);
At disassembly of hub of front wheel apply device 360-006 shown in figure 8.2.5 for squeezing of outer
rings of bearings 7 and 24, and apply device (manufactured as 360-005, shown on figure 8.2.7) for squeezing
of inner ring of inner bearing 24.
8.2.3 Check-up of technical condition of front axle parts of dump trucks BELAZ–75131, BELAZ–
75132 and of swivel member with hub of dump trucks BELAZ–7514-10, BELAZ–75145
After disassembly test technical condition of working surfaces of parts by external examination and
measurement of their critical parameters.
Rated and maximum permissible sizes of parts of front axle of dump trucks BELAZ-75131 and BELAZ-
75132 are specified in table 8.2.1, rated and maximum permissible sizes of swivel member with hub of dump
trucks BELAZ-7514-10 and BELAZ-75145 are specified in table 8.2.2.
Besides, mounting of swivel members with cracks is not permitted. Pivots of swivel members of dump
trucks BELAZ-75131 and BELAZ-75132 are discarded also at presence of cracks, faults and wear of cylindri-
cal surface.
Hubs of front wheels are subject to discard or repair at presence of cracks, faults of thread under studs
of wheels and wear of mounting surfaces under bearings.
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8-40
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Figure 8.2.8 - Front wheel with brakes and swivel gear of dump trucks BELAZ-7514-10 and BELAZ-75145:
1 - pinch ring; 2 - adjusting barrel; 3 - external cover of front hub; 4 - drive gear of speedometer sensor; 5 - sealing gasket; 6, 31, 39, 43, 45, 51 - bolts;
7, 24 - bearings; 8, 23 - studs; 9 - drum brake; 10 - arrester of volume; 11 - internal cover of hub; 12 - swivel member; 13 – barrel of pivot; 14 - pivot; 15 -
greaser; 16 - safety valve; 17 - bracket; 18 - wiring harness of speedometer; 19 - stud of lever of rear suspension; 20, 22 - nuts; 21 - expanding barrel; 25 - hub
of front wheel; 26 - finger of spring; 27, 33, 36, 42 - splints; 28 - spring; 29 - pad with straps; 30 - wheel cylinder of front brake; 32 - protective boot; 34 - split
key; 35 - plunger; 37 - lever of steering trapezoid; 38 - washer; 40 - strap of shaft of pads; 41 - shaft; 44 - stuffing box; 46 - choke; 47 - scratcher; 48 – wiper
ring; 49 - cuff; 50 – support ring
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Table 8.2.1 — Rated and maximum permissible sizes of major parts of front axle
of dump trucks BELAZ–75131, BELAZ–75132
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7513 – 3001005
Beam of front axle with lever +0,09 Steel 40 Л 156 – 229 НВ
Diameter of hole under pivot 210 210,2
7513 – 3001014
Swivel member
Diameter of wrist pin under bearings −0,017
280 279,88 Steel 45 241 – 285 НВ
−0,049
−0,018
320 319,88 Steel 40Л 156 – 229 НВ
−0,054
7513 – 3103015
Hub of front wheel
−0,045
Diameter of holes under bearings 420 420,00
−0,108 Steel 40Л 156 – 229 НВ
−0,045
480 480,00
−0,108
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Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7519 – 3103089-20
Pinch ring
Steel 40Л 156 – 229 НВ
Outer diameter under sealant 410 408,00
−1,55
7513 – 3103070-01
Inner cover of front hub ТВЧ h 1,5 - 4 mm
Steel 35
Outer diameter under sealant 480 479,75 НRCэ40
−0,125
Table 8.2.2 — Rated and maximum permissible sizes of major parts of front wheel
of dump trucks BELAZ–7514-10, BELAZ–75145
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7519 – 3001013-30
Swivel member
−0,017 Steel 45 241 – 285 НВ
Diameter of neck of wrist pin under 280 279,88
inner and outer bearing −0,049
7519 – 3103015
Hub of front wheel
−0,045 Steel 40Л 156 – 229 НВ
Diameter of neck under bearing 420 420,00
−0,108
7519 – 3103089-20
Pinch Ring
Steel 40Л 156 – 229 НВ
Outer diameter under sealant 410 408,00
−1,55
7519 – 3103070-01
Inner cover of front hub ТВЧ h 1,5 - 4 mm
Steel 35
Outer diameter under sealant 480 479,75 НRCэ40
−0,125
8.2.4 Assembly and mounting of front axle of dump trucks BELAZ-75131 and BELAZ-75132
The parts of front axle delivered on assembly, should be cleared of mud, washed out and blown through
by compressed air.
Before assembly of barrel of pivot 19 (see figure 8.2.1), pivot 20, cover 13 and liner 11 are to be cleared
till full removal from their surface of dust, mud and preserving lubrication and are to be dried by wiping with soft
paper or textile fabric napkins.
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Assembly of front axle is to be executed on special stand. At wear out or mechanical damage of metal-
plastic stratum of pivot barrels extract them from eyelets of swivel member and install new.
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of pivot;
- turn locking member 16 against stop in combined bores of pivot and beams;
- on support surface in upper eyelet of swivel member install liners 11, cover 13 and fix them with bolts
12, preliminary having greased surface of liners with lubricant Литол-24;
- make sure that swivel member rotates on shaft of pivot to left and to right without jams. Use hoisting
device;
- install arrester 1 (see figure 8.2.2) with ring 30 in lower eyelet of swivel member;
- install pivot rod 2 of steering trapezoids and fix it by nuts 5 with torque of 800 - 1000 N.m to swivel
member, having installed expanding barrels 4 on studs 6 under nuts 5;
- connect and fix pipe ducts of braking system and lubricating system;
- install another swivel member on beam of front axle in the same sequence;
- install and fix pull-rod of steering trapezoid and cylinders of turning movement (see "Steering" section)
to pivot rod of swivel members and brackets of beam of front axle;
- after assembly grease barrels of pivots with lubricant Литол-24 through press-greasers 18 (see figure
8.2.1). Amount of lubrication is to be approx 0,2 - 0,3 kg in each eyelet of swivel member.
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8.2.5 Assembly and mounting of hub of front wheel on dump trucks BELAZ-7514-10 and
BELAZ-75145
The parts delivered on assembly, should be cleared from mud, washed and blown by compressed air.
7513-3902080 RM
member. Before mounting fill lubricant Литол-24 in cavity of arrester of volume 10 of hub;
- install inner ring of external bearing 7 on wrist pin of swivel member, carefully having filled lubricant
Литол-24 in space between rollers of bearing, and by means of device (see figure 8.2.9) press hub of front
wheel against stop;
- install pinch ring 1, preliminary having filled lubricant Литол-24 in cavity of ring, combine bores and fix
ring with bolts 43 without torquing them;
- perform adjusting of roller taper bearings.
Adjusting of taper bearings is to be performed as follows:
- turning hub (at three revolutions min) tighten six bolts 43 with torque of 100 - 140 N.m. Repeat opera-
tion till suitable twisting torque;
- unscrew bolts on 22 - 280;
- tighten adjusting barrels 2 with torque of 100 - 140 N.m;
- tighten twelve bolts 43 with torque of 100 - 140 N.m and splint by splints 42;
- install sealing gasket 5 on drive gear of speedometer sensor 4, combine bores, install drive gear of
speedometer sensor and fix it with bolts 6 to pinch ring 1, having connected wiring harness of speedometer 18
(for left wheel only);
- install external cover 3 of front hub and fix it with bolts 45;
- install wheels on hubs of front wheels (see «Wheels and tires» section). After torquering of nuts pump
up tires with air up to required pressure;
After mounting of wheels on hubs, adjust toe-in of front wheels without removing dump truck from jambs.
8.2.6 Adjusting of bearings of front wheel hubs during operation of dump trucks
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8-47
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8-48
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8-49
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It is necessary to observe the specified requirements at performing any works connected with necessity
of unfastening or removal of wheels.
At operation of dump truck in key part of wheel rim there can be cracks. If there is air in tire at releasing
of wheel fastening there can be sudden rupture of rim that can result in accidents.
For unfastening front wheel unscrew nuts 4 (see figure 8.3.1) from studs 3 and remove clips 2 of wheel
fastening.
For unfastening dual (rear) wheels unscrew nuts 5 (see figure 8.3.2) from studs 6 first at half of altitude
only and release clips 1. Having made sure that clips are released, unscrew nuts completely and remove clips. At
completely unscrewed nuts there can be blowout of clips, therefore it is forbidden to stand opposite clips of rear
wheels that are being removed.
At unscrewing and screwing nuts of rear wheels fastening it is necessary to apply special work tool (fig-
ure 8.3.3) for key support and to support wheel with fastening device. Before removal of internal wheel from
hub of rear axle remove spacing ring 10 (see figure 8.3.2).
At removal of wheels from hub it is necessary to preserve stud of wheels, valves and extension leads of
valves from damage.
Figure 8.3.3 – Work tool 360-012 for key support at unscrewing and screwing nuts of rear wheels fastening:
1 - key; 2 - holder; 3 - pin; 4 - washer; 5, 6 - bolts; 7 - disk; 8 - beam
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Wheeled manipulator (figure 8.3.4) is designed for mechanization of installation works on replacement of
wheels and for accomplishment of operations on canting, warehousing and transportation of large-sized
wheels.
IT IS INADMISSIBLE TO BEAT OUT RIMS FROM TIRES WITH THE HELP OF SLEDGE HAMMER IN ORDER
TO PREVENT DEFORMATION OF WHEEL PARTS, AND EMERGENCE OF NICKS AND CRACKS.
DISMANTLING OF TIRE FROM RIM IS CARRIED OUT ON TIRE ASSEMBLY STAND AT ABSENCE OF AN AIR
PRESSURE IN TIRE.
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Figure 8.3.5 – Tire assembly stand ЭСМ 5 for assembling and dismantling of tires:
1 - power cylinder; 2 - ground; 3 - protective casing; 4 - mobile plate; 5 - guiding plate; 6 - support of upper cross-piece; 7 - upper
cross-piece; 8 - jamb; 9 - bracket; 10 - pumping plant; 11 - hand lever; 12, 13, 14, 15 - pipe ducts; 16 - cylinder of mobile plate lifting;
17 – lower cross-piece
Before assembling check completeness of tire and wheel parts. Wheel and tire should be of prescribed
size only.
Only wheels with undisturbed coloring of all parts from internal and external sides are admitted for as-
sembling of tires. Application of wheel parts that are subjected to corrosion can result in their breakage during
operation that can cause accidents. Besides, application of unpainted wheel parts complicates not only as-
sembling, but also subsequent dismantling as tire adheres more strongly to unpainted surfaces of tire beads
than to the colored surfaces.
Before assembling test condition of tire by external examination. Inner hollow of it should be clean and
dry. Tire bead should not have leftovers of fin. Presence of moisture, mud and fin of rubber can become rea-
son of complicated or impossible air release from tire because of blockage of valve canal.
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Check carefully condition of rim elements, paying special attention on absence of cracks on flute for key
ring and sealing rings, on fluting planes of clamps of bead grounding and landing ring, on welded connections
of key part of rim and bead grounding to shell of rim. It is recommended to apply visual quality monitoring,
color, magnetic or ultrasonic flaw detection to reveal cracks. At visual control it is possible to take advantage of
magnifying glass.
It is forbidden to admit to assembling the rims and other wheel parts having such defects as cracks,
presence of rust and rolls of paint in places contacting with tire or other wheel parts, and also with infringement
of geometry (increased ovality of bead ring and rim, twisting of key ring, indents, agnails, etc.).
It is forbidden to use rims with bad condition of key flute and key rings with above mentioned defects as
at tire inflation there can be spontaneous dismantling.
Clear dirty sections of wheel, especially landing shelves of rim and places at valve bores of mud and
rust with metal brush, degrease and tint them. At collapse of more than 25 % of all coloring of wheel parts it is
necessary to perform full coloring, using soils and enamels intended for metal.
At assembling tire on rim it is necessary to observe caution in order to prevent damage of tire beads,
sealing ring and elements of rim providing leakproofness of joints. Re-use of sealing ring is not permitted. It is
forbidden to use bore fore valve for rim strapping.
For protection of slide valves from clogging and damage the valve should comprise cap.
IT IS FORBIDDEN TO:
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Figure 8.3.6 – Work tool 360-016 for alignment of internal wheel with tire on hub:
1, 4 - bolts; 2 - plate; 3 - chock; 5 - nut
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- install work tool on hub of rear wheel and tighten nuts 5 of wheel fastening in regular intervals;
- after mounting of internal wheel on taper of hub, tighten three bolts 1 for its fixing;
- remove work tool from hub of rear axle;
- install external wheel on hub;
- install clips and tighten nuts of wheel fastening gradually in 3 - 4 takings crosswise (serially oppositely).
Final tightening torque is 800 - 900 N.m. An admitted wheel wobble on side member of tire case should be no
more than 10 mm. Retightening of fastening nuts is to be performed after first running-in, and further after
every two - three running-ins up to stabilization of tightening torque of all nuts;
- unscrew bolts 1 from spacing ring;
- remove lining chocks from under internal wheel (if they have been installed);
- pump up tires with air up to operating pressure level and screw caps on valves.
On dump trucks valves such as БС and extension leads УГ17 of increased flow area are installed.
In order to speed-up tire inflation and deaeration through valve БС and extension lead УГ17 apply spe-
cial device (figure 8.3.7).
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8-56
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9 STEERING
9.1 General information
The steering of dump trucks BELAZ-7514-10, BELAZ-75145 is of hydrovolumetric type with hydraulic
closed loop, consists of steering tube with hydraulic steer, release valve, valve of difference of pressures, hy-
drodistributor, two cylinders of turning movement executed as unit with tracking cavities, liquid damper, auto-
matic machine of unload of pump, pneumohydraulic accumulators, oil-tank, gear pumps, pivot rods, transver-
sal pull-rod and oil pipes.
Steering of dump trucks BELAZ-75131, BELAZ-75132 is of hydrovolumetric type with internal hydraulic
closed loop. It comprises hydraulic steer, jointed by propeller shaft with shaft of steering tube, booster of
stream, back-pressure valve, collector, two hydraulic cylinders of turning movement, axial-piston pump of vari-
able productivity, filters, three pneumohydraulic accumulators, oil-tank and oil pipes.
Repair of pneumohydraulic accumulators is shown in section "Braking systems".
9.2 Possible failures of steering
9.2.1 Basic failures of steering of dump trucks BELAZ-7514-10, BELAZ-75145, reasons and
methods of their elimination
For definition of possible reasons of failures of steering and methods of their elimination it is necessary
to be guided by table 9.1.
Table 9.1 – Basic failures of steering, reasons and methods of their elimination
9-1
Steering
7513-3902080 RM
9.2.2 Basic failures of steering of dump trucks BELAZ-75131, BELAZ-75132, reasons and meth-
ods of their elimination
For definition of possible reasons of failures of steering and methods of their elimination it is necessary
to be guided by table 9.2.
Table 9.2 – Possible failures of steering, reason and methods of their elimination
Yawing of dump truck at Piston of hydraulic cylinder is slackened Repair hydraulic cylinder
in-line motion
Breakage of springs of neutral position in steer Replace springs of steer
Curving stock of hydraulic cylinder or fault of nozzle Replace out-of-order parts
Wear of parts of steer Replace steer
At slow twirl of steerable Wear of piston seals of hydraulic cylinder Replace sealing
wheel steered wheels
are not pivoted Wear of parts of steer Replace steer
9-2
Steering
7513-3902080 RM
pump works at pressure exceeding acceptable value Adjust valve of cut-off on required pressure
Insufficient level of working fluid in hydraulic tank Restore fluid level
Excessive heating of
hydraulic system Hit of air in sucking hydroline Restore leakproofness of sucking hydroline
Abnormally adjustes or out-of-order pressure-relief
Adjust or replace pressure-relief valve
valve in hydraulic system of hoisting mechanism
9-3
Steering
7513-3902080 RM
9-4
Steering
7513-3902080 RM
9.3.1.9 Removal of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
The cylinder of turning movement is removed from dump truck in following sequence:
- disconnect sleeves of high pressure from cylinder of turning movement;
- unscrew nuts from conic fingers on brackets of bar of steering trapezoid and frame;
- moor cylinder of turning movement with help fastening device and hoisting gear;
- dismantle conic fingers from brackets of bar of steering trapezoid and frame and remove cylinder of
turning movement from dump truck.
Analogously second cylinder of turning movement is removed.
The pull-rod of steering trapezoid is removed from dump truck in following sequence:
- unscrew nuts of conic fingers of fastening of bent for to bars of steering trapezoid;
- dismantle conic fingers from bars of steering trapezoid and remove pull-rod from dump truck.
For removal of bars of steering trapezoid unscrew nuts of their fastening to swivel members. Then, ex-
tract conic barrels and remove bars of steering trapezoid.
9-5
Steering
7513-3902080 RM
9.3.2.6 Removal of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
The cylinder of turning movement is removed from dump truck in following sequence:
- disconnect sleeves of high pressure from cylinder of turning movement;
- unscrew nuts from conic fingers on brackets of bar of steering trapezoid;
- moor cylinder of turning movement with help fastening device and hoisting gear;
- dismantle conic fingers from brackets of bar of steering trapezoid and beam of front axle and remove
cylinder of turning movement from dump truck.
9-6
Steering
7513-3902080 RM
The pull-rod of steering trapezoid is removed from dump truck in following sequence:
- unscrew bolts 7 and remove pinch plates 8 (see figure 9.25);
- remove distance sleeve 9;
- squeeze finger 4 from hinged spherical bearing 10;
For removal of bars of steering trapezoid unscrew nuts of their fastening to swivel members. Then, ex-
tract conic barrels and to remove bars of steering trapezoid.
9.4 Disassembly of units of steering
9.4.1 Disassembly of units of steering of BELAZ-7514-10, 75145
9-7
Steering
7513-3902080 RM
9-8
Steering
7513-3902080 RM
9-9
Steering
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- extract from case 16 choke 28, spring 27 and split key 23;
- extract from case 16 choke 11, spring 15, barrel 17 with grid 14, plunger 18, pusher 22, adjusting collar
9-10
Steering
7513-3902080 RM
9-11
Steering
7513-3902080 RM
9.4.1.7 Disassembly of valve of difference of pressures, release valve and back-pressure valve,
Disassembly of valve of difference of pressures is to be carried out as follows:
- unscrew transition nut 3 with washer 1 and ring 2 (figure 9.10);
- extract from case 5 guiding 4, spring 7 and valve 6.
9-12
Steering
7513-3902080 RM
9-13
Steering
7513-3902080 RM
9-14
Steering
7513-3902080 RM
- remove stock 4;
- take out splint 18 from finger 19;
- remove finger 19 and stop member 6;
- unscrew screw 14 on shaft 20 and remove bar 15, spring 16 and barrel 17;
- extract shaft 20 of bore in bracket 8;
- remove barrel 1 and arrester 2;
- unscrew nut 7 and remove pusher 9.
9-15
Steering
7513-3902080 RM
9-16
Steering
7513-3902080 RM
9-17
Steering
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9-18
Steering
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Shock-proof valves (figure 9.20) are maintained as separate units entirely. Sealing rings 1 and 3 can be
substituted separately.
The pressure-relief valve 16, throttle with back-pressure valve 40 and valve of backpressure 11 (figure
9.19) also are maintained as separate units entirely.
Disassembly of valve core of booster 41 is necessary only in event that it is required to replace sealing
ring 2 (figure 9.21), spring 9 or throttle 11, otherwise this unit is subject to substitution entirely.
- take out retaining ring 7;
- take out pin 5;
- take out choke 10 and spring 9;
- take out retaining ring 6 and pin 4;
- extract internal valve core 8;
- turn out butterfly valve of one-sided operation and extract ring 2;
- turn out throttle 11 of choke 10.
Eliminate opportunity of pollution of unit, install time plastic choke in ports of booster of stream.
9-19
Steering
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9-20
Steering
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Disassemble bearing mount assembly on head of cylinder rod of turning movement in following se-
quence:
- turn out greaser 23 of cover 24;
- unscrew bolts of fastening 25 of cover of hinged spherical bearing 20, remove cover 24 and sealing 26;
- unlock bolts 22 fastening hinged spherical bearing on conic finger 18;
- remove thrust washer 21;
- squeeze conic finger 18 from inner ring of hinged spherical bearing 20;
- squeeze hinged spherical bearing 18 of nozzle of stock and remove scratcher 19.
Analogously disassemble bearing mount assembly on nozzle of stock 9 of cylinder of turning movement.
9-21
Steering
7513-3902080 RM
Table 9.3 - Nominal and maximum permissible sizes of basic parts of steering
9-22
Steering
7513-3902080 RM
75212-3428098-10 9,3+0,09
9.7 - 21 Barrel difference Steel 20Х 56-62 HRC
inner diameter difference
of diameters of diameters
75212-3428096-10 0,01…0,02
0,03 max
9.7 - 22 Pusher process on part Steel 40ХН 48-54 HRC
outer diameter 75212-3428098-10
75212-3416254
9.7 - 50 Barrel Steel 20Х 56-62 HRC
inner diameter 32+0,027 difference
of diameters
75212-3416092 process on part
75212-3416254 0,03 max
9.7 - 48 Valve
outer diameter
75125-3428026 diameter of imprint
9.7 - 25 Saddle 7+0,22 of bead Steel 40Х 34-42 HRC
inner diameter 7,5 max
7512-3429020/021
9.13 - 37 Body of cylinder 140+0,1 140,5 Steel 35 —
inner diameter
70-0,030 69,88
-0,076
7512-3429046
9.13 - 36 Rod 75 -0,030 74,87 Steel 40ХН 59-65 HRC
-0,104
outer diameter fault of chromic
coverage is not
permitted
radial clearance in
9.13 – 16 GШСЛ-70
— spherical joint ШХ15 59-65 HRC
9.15 – 3 Hinged bearing
0,5 max
9-23
Steering
7513-3902080 RM
Table 9.4 - Nominal and maximum permissible sizes of basic parts of steering
7513-3429046/048 69,88
70-0,030 fault of chromic 241-285 HRC
9.24 - 3 Rod -0,076 Steel 40Х
coverage is not ТВЧ 47-57 HRC
outer diameter
permitted
75132-3429020
9.24 - 4 Body of cylinder 140
+0,1
140+0,5 Steel 35Х
inner diameter
radial clearance in
GШСЛ-70
9.24 – 20
Hinged bearing spherical joint 0,5 ШХ15 59-65 HRC
max
radial clearance in
ШСЛ-90К1
9.25 – 10
Hinged bearing spherical joint 0,5 ШХ15 59-65 HRC
max
GENERAL MECHANICAL RUBBER GOODS (SEALING RINGS, STUFFING BOXES, LAYER PADS) AT AS-
SEMBLY ARE SUBJECT TO OBLIGATORY REPLACEMENT.
7513-3902080 RM
- install on shank of valve core 13 axial bearer 16, thus facet on lower cartridge clip of bearing should be
located on side opposite to bearing (it conversion to seating of valve core);
- grease external surface of barrel 9 and shank of valve core with 13 hydraulic oil and half-assembly in
horizontal position install in case 18, using easy rotary motions. Thus it is necessary to observe that pin 10 is
placed in horizontal plane (for prevention of its shedding in propoints of case);
- install half-assembly in verticality shank of valve core 13 downwards;
- insert bead of back-pressure valve 17 into bore in case 18 and screw in this bore thread barrel 19;
- grease rubber sealing ring with grease and install in groove on case;
- install on case 18 distributor disk 7 so that bores in disk coincided with corresponding bores in case;
- install cardan 8 in valve core 13 so that universal-joint fork enveloped pin 10;
- expose propeller shaft in verticality with help of mounting fork which can be manufactured of thin sheet
metal;
- install sealing rings 20 greased with grease in grooves of wreath 5 of hydromotor of closed loop 1;
- install wreath 5 with spider 6 on case 18 so that spline joint cardan 8 and spider 6 has gathered;
- install cover 4;
- turn special bolt 21 with rolled head with seal washer in thread barrel 19;
- turn bolts 3 with seal washers;
- test smoothness of twirl of shaft of steer. At non-uniform force, required for twirl to release fastening of
bolts, carry out retightening at fixed twirl of shaft of steer.
9-25
Steering
7513-3902080 RM
9-26
Steering
7513-3902080 RM
9-27
Steering
7513-3902080 RM
9.6.1.7 Assembly of valve of difference of pressures, release valve and back-pressure valve,
Assembly of valve of difference of pressures is to be carried out as follows:
- in bore of case 5 install valve 6, spring 7 and guiding 4 (see figure 9.10);
- on thread surface of transition nut 3 install washer 1, sealing ring 2 preliminary greased with lubricant
"Литол-24" and turn it in case 5.
The difference of pressures between cavities II and I at expenditure of working fluid 15 - 25 l/min should
be 0,35 - 0,4 MPa.
9-28
Steering
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9-29
Steering
7513-3902080 RM
9-30
Steering
7513-3902080 RM
9-31
Steering
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Assemble bearing mount assembly on cylinder body of turning movement in following sequence:
- press conic finger 18 in inner ring of hinged spherical bearing 20;
- install thrust washer 21 and fix with bolts 22;
- lock bolts 22 of fastening of hinged bearing 20 on conic finger 18;
- install scratcher with protective washer 19;
- press hinged spherical bearing 20 in cylinder body, preliminary having greased with lubricant Литол-24
spherical surfaces of bearing;
- install sealing ring 26;
- install cover 24 and turn bolts 25 of fastening of cover of hinged spherical bearing;
- turn greaser 23.
Analogously assemble bearing mount assembly on nozzle of cylinder rod of turning movement.
7513-3902080 RM
9-33
Steering
7513-3902080 RM
9.7.1.9 Mounting of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
Hydraulic cylinders of turning movement is installed on dump truck in following sequence:
- install bars of steering trapezoid on swivel members;
- install on studs conic barrels;
- screw nuts and fix them bars of steering trapezoid with torque of 350-430 N.m;
- moor cylinder of turning movement (see figure 9.13) with help of fastening device and hoisting gear;
- install conic fingers of cylinder body of turning movement in bracket of spar of frame, and conic fingers
of nozzle of stock - in pivot rod of steering trapezoid;
- tighten nuts on conic fingers with torque of 500-700 N.m;
- similarly install second cylinder of turning movement;
- connect sleeves of high pressure to cylinders of turning movement thus rod end of left cylinder of turn-
ing movement head end left - with rod end of right cylinder should be connected to head end of right cylinder.
9-34
Steering
7513-3902080 RM
9.7.2.6 Mounting of hydraulic cylinders of turning movement and pull-rod of steering trapezoid
Hydraulic cylinders of turning movement are installed on dump truck in following sequence:
- install bars of steering trapezoid on swivel members;
- install on studs conic barrels;
- screw nuts and fix them bars of steering trapezoid with torque of 350-430 N.m;
- moor cylinder of turning movement (see figure 9.24) with help of fastening device and hoisting gear;
- install conic fingers of cylinder body of turning movement in brackets of frame, and stock - in pivot rods
of steering trapezoid;
- tighten nuts on conic fingers with torque of 500-700 N.m;
- similarly install second cylinder of turning movement;
- connect sleeves of high pressure to cylinders of turning movement thus rod end of left cylinder of turn-
ing movement head end left - with rod end of right cylinder should be connected to head end of right cylinder.
ATTENTION:
1 FILLING OF OIL IN TANK OF HYDRAULIC SYSTEM PERFORM THROUGH FILTER ONLY!
2 MUD AND ADMIXTURES OF ALL ASPECTS IS THE PRINCIPAL REASON OF MAJORITY OF
FAILURES IN HYDRAULIC SYSTEM!
3 DELAYED REPLACEMENT OF FILTERS OF HYDRAULIC SYSTEM AND POLLUTION OF WORK-
ING FLUID RESULT IN CUTTING-DOWN OF RESOURCE OF HYDRAULIC APPARATUSES, JAMMING
AND OTHER FAILURES OF STEERING!
9-35
Steering
7513-3902080 RM
9-36
Braking systems
7513-3902080 RM
10 BRAKING SYSTEMS
10.1 General information
Dump trucks BELAZ-7514-10, BELAZ-75145, BELAZ-75131 and BELAZ-75132 are arranged with ser-
vice, parking, auxiliary and emergency braking systems.
The service braking system with the hydraulic actuator has front brake circuit and a rear brake circuit,
operates on all wheels. It is intended for speed regulation of driving or a shut-down of a dump truck in any road
conditions, and also at insufficient efficiency of a auxiliary brake.
The parking braking system has the hydraulic actuator and operates on wheels of a rear axle. It is in-
tended for braking a dump truck on parking places, at loading and unloading, and also in emergency situations
at failure of a service braking system.
Auxiliary brake - electric in a condition of braking operation of traction motors.
As an emergency braking system the parking and intake circuit of service system is used.
10-1
Braking systems
7513-3902080 RM
The brake cylinder 5 is fixed on a steering knuckle 17 with the help of four bolts 6, has two pistons and
effects on both shoes simultaneously. The spacing between brake shoes and a drum 21 is ensured with auto-
matically-controlled special device installed in a brake cylinder. Coupling springs 3 are fixed on the one hand
on fingers of 1 of brake shoes, and on the other side on plates of a brake cylinder and intended for returning of
shoes in a home position when unbraking a dump truck. To prevent of hit of a mud to a brake cylinder the pro-
tective shroud 7 is installed onto it. The force to a brake shoe from the cylinder is transmitted through a plunger
10.
Brake gears of rear wheels are built on the case of a reducer of a motorized wheel 17 (figure 10.2).
They are executed with the carried shoe supports and have automatic regulation of a spacing between brake
shoes 6 and a drum 5 which is ensured with the special device installed in a brake cylinder.
The brake cylinder 2 is installed in an eyelet of the case of a reducer 17 and fixed to it by bolts 1. The
brake shoe with cover plates 6 is installed on an axle 18. The coupling spring 3 is fixed on the one side to a
brake shoe, on the other side on a finger of a spring 4 and intended for returning of a shoe in a home position
at unbraking a dump truck. To prevent of hit of a mud to a brake cylinder the protective shroud 9 is installed
onto it. The force to a brake shoe from the cylinder is transmitted through a plunger 8.
Figure 10.2 - Brake gear of a rear wheel of dump trucks BELAZ-7514-10 and BELAZ-75145:
1, 11 - bolts; 2 – a wheel cylinder of rear brake; 3 - a coupling spring; 4 - a finger of a spring; 5 - a brake drum; 6 - a shoe with
cover plates; 7 - a block of shoe; 8 - a plunger; 9 - a protective shroud; 10 – a rear wheel hub; 12 - an adapter; 13 - a splint; 14 - an
adapter; 15 - a tube; 16 - a angle piece; 17 - the case of a reducer of a motorized wheel; 18 - a shoe axle; 19 - a locking bolt
10-2
Braking systems
7513-3902080 RM
traction motors rigidly. On a axle 28, fixed in a carriage, two brake shoes 1 fixed with springs 2 and 12 are
rested. The upper ends of shoes are clamped to an expansion-type knuckle 21 installed into an opening of a
carriage through rollers 11by coupling springs.
On castle-type end of the axle of an expansion-type of knuckle the adjusting bar 22, jointed with a cylin-
der rod of a parking brake 9 is fastened by means of a fork 4 and the extension lead of a rod 6 with a finger 3.
The brake drum 15 with a flange 17 is installed on castle-type end of an armature axle 20 of traction motor and
fixed by a bolt 19 through plates 18.
When braking the force of springs of the cylinder 9 is transmitted to an adjusting bar 22 which turns an
expansion-type knuckle 21 and clamps shoes 1 to a brake drum 15.
Figure 10.3 - Brake gear of a parking braking system of dump trucks BELAZ-7514-10 and BELAZ-75145:
1 - a brake shoe; 2, 12 - coupling springs; 3 - a finger; 4 - a fork of a rod; 5 – an indicator; 6 - the extension lead of a rod; 7 - a
washer; 8 - a nut; 9 - a parking brake cylinder; 10, 14, 23 - splints; 11 - a roller; 13 - a carriage; 15 - a brake drum; 16, 19, 26 - bolts; 17 - a
flange; 18 - a plate; 20 - an armature axle of the traction motor; 21 - an expansion-type knuckle; 22 - an adjusting bar; 24 - the end bracket
of the traction motor; 25 - a ring; 27 - a sensor of a speed limitation; 28 – a shoe axle; 29 - a support washer
10-3
Braking systems
7513-3902080 RM
Brake gears of front wheels - one-disk, dry friction with the hydraulic actuator.
The case of a brake 2 (figure 10.4) is fastened to a steering knuckle 1 of front axle with two bolts 13. The
brake disk 4 is fastened to the hub of a front wheel with bolts. There are six cylinders (three from each side) in
the case of a brake into which pistons 6 are inserted, on supports 10 of case of a brake two brake linings 5 are
installed. The piston is sealed by a rubber cuff 15 with the guard ring 14 on an outer diameter, and the clutch 3
protects from hit of a mud on a service surface of the piston. Cylinders are protected by covers 7 outside. Cyl-
inders are interconnected by ports for input of a hydraulic fluid under the piston.
Figure 10.4 - Brake gear of a front wheel of dump trucks BELAZ-75131 and BELAZ-75132:
1 - a steering knuckle; 2 - the case of a brake; 3 - a protective clutch; 4 - a brake disk; 5 - a cover plate; 6 - the piston; 7 - a cover;
8, 13 - bolts; 9, 11 - rings; 10 - a support; 12 - an adjusting washer; 14 - a protective ring; 15 - a cuff
Brake gears of rear wheels - one-disk, dry friction with the hydraulic actuator.
On the end bracket of each traction motor 13 (figure 10.5) it is built two service brakes through brackets
22 and 23. The service brake consists of two cheeks 3 and 17 which are fastened with studs 8 through inserts
19 and supports 20. To cheeks eight cylinders 11 (four from each side) are fastened inside which pistons 29
are installed. The piston is sealed by a rubber ring 63 with a protective washer 62 on an outer diameter, and
the clutch 26 protects from hit of a mud on a service face of the piston. Cylinders are interconnected by internal
ports for input of a hydraulic fluid under the piston. Each cylinder has the device of an automatic adjustment of
a spacing between a brake shoe 28 and cover plates 27.
The brake disk 28 is fastened by bolts to a flange 16 installed on splines of the axle of a rotor of the trac-
tion motor.
10-4
Braking systems
7513-3902080 RM
Figure 10.5 - Brake gears of rear wheels and a parking brake of dump trucks BELAZ-75131 and BELAZ-75132:
1 - hoses of a high pressure; 2, 6, 18 – angle pieces; 3, 17, 50, 52 - cheeks; 4, 10, 14, 21, 25, 54 - bolts; 5 - a parking brake cylin-
der; 12 - T-connector; 7, 32, 34, 41 - nuts; 8 - a stud; 9, 20 - supports; 11 – a cylinder of a working brake; 13 - the traction motor; 15 - a
plate; 16 - a disk with a flange; 19 - an insert; 22, 23 - brackets; 24, 36, 38, 59, 63 – sealing rings; 26, 51 - protective clutches; 27 - a brake
cover plate; 28 - a brake disk; 29, 48 - pistons; 30 - a rod; 31, 49 - cases; 33 - a thrust block; 35, 39, 62 - protective washer; 37 - a plug;
40 - the locking bolt; 42 - the indicator; 43 - a splint; 44 - a nut of unbraking; 45 - a washer; 46 - a cover; 47, 55, 64 - springs; 53 - adjusting
shims; 56 - a lock ring; 57 - a stop ring; 58 - an adjusting washer; 60 - the frictional bush; 61 - a cup
10-5
Braking systems
7513-3902080 RM
Possible troubles of braking systems and methods of their removal are given in Table 10.1.
Table 10.1 — Possible troubles of braking systems and methods of their removal
Insufficient braking efficiency Cover plates are oiled or worn out Replace cover plates
Wheel brake gears do not unbrake The piston of brake gear is jammed Eliminate jamming of the piston
Nonhermeticity of pair (sleeve–valve) of brake Replace the pair (sleeve -valve)
valve
Low efficiency of parking brake system Big clearance between braking disk and To adjust a clearance
braking cover plates of parking brake
To replace a knuckle
The knuckle of parking brake valve
Insufficient capacity of hydropneumatic Low (high) pressure of nitrogen in a gas space Discharge oil from oil space, check-
accumulator, drop of pressure when of hydropneumatic accumulator pressure og nitrogen, bring it to the
braking norm
Drop of pressure in hydropneumatic Nonhermeticity of pair (sleeve–valve) of brake Replace the pair (sleeve -valve)
accumulator when engin is shut down valve
Drop of pressure of nitrogen in hy- External nonhermeticity of priming valve To check with soap solution, to elimi-
dropneumatic accumulator nate nonhermeticity
Nonhermeticity between gas and oil spaces
Replace sealing of piston of hy-
dropneumatic accumulator or replace
a hydropneumatic accumulator
10-6
Braking systems
7513-3902080 RM
- to take out a splint 2 and to take a finger of 1 springs from an opening of a brake shoe;
- to take plungers 10 out of a brake cylinder 5;
- to unscrew bolts 6 and to remove a brake cylinder;
- to take centering bush 18 out of opening in steering knuckle 17.
Disassembling of a brake cylinder is made in the following sequence:
- to unscrew bolts 12 (figure 10.6) and to remove a plate 13, a cover 14 and a spring 8;
- using a mandrel (figure 10.7) to take semi-rings 11 out of a groove of a rod 18 (look figure 10.6);
- to remove a washer 10 and to take a spring 9 from a rod;
- to take guiding 17 with a frictional ring 15, a separator 16, rollers 7 and a block 6 out of the cylinder;
- to press a frictional ring 15 with guiding 17;
- to take a piston 5 in assembly with a nut 20, a sealing ring 19, a cuff holder 3, a cuff 4 and a rod 18 out
of a cylinder body 1;
- to unscrew a nut 20 to remove cuff holder 3 and a cuff 4 from the piston 5;
- to remove the piston 5 from a rod 18;
- to take a sealing ring 19 out of a groove of a rod;
- analogous operations are performed for the second section of the cylinder
10-7
Braking systems
7513-3902080 RM
Figure 10.8 - Sizes of brake shoes, rivets and openings in cover plates:
10-8
Braking systems
7513-3902080 RM
Before setting of shoes (if substitution of cover plates on new ones was performed) to return pistons of
brake cylinders and elements of an automatic adjustment of clearance in a home position, for what:
- to unscrew bolts 12 (look figure 10.6) to remove a plate 13, a cover 14, a spring 8, a separator 16 and
to take out rollers 7;
- to move a rod with the piston against the stop to a restrictive bolt 2;
- to displace a frictional ring 15 to the right on 5 - 10 mm from a butt-end of guiding 17;
- to install rollers 7, a separator 16, a spring 8, a cover 14, a plate 13 and to fix them with bolts 12;
- analogous operations should be done for the second section of the cylinder.
Testing of a brake gear on leakproofness and serviceability
To give pressure 16 МPа to a cavity of brake cylinders, to keep within five minutes. Escapes are not ad-
mitted. After removal of pressure the clearance between shoes and a brake drum of 0,5 - 1,5 mm should be.
10-9
Braking systems
7513-3902080 RM
10-10
Braking systems
7513-3902080 RM
- to take a piston 14 as an assembly with a nut 18, a sealing ring 15, a cuff holder 17, a cuff 16 and a rod
11 out of a cylinder body 13;
- to unscrew a nut 18 to remove a cuff holder 17 and a cuff 16 from the piston 14;
- to remove the piston 14 from a rod 11;
- to remove a sealing ring 15 out of a groove of a rod 11.
Before setting of shoes (if substitution of cover plates on new ones was performed) to return pistons of
brake cylinders and elements of an automatic adjustment of clearance in a home position, for what:
- to remove a cover 4 (look figure 10.10), a spring 9, a separator 10 and to take out rollers 3;
- to move a rod with the piston against the stop to a bottom of a cylinder body;
- to displace a frictional ring 8 to the right on 5 - 10 mm from a butt-end of guiding 12;
- to install rollers 3, a separator 10, a spring 9, a cover 4 and to fix them with bolts 1.
10-11
Braking systems
7513-3902080 RM
- to fix a parking brake cylinder with nuts 1 and to fix a cover with a power transmission screw 6;
- to turn out nuts from bolts of fastening of a clamp 22 (look figure 10.11) and to remove clamps;
- to turn out the power-transmission screw 6 (look figure 10.12) up to a full release of a spring 14 (look
figure 10.11);
- to remove a parking brake cylinder from accommodating;
- to remove a cover 15, a spring 14 and a cup 13;
- to take a protective clutch 3 out of a groove of a lock nut 1 and to remove a clutch;
- to take a plunger 9 with a lock nut 1, a rod 2, a block 4, a liner 6, a nut 20, a lock washer 21, the screw
of disengaging 16 out of the case 12 of the cylinders;
- to take a felted ring 5, sealing ring 8 and protective washer 7 out of grooves of the case 12;
- to remove a cuff 10 and a protective washer 11 out of a groove of a plunger 9;
- to turn out a block 4 and to take it out of a plunger 9;
- to take a rod 2 and the liner 6 out of a plunger 9;
- to unlock a lock washer 21 to turn out a nut 20 and to take the screw of disengaging 16 out of a
plunger 9.
10-12
Braking systems
7513-3902080 RM
10-13
Braking systems
7513-3902080 RM
10-14
Braking systems
7513-3902080 RM
If brake cover plates are worn out on the size of rivet rolling, they must be replaced both of left and right
brake gear simultaneously.
After replacement of cover plates, brake shoes are treated and installed two by two. Sizes of brake
shoes, rivets and openings in cover plates for setting with a new drum are given in figure 10.14. In case of a
brake drum boring the radius of pads should be increased accordingly.
Figure 10.14 - Sizes of brake shoes, rivets and openings in cover plates
7513-3902080 RM
10-16
Braking systems
7513-3902080 RM
10-17
Braking systems
7513-3902080 RM
10-18
Braking systems
7513-3902080 RM
10-19
Braking systems
7513-3902080 RM
- to install a bulb with gas in the special place arranged with accommodating for fixing of a bulb. When
change a bulb to fix it;
- to unscrew valves and connecting nuts only by the corresponding wrenches, not hitting on them;
- to supply gas to pneumohydraulic accumulators smoothly through reducing reducer;
- to observe common safety precautions regulations on a work place.
10-20
Braking systems
7513-3902080 RM
10-21
Braking systems
7513-3902080 RM
- to turn out a cover 6 (figure 10.20) and to take a sealing ring 5 out of a groove of a cover;
- to turn out a rod 4 and to take it from the case 1 in assembly with filter elements 3;
- to turn out a nut 2 and to remove filter elements 3 from a rod 4.
10-22
Braking systems
7513-3902080 RM
Removal and disassembling of the control valve of a parking braking system is performed in the follow-
ing sequence:
- to disconnect oil hoses and an electricity cable of the switch of a stop light from the control valve;
- to unscrew bolts of fastening of the control valve to a bracket of the panel of a floor of a cabin;
- to remove the control valve from a dump truck;
- to unscrew bolts 10 (figure 10.21) and to remove a cover 14 of a valve in assembly with a pusher 15,
an axle 2, a holder 16, a bar 17, a protective case 18, a cam 20 and a nut 19 from a cup 21;
- to remove a protective case 18 from a cover 14;
- to turn out a nut 19 and to turn out a bar 17 with a holder 16;
- to take out an axle 2 and to remove a cam 20 and a pusher 15;
- to take adjusting washers 13, a spring 12 and a plate 11 of spring out of a cup 21;
- to turn out a fuse 24 with a sealing ring 9 and a pusher 8 of a glass 21;
- to take a pusher 8 with a sealing ring 22 out of a plug 24;
- to unscrew bolts 10 and to take a cup 21 out of the case 4;
- to turn a plug 3 with a spring 28, the piston 27 and a sealing ring 4 out of the case 1;
- to take a bush sleeve 7 with a valve core 6 and sealing rings 4, 5, 25, 26 out of the case 1;
- to take a valve core 6 out of a bush sleeve 7.
Assembling of the control valve by a parking braking system is performed in the following sequence:
- to place sealing rings 4, 5, 25, 26 into grooves of a barrel 7;
- to insert a bush sleeve 7 with a valve core 6 into the case 1;
- to turn a plug 3 with a sealing ring 4, a spring 28 and a piston 27 into the case 1;
- to place a sealing ring 23 into a groove of a cup 21;
- to insert a cup 21 into the case 1 and to fix it with bolts 10;
- to insert a pusher 8 with a sealing ring 22 into an opening of a plug 24;
- to turn a plug 24 with a sealing ring 9 and a pusher 8 into a cup 21;
- to install a pusher 15 into an opening of a cover 14 of a valve;
- to install a cam 20 into an opening of a cover 14 and to fix by an axle 2;
10-23
Braking systems
7513-3902080 RM
- to turn a bar 17 with a holder 16 and a nut 19 into an opening of a cam 20 so that a holder 16 has come
into axle openings 2 and openings of a pusher 15. Thus size D should be 6 - 7 mm;
- to fix a bar 17 with a nut 19;
- to put a protective case 18 on a cover 14 of a valve and to fix by a splint - wire;
- to insert a plate 11, a spring 12 and adjusting washers 14 into a cup 21;
- to insert a cover 14 in assembly with a pusher 15, a shaft 2, a cam 20, a nut 19, a holder 16, a bar 17
and a protective case 18 into a cup 21 and to fix with bolts 10.
Size C should be 0 - 0,3 mm. It is provided with selection of adjusting washers 13.
10-24
Braking systems
7513-3902080 RM
If a bar 17 is in A and B positions at pressure of a hydraulic fluid in output I (12 ± 0,5) МPа escapes
through an output III should not exceed 0, 05 l within 1 minute. At displacement of a bar 17 from B position to A
position and back, pressure in a cavity II should rise up to (12 ± 0,5) МPа and lower up to 0 МPа.
Setting of the control valve of a parking braking system is performed in the following sequence:
- to install the control valve on a bracket of the panel of a floor of a cabin and to fix it with bolts;
- to connect oil hoses to the control valve: to connect output I of the control valve to a pneumohydraulic
accumulator, an output II - to a parking brake cylinder, an output III - to drain into an oil-tank;
- to connect an electricity cable of the a stop light switch.
10.3.5 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-7514-
10, BELAZ-75145
After disassembling to check technical conditions of service surfaces of parts by an external examination
and metering of their critical parameters. There should not be corrosion, burrs and other mechanical injuries on
service surfaces of parts.
The basic nominal and maximum permissible sizes of parts of braking systems of dump trucks BELAZ-
7514-10, BELAZ-75145 are given in table 10.2.
Table 10.2 - Nominal and maximum permissible sizes of basic parts of braking systems of dump
trucks BELAZ-7514-10, BELAZ-75145
Dimensions, мм
Number, name of part and parame-
Maximum permis- Material Hardness
ters to be checked Nominal
sible
549А – 3501055 −0,05
Piston
120 119,80 АК6Т1
− 0,14
External diameter
549 – 3501049
+0,06
Frictional ring 73,7 73,80 Steel 45
Internal diameter
549А – 3501056 241 – 285 НВ
−0,075
Piston rod 48 47,800 Steel 45 ТВЧ h 1,5 – 3,0mm
− 0,160 НRС>50
External diameter
549А – 3501046-10
549А – 3502046-10
СЧ20
Cylinder case +0,07
120 120,10
Internal diameter
549А – 3501070
+0,35
Brake drum 950 955,00 Steel 40Л
Internal diameter
549А – 3501090 −1,10 Frictional layer may Asbestos code
Brake shoe
950 be worn out to rivet composition
−1,65 heads 207-17
External diameter
7512 – 3514025 Clearance in cou-
+0,027 pling with valve core
Bush sleeve 12 7512–3514026
Steel 40Х 40 – 46 НRCэ
Internal diameter 0,01 – 0,03 no more
10-25
Braking systems
7513-3902080 RM
10-26
Braking systems
7513-3902080 RM
The further assembling of brake gears of front wheels is performed in the following sequence:
- to install a brake disk 8 (look figure 8.2.2) onto the hub of a front wheel and to fix it with bolts 24 and
washers;
- to install the hub of a front wheel in assembly with a brake disk on a steering knuckle 7 (the order of
setting look in section "Front axle");
- with the help of load-lifting means to install cases of a brake 2 (look figure 10.4) on a steering knuckle,
having fixed them with a lower bolt, not tightening a bolt against the stop on two - three revolutions, having en-
closed a washer under a bolt head;
- to turn the case of a brake hold on lower bolt smoothly in a horizontal position and to install brake
cover plates 5. If brake cover plates are worn out to replace them in brake gears of the left and right wheels
simultaneously;
- to fix the case of a brake 2 to a steering knuckle 1 with bolts 13 with torque of 1500 - 1800 N.m. With
adjusting washers 12 to provide a clearance of 1,5 mm min between butt-ends of brake cover plates 5 and a
brake disk 4;
10-27
Braking systems
7513-3902080 RM
Replacement brake cover plates without disassembling of brake gears of front wheels
When brake cover plates are worn out to replace cover plates of brake gears of left and right wheels si-
multaneously.
Replacement of cover plates of brake shoes is performed in the following sequence:
- to install thrust blocks under wheels of a dump truck;
- to remove a front wheel from the hub (the order of removal of wheels look in section « Wheels and
tires);
- to release a pressure in a hydraulic system of brakes (releasing of pressure is made by turning out of
lock needles of the brake valve);
- to disconnect pipes of a braking system from cases of a brake 2 (look figure 10.4);
- to release the lower bolt 13 of fastening of the brake case to a steering knuckle 1 up to releasing of a
spring lock washer;
- supporting the case a brake to unscrew the upper bolt;
- to turn the case of a brake hold on lower bolt smoothly in a horizontal position and to remove brake
cover plates;
- to return pistons of the case of a brake in a home position, having moved pistons against the stop of
butt-ends to covers 7;
- to install new cover plates;
- to tighten bolts 13 with torque of 1500 - 1800 N.m. With adjusting washers 12 to provide a clearance
of 1,5 mm min between butt-ends of brake cover plates 5 and a brake disk 4;
- to connect pipes of a braking system to cases of brakes.
10.4.2 Repairing of brake gears of rear wheels and a parking braking system
Removal and disassembling of brake gears of rear wheels and brake gears of a parking brake is rec-
ommended to perform with removal of electric motorized wheels. Fractional disassembling, and in unusual
cases full disassembling are possible without removal of electric motorized wheels in an axle casing.
Disassembling of brake gears of rear wheels and parking braking system.
Removal of a brake gear of rear wheels and brake gear of a parking brake in assembly with a electric
motorized wheel from a dump truck is made in the following sequence:
- to release pressure in a hydraulic system of brakes (releasing of pressure is made by turning out of
lock needles of the brake valve);
- to remove rear wheels from the hub (the order of removal of wheels look in section « Wheels and
tires);
- to remove a motorized wheel from a dump truck and to make disassembling of a reducer of a motor -
wheel (the order of removal and disassembling look in section "Electric motorized wheel").
Disassembling of a brake gear of rear wheels and brake gear of a parking brake is made in the following
sequence:
- to remove all sleeves of a high pressure 1 (figure 10.5);
- to unlock nuts 7 and to turn them out of studs 8;
- to remove external cheeks 3 of service brakes with cylinders 11 of service brakes, brake cover plates
27, supports 9, bolts 54, springs 55 from studs 8.
Before removal of an external cheek 50 of parking brakes to unlock and to turn a nut 44 before disen-
gaging brake cover plates 27;
- to remove external cheeks 50 of parking brakes with cylinders 5 of parking brakes, a brake cover
plates 27, supports 9, bolts 54, springs 55 from studs 8;
- to remove supports 20 and inserts 19 from studs 8;
- to turn out studs 8;
- to unscrew a bolt 14 and to remove plates 15;
- to remove a brake disk with a flange 16 from the shaft of the traction motor (the disk with a flange is
treated and balanced jointly and disassembling is not admitted);
- to unscrew bolts 10 and to remove an internal cheek of a parking brake 52 with a brake cover plate 27,
thrust blocks 33, nuts 34, supports 9 and adjusting shims 53;
- to unscrew bolts 4 and to remove internal cheeks 17 of service brakes with brake cylinders 11, brake
10-28
Braking systems
7513-3902080 RM
TURNING OUT OF NUTS 44 OF DISENGAGING FOR DISASSEMBLING OF A COVER OF THE PISTON AND
TAKING OUT A SPRING 47 ARE STRICTLY FORBIDDEN WITHOUT THE SPECIAL ACCOMMODATING PROVIDING
RELIABLE FIXING OF THE PISTON 48 OF A COVER 46 AND SMOOTH RELEASING OF A SPRING 47.
Assembling, adjustment and testing of brake gears of rear wheels and brake gears of a parking
brake
The details supplied on assembling, should be washed carefully out in a diesel fuel and blown up by
compressed air. Oil channels should be cleaned and blown through by compressed air.
When assembling a brake gears of service and parking brakes use a new package of general me-
chanical rubber goods (sealing rings, cuffs, protective clutches)
Assembling of a brake gear of rear wheels and brake gear of a parking brake is made in the following
sequence:
Assembling of a parking brake cylinder.
- to install sealing rings 36, 38 and protective washers 35, 39 into grooves of the case 49 (look figure
10.5) (protective washers should be on the opposite side of a cavity of a high pressure);
- to turn a cover 46 in assembly with the piston 48, indicators 42, a nut 44, a washer 45 and a splint 43
into the case 49;
Assembling of an external cheek of a parking brake.
- to install parking brake cylinders 5 into openings of an external cheek 50 of parking brake;
- to install a protective clutch 51 into grooves of a cheek 50 and of the piston 48 and to fix parking brake
cylinders 5 with bolts;
- to turn supports 9, preliminary having greased the thread surface with a graphite lubricant, to install a
brake cover plate 27 on them;
- to turn bolts 54 with springs 55 into openings of a brake cover plate 27;
10-29
Braking systems
7513-3902080 RM
- to splint supports 9 and bolts 54 (splitting should not hinder from displacement of a bolt 54 in an axial
direction on distance not less than 25 mm);
Adjustment of clearances between brake cover plates and a disk is performed in the following sequence:
- turning thrust blocks 33 to adjust a clearance of 1 - 1,5 mm between a brake cover plate 27 and a
brake disk 28. After setting a necessary clearance to stop thrust blocks 33 with nuts 34;
- turning covers 46 in assembly with the piston 48 to adjust a clearance of 1 - 1,5 mm between a brake
cover plate 27 and a brake disk 28 by special wrench for openings in a cover 46. To turn out nuts 44 of disen-
10-30
Braking systems
7513-3902080 RM
gaging before coincidence of nut openings to a opening of the screw and to stop by a splint 43;
- to screw in locking bolts 40 and to stop by nuts 41.
- to make assembling of a reducer of a motorized wheel and to install the motorized wheel onto a dump
truck (look the order of assembling and setting in section "Electric motorized wheel");
- to install rear wheels onto hubs (look the order of setting of wheels in section « Wheels and tires).
Fractional disassembling of brake gears of rear wheels for removal of the brake cylinders lo-
cated on internal cheeks
For removal of the brake cylinders located on the lower internal cheek it is necessary:
- to release pressure in a hydraulic system of brakes (release of pressure is made by turning out of lock-
ing needles of the brake valve);
- to unsplint and turn out nuts 7 (look figure 10.5) of fastening of the lower external cheek 3;
- to remove the lower external cheek 3 from studs 8 in assembly with cylinders 11, brake cover plates
27, supports 9, bolts 54 and springs 55;
- to turn studs 8 out;
- to unscrew bolts 4 and to lower an internal cheek 17 in assembly with cylinders 11, brake cover plates
27, supports 9, bolts 54 and springs 55 downwards in parallel with a brake disk;
- to unscrew bolts of fastening 25 of brake cylinders 11 and to remove brake cylinders for looking over.
Assembling and setting of cheeks to make in inverse sequence.
The upper internal cheek is removed analogously to lower cheek. Taking into account, that the bracket
of a parking brake 22 together with the upper internal cheek are fastened by bolts 4, parking brake cylinders
should be braked to keep the whole gear of a parking brake on a brake disk, thus wheels should stand on land.
Replacement of brake cover plates of brake gears of rear wheels and brake gears of a parking
brake
Replacement of brake cover plates is made without removal of a reducer of a electric motorized wheel, in
an axle casing.
Replacement of brake cover plates of brake gears of rear wheels and parking brake is performed in the
following sequence:
- to release pressure in a hydraulic system of brakes (release of pressure is made by turning out of lock-
ing needles of the brake valve);
- to unlock a nut of disengaging 44 (look figure 10.5) and to turn it against the stop;
10-31
Braking systems
7513-3902080 RM
- to unlock and to turn out supports 9 and bolts 54 on all cheeks of a service brake and if necessary on
cheeks of a parking brake;
- to take brake cover plates;
- to move pistons 29 of cylinders of a service brake 11 against the stop to the case 31;
- to install new brake cover plates 27, to turn in supports 9 and bolts 54 and to lock them;
- to adjust clearances between brake cover plates of a parking brake and a brake disk;
- to unscrew nuts 44 of disengaging before coincidence of nut openings to a opening of the screw and to
stop them by a splint 43.
10.4.3 Checking of technical conditions of parts of braking systems of dump trucks BELAZ-
75131, BELAZ-75132
After disassembling to check technical conditions of service surfaces of parts by an external examination
and metering of their critical parameters. There should not be corrosion, burrs and other mechanical injuries on
service surfaces of parts.
The basic nominal and maximum permissible sizes of parts of braking systems of dump trucks BELAZ-
75131, BELAZ-75132 are given in table 10.4.
Table 10.4 - Nominal and maximum permissible sizes of basic parts of braking systems of dump
trucks BELAZ-75131, BELAZ-75132
Dimensions, mm
Number, name of part
Maximum permis- Material Hardness
and parameters to be checked Nominal
sible
7513 – 3501072
Disk
32 28,00 Steel 35 187 – 241 НВ
− 0,39
Thickness
7513 – 3501089
+0,035
Brake case 90 90,050 Steel 45 187 – 241 НВ
Internal diameter
7513 – 3501102
Piston
89,900
−0,036
External diameter 90 There must not be
Steel 45 241 – 285 НВ
− 0,090
damages of chrome
coating
7555 – 3501190 Asbestos code
Cover plate 40 15,0 composition
−1,0 207–17
Thickness with frame
75132 – 3507232-10
Cylinder case of parking brake
Internal diameter +0,035
90 90,050 Steel 45 40 – 46 HRCэ
Internal diameter
+0,054
105 105,100
10-32
Braking systems
7513-3902080 RM
−0,036 Steel 45
External diameter 105 104,900
− 0,071
10-33
Braking systems
7513-3902080 RM
10-34
Pneumatic system
7513-3902080 RM
11 PNEUMATIC SYSTEM
11.1 General information
The pneumatic system intended to provide engine pneumatic starter system, pneumatic gears of cabinet
of traction electric drive, radiator shutters by compressed air, to connect the appliance for tires inflation and to
feed the balloon of a pneumocushioning of the driver's seat (for dump trucks BELAZ-75131, BELAZ -75132).
Table 11.1 — Possible troubles of pneumatic system and methods of their removal
Trouble and symptom Probable cause Method of removal
The pneumatic system has a significant Pipelines or hoses are damaged Replace pipelines and hoses
leak of compressed air
Failure of a pressure regulator Repair the pressure regulator
Faulty sealing of connections of pipelines, Tighten connections, replace damaged
hoses, end fitting connection parts and sealings
Decrease of productivity of the compressor Breakage of suction or pressure valves Replace valves
Deterioration of pistons or rings Replace pistons or rings
Cylinder-head gasket is damaged or tight- Tighten gasket or tighten cylinder head
ened not tightly bolts
There is a lot of oil in condensate Piston rings, oil sealing of crankshaft,
bearings of lower crosshead of compres- Replace worn out parts
sor are worn out
Pressure regulator does not maintain
Control of regulating device is broken Make an adjustment
working air pressure
The air leak from the connecting pipe of a Diaphragm of regulating device is dam-
Replace the diaphragm
pressure regulator into an atmosphere aged
when filling up the system with air
The valve of air exhaust into atmosphere Clean and blow through or replace the
is damaged or polluted valve
Dehumidifier does not ensure automatic Internal cavity of dehumidifier is polluted Disassemble and wash the dehumidifier
removal of a condensate
Diaphragm is damaged Replace the diaphragm
11-1
Pneumatic system
7513-3902080 RM
11-2
Pneumatic system
7513-3902080 RM
Assembling of a dehumidifier.
Assembling of a dehumidifier should be performed in the conditions providing protection of a compo-
nents from a dust, abrasive elements, oil, water and a mud. There should not be burres and a rust on parts,
and there should not be scratches and other faults on service surfaces. Before assembling clean all channels
of cuttings and mud, blow through by compressed air. After that wash parts in a diesel fuel or white spirit and
dry them up.
Before assembling pay special attention to a condition of rubber sealing ring. At an opportunity
use a new package of general mechanical rubber goods. When mounting sealing rubber rings keep up
that rings are not twisted in grooves and are not undercut.
When assembling friction surfaces of parts to grease with a thin layer of lubrication Litol-24.
Test of a dehumidifier
Dehumidifier is to be tested on setting which scheme is given in figure 11.2.To check operation of the
valve 8. The valve should open at air pressure reaching 4 +2,0 МPа (the test is carried out without the refrig-
− 0,5
erant, places of connection of the refrigerant are closed by plugs 10).
For inspection of leakproofness to connect a refrigerant instead of plugs10. To open the crane 4 and to
fill in a dehumidifier with compressed air under pressure 0,6 - 0,8 МPа. Inspection is performed by a soap
emulsion. An admissible leakage is 50 sm3 per one minute.
For inspection of operation of the valve of automatic drain to enclose the crane 4, by the crane 7 through
a throttle 6 to lower an air pressure up to 0,1 МPа, thus on downtakc tube strong formation of soap bubbles
should be observed.
To reach and maintain an air pressure in a dehumidifier of 0,7 МPа, thus formation of soap bubbles on
downtakc tube should stop immediately. To lower an air pressure in a dehumidifier from 0,7 МPа to zero, thus
strong formation of soap bubbles on downtakc tube should be observed.
11-3
Pneumatic system
7513-3902080 RM
11-4
Pneumatic system
7513-3902080 RM
11-5
Pneumatic system
7513-3902080 RM
11-6
Pneumatic system
7513-3902080 RM
- to fill in a receiver 8 up to pressure, equal to pressure in a receiver 4. Manometers 5 and 9 should dis-
play equal values;
- to check on leakproofness, having covered places of possible escapes by a soap emulsion;
- to enclose the crane 2, to open cranes 10 and 11, to release air from receivers, again to enclose cranes 10
and 11;
- to open the crane 2, to check on adjustment once more and to correct if necessary;
- to release air from a receiver 4 through the crane 11, thus the manometer 9 should not display pres-
sure decrease.
11-7
Pneumatic system
7513-3902080 RM
11-8
Pneumatic system
7513-3902080 RM
Testing of antifreezer.
To test the antifreezer on leakproofness by an air pressure of 0,6 – 0,8 МPа, having covered the places
of possible escapes with by a soap emulsion. Escape of air is not admitted. If necessary to replace sealing
rings in the places of escapes.
11-9
Pneumatic system
7513-3902080 RM
11-10
Electrical equipment
7513-3902080 RM
12 ELECTRICAL EQUIPMENT
During a continuous duty of dump trucks in an electric equipment there can be characteristic faultiness ,
such as the electric wires isolation destruction, the electric machines sweepers attrition, the plugs and contacts
oxidation, the electric apparatuses adjustment. violation
To attend the big attention to the electric wire technical condition devices and apparatuses and duly re-
moval of faultiness for maintenance in good condition of the dump truck electric equipments . To eliminate the
faultiness in good time. Fine faultiness of the electric equipment, not eliminated it is duly, can reduce further in
serious failures which removal will demand a significant time and means.
The electric equipment repair make in the specially places . This places should be equipped for these
purposes by the qualified specialists with special gears instruments, stands and accessories application..
Accumulator batteries ensure reliable operation of electrogears, have no weep of an electrolyte and
slackened landing of dowels.
The alternator works noiselessly, without a brush sparking and excessive heat and gives a current, suffi-
cient for a charge of accumulator batteries and power supply of users.
Gears of illumination are completed with rectified lamps which force of light corresponds to a technical
data of a gear. The direction of a luminous flux of headlights is adjusted according to the instruction.
All test instruments operate and testify with a suitable exactitude.
Window wipers ensure full clearing a glass, their operation is not accompanied by knock and noticeable
noise.
Electromotors of heaters do not create significant noise at operation.
Cutout switches and switches ensure reliable turning on and cutting off of the corresponding gears of an
electrical equipment
Possible failures of an electrical equipment and modes of their elimination are reduced in Table 12.1.
Table 12.1 – Possible faultiness in electric equipment and ways of their removal
The name of failure and its
The probable reason Mode of elimination
external development
Fuse F21 has fused To replace fuse
Breakage of the electric circuit To test integrity of the circuit
By pressure the button of the cutout switch
of "weight" accumulator batteries are not Cutout switches S14 and SB2 are defec- To test serviceability of cutout switches.
connected to the electrical network tive Faulty devices to replace.
Electric drive connection to batteries is
To test electric drives connection
wrong
Alternator or voltage control box is defec-
To test charging current
tive
Accumulator batteries are dischargeed A short-circuit between plates in the ac-
cumulator battery Repair or replace accumulator battery
Plates sulphation
Lowering of an electrolyte level in accumula-
Gassing Test of the voltage control box accuracy
tor batteries
Excessively a high electrolyte level Test electrolyte level
The big force of a charge current To test
The electrolyte escapes from vent holes of Test voltage control box
serviceability of a voltage control box
one or several accumulators in charging time
Plates short circuitв in one of accumulator
Repair or replace accumulator battery
batteries
12-1
Electrical equipment
7513-3902080 RM
12-2
Electrical equipment
7513-3902080 RM
12-3
Electrical equipment
7513-3902080 RM
Table 12.2 – - Fuses of system of the low-voltage equipment of dump trucks BELAZ-75131, BELAZ-75132
Ruses designation
Protected circuits
in block
Feed circuit of the lock -cuto switch, of the switch of engine emergency shut-down, voltmeter, engine protective
F 1A (BELAZ-75132)
relay on pressure
F 1A (BELAZ-75131) Feed circuit of the electronic module of the engine control
F 2Б Feed circuit of the reverse motion and reversing light signal
F 3В Feed circuit of the metering equipments
F 4Г Feed circuit the blocks of the control lamps , control lamps
F 5Д Feed circuit of the overall dimensions indicators (port side)
F 6Е Feed circuit of the overall dimensions indicators (starboard),of the fog lamp
F 7Ж Feed circuit of the lamp lower beams (port side)
F 8И Feed circuit of the lamp lower beams(starboard)
F 9К Feed circuit of the lamp high beam (port side)
F 10Л Feed circuit of the lamp high beam (starboard)
12-4
Electrical equipment
7513-3902080 RM
Table 12.3 – Protective devices of the iow –voltage installation of the dump trucks BELAZ-7514, BELAZ-75145
Ruses designation
Protected circuit
in block
F 1A (BELAZ-7514) Feed circuit of the oil heater system the returnes regulator
F 1A (BELAZ-75145) Feed circuit of the lighting lamp of the fuel tank
F 2Б (BELAZ-7514) Feed circuit of the electron relay of the protection on pressure, lock blocking relay, voltmeter, buzzer, timer
F 2Б (BELAZ-75145) Feed circuit lock blocking relay, voltmeter, buzzer, timer
F 3В Feed circuit of the lock-cutout switch, of the test instrumentes
Feed circuit of the cab fans heaters, of the fan driver blower , limit switch of traction motors blower, of hte hand lamp
F 4Г socket
F 5Д Feed circuit of the sizes indicators of the port side , of the highlight rheostat, fog lamp
F 6Е Feed circuit of the sizes indicators of the starboard
F 7Ж Feed circuit of the switch lower beam
F 8И Feed circuit of the lighting lamps of the motor section
F 9К Circuit of the lamps high beam, (port side)
F 10Л Circuit of the lamps high beam, (starboard)
F 11А Feed circuit сигнала reverse motion and rear lamp
F 12Б Feed circuit of the electronic module and control interposing relay of the engine temperature conditions
F 13В Feed circuit of the control lamps block, of the radiator blind switch
F 14Г Feed circuit of the parking brake system, stop-light, of control fuel level sensor from owerflow
F 15Д Feed circuit opf the fuel pumping system,body lifting and lowering
Feed circuit or the turns relay, of the alarm signaling switch , turns lamp indicators left and right sides, body high-
F 16Е
light lamp
F 17Ж Feed circuit of the warning signal, of the control lamp block, control lamp
F 18И (BELAZ-7514) Feed circuit of the engine protection on the pressure and oil pumping in the lubrication system after engine stop
F 18И (BELAZ-75145) Feed circuit of the fan engine switching on
12-5
Electrical equipment
7513-3902080 RM
Before to start service or jobbing of the storage battery, check up and clarify the reasons of possible
faultiness. For the control of the storage batteries condition remove them from the dump truck, delete the mud,
moisture and electrolyte from covers of jars of interelement crosspieces. To test the condition of the mon-
oblock, the covers, the mastics, the plugs and interelement crosspieces.
After survey of storage batteries to test their fitness to operation and charge degree. Fitness to operation
is defined on the voltage gauged by the accumulator tester in the each battery element.
The voltage should be in completely charged element 1,8-1,85 V (under load) and be kept resistantly to
during 5 - 6 sec. (look table 12.4).
Тable 12.4 – –-Parameters describing degree of the elements fitness of storage battery to operation
Voltage in element, V Fitness to operation degree, %
1,85 100
1,7 75
1,6 50
1,5 25
1,3 0
12-6
Electrical equipment
7513-3902080 RM
The charging degree of the storage battery depending on the density of electrolyte is reduced in
table 12.5.
Table 12.5 - The charging degree of the storage battery depending on the density of electrolyte
0 3
Electrolyte density, reduced t 25 С, g/sm
Flat battery
Completely charging battery
на 25 % на 50 %
1,30 1,26 1,22
1,28 1,24 1,20
1,26 1,22 1,18
1,24 1,20 1,16
1,22 1,18 1,14
The electrolyte density is established with the help of the areometer in each element of the battery.
The control of the electrolyte level in storage battery is carried out by means of glass tube diameter 3 - 5
mm on which two labels on distance of 10 and 15 mm from the end face are put. For electrolyte level the con-
trol to turn out the fuse in battery and to insert the tube into an aperture against the stop in face shield. To en-
close by finger the free end of the tube and to lift it is electrolyte should fill in the tube up to any level between
labels. It is electrolyte level.in battery
The battery unloaded more than on 25 % in the winter and more, than on 50 % in the summer, it is nec-
essary to remove from maintenance and to lead its recharge.
Before charging the new or repaired battery and depending on climatic region the electrolyte defined
densities (table 12.6) should be filled.
Electrolyte density,
Climatic region (mounthly air temperature 0 3
Season to plus 25 С, g/см
in January, C
filled В конце зарядки
To refill of one battery type 6СТ-190 it is required 12 l of electrolyte. Electrolyte prepares from sulfuric
battery acid and distilled water in utensils, rack against sulphuric acid - ceramic, plastic, deflate ebonite, lead.
In utensils water all over again is filled in, then at continuous stirring sulphuric acid. For deriving electrolyte of
the corresponding density it is necessary to be guided by table 12.7.
Table 12.7 – Ratio between electrolyte density, water amount and sulfuric acid in 1 l of the electrolyte
0 3 0 3
Required electrolyte density at 25 С, g/sm 25 С, г/см 1,20 1,22 1,24 1,26 1,28 1,40
3
Amount of the sulfuric acid the density 1,83 г/см , л 0,200 0,221 0,242 0,263 0,285 0,426
The temperature of the electrolyte which is filled in the battery, should be not less plus 15 0С and no
more plus 25 0С in regions with cold and temperate climate and no more plus 30 0С in regions with the tropical
climate.
12-7
Electrical equipment
7513-3902080 RM
Before refuel of electrolyte to turn out from the battery the fuse and to remove from them film closing the
vent, and to cut off a protuberance at the fuse end . If instead of film and protuberance the sealing disk under
fuse is applied, to delete it. After filling the battery by electrolyte vents should remain open.
To fill in electrolyte until the surface of electrolyte will not touch the lower end of the tube of neck. At the
tube absence to fill in electrolyte up to the level on 10 - 15 mm higher welding shield.
Later 20 mines but not later than through 2 hour after electrolyte filling to check its density. If the density
of electrolyte will decrease no more than for 0,03 g/sm3 against the density of filled electrolyte batteries can be
handed over in maintenance.
If the density of electrolyte will be reduced more than on 0,03 g/sm3 batteries are necessary to charging.
The temperature of electrolyte in battery before charging should be no more than 30 0С in cold and mod-
erate zones and no more than 35 0С in hot dry and warm wet zones. If temperature of electrolyte more speci-
fied, it needs to be cooled.
For charging the positive side of the battery is connected to the positive pole of the current source, and
negative - to negative.
The strength of charging current is established depending on the charging condition. The following
charging conditions storage batteries are applied:
charging the new or repaired storage batteries (first charging). For dry charging batteries the charging
current - 19 amp;
- next batteries charging while in service (boost charge). Charging current - 19 amp.;
- control-conditioning cycle or the warning of sulphation plates (recharge). Charging current - 19 amp.
To charge the battery it is necessary until the ample effervescence in all elements of the battery will oc-
cur, and the density of electrolyte and voltage will stay fixed within two hours. If the temperature of electrolyte
0
appears more than 45 С it is necessary to reduce charging current half or to interrupt charging for the while,
necessary for reduction of temperature up to 30 - 35 0С. Batterie voltage to inspect the voltage meter with the
scale on 30 V with scale interval of 0,2V.
In the end charging, if the density of electrolyte gauged in view of the temperature correction (table
12.8), will differ from norm to modify the electrolyte density . The distilled water is add at thus, if the electrolyte
density more norm, and the acid of the density 1,4 g/sm3 is refilled, if it less norm.
After the adjustment of the electrolyte density to continue batteries charging on 30 minutes to complete
hashing electrolyte, and then batteries to disconnect. Later 30 minutes after batteries switching-off to measure
the electrolyte level in all accumulators of the battery.
If the electrolyte level will be less norms, to add in the accumulator electrolyte the density what is speci-
fied in table 12.6. At the electrolyte level more norms the electrolyte excess to select at the rubber bulb.
12-8
Electrical equipment
7513-3902080 RM
12.3.3 The repair work which is not requiring the disassembly of the storage battery
For removal of outside damages of the storage battery it is necessary to merge electrolyte and to en-
close apertures of jars fuses.
Cracks in acid-proof mastic are eliminated by heating of mastic to such condition when it fills in the
crack. It is not recommended to apply to heating mastic the blow lamp or other heating means with open flame.
At the leak of electrolyte through the slot covers dress by screw-driver, fill by mastic and smooth by the
hot blade. If electrolyte dribbles at the terminal block pins, delete mastic around of the pin and solder up its
connection with by the cover. After that the place around of the pin again fill up by mastic and smooth down by
the hot blade.
The broken off interelement crosspieces solder by the carbon. In the place of the crosspiece connection
by three-square file cut the flute on all width. Under the crosspiece put the strip of the tin which cleaning cloth
turn up up so that they densely joing to the crosspiece and have formed the tray. The crosspiece end fuse with
the help of the carbon which through the special header is connected to the positive pole of the current source.
Alternatively of the source of the electric power it is possible to use the storage battery. For complete the weld
filling add the lead. In the soldering time do not suppose formation of the electric arc between lead and the coal
rod.
Strongly injured crosspiece replace by new for what a special hob drill a ring bore around of the lead-out
dowel and remove a web.
New web dress on on lead-out dowels, notched on the ends, and then space between each dowel and a
web fill up with the melted lead.
Removal of the insignificant sulphation make in the following sequence:
- unload the storage battery by current 17,4 amp. at the
ten-hour condition up to the voltage
1,7 V in each element (Figure 12.1);
12-9
Electrical equipment
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12-10
Electrical equipment
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12-11
Electrical equipment
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Screen sizes
Dump truck mark Lower headlights Upper headlights
H h a H1 h1 a1
BELAZ-7514-10 1375 345 1450 1875 280 1830
BELAZ-75145 1380 345 1100 3160 473 2740
BELAZ-75131, BELAZ-75132 1460 320 630 2370 250 2750
12-12
Electrical equipment
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12-13
Electrical equipment
7513-3902080 RM
12-14
Power takeoff and cardan shaft
7513-3902080 RM
Technical state of the power take off is determined in the operation process:
– external examination;
– orally ( operation noisiness);
– over heat .
By the external examination over oil leakage you can find out the wear-out or damage of glands, packing
rings and collars. Orally you can find out random breakdowns or weakening of parts fastening. Over heat you
can define abnormal performance of bearings or change of oil level at the reducer.
Realize removal of power takeoff from the truck in the following way:
– start motor, lift the platform to the extreme upper position and stop it ;
– muffle motor;
– drain the oil out off the takeoff , having unwrenched drain plug;
– shut the flap on oil tank of the united hydraulic system, for exclusion of oil leakage under the detach-
ment of suction hoses from pumps;
– detach the hoses from pumps;
– disconnect cables from the motor speed transducer and generator ( for power takeoff of the truck
BELAZ–7514-10);
– take off generator, pumps and speed transducer;
– detach the flange of cardan shaft from flange of rower takeoff;
– dissplint and unwrench the nuts of power takeoff fastening to the frame chassis brackets;
– fasten the power takeoff by suspension (figure 13.5), take out bolts and bushes, take off the power
takeoff from the truck and mount to the stand (figure 13.6) or stand (figure 13.7) for disassemblage.
13-1
Power takeoff and cardan shaft
7513-3902080 RM
Figure 13.1 —Mounting of power takeoff of the truck BELAZ–7514-10 (view from the side of back axle,
profile А-А and Б-Б shown on the figure 13.3):
1 – plug of filter hole; 2 – pump; 3, 4 – brackets; 5 – adjustment gasket; 6 – support pad; 7 – sleeve; 8 – adjustment washer;
9 - power takeoff ; 10 – plug of drain hole; 11 – plug of locating hole
Figure 13.2 — Mounting of power takeoff to the truck BELAZ–75145 (view from back axle side,
profile А-А and Б-Б are shown on the figure13.4):
1 – plug of filter hole; 2 – pump; 3, 4 – brackets; 5 –adjustment gasket; 6 –support pad; 7 – sleeve; 8 –adjustment washer; 9 plug
of locating hole; 10 –power takeoff; 11 – plug of drain hole
13-2
Power takeoff and cardan shaft
7513-3902080 RM
13-3
Power takeoff and cardan shaft
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13-4
Power takeoff and cardan shaft
7513-3902080 RM
Realize disassemblage of power takeoff of the truck BELAZ–7514-10 in the following way:
– take off the case cap with lining, having unwrenched the nuts of its fastening;
– take off pumps НШ-100 ( 3 units), having unwrenched bolts of pump fastening to the case ;
– take off reducing ring 5 (see figure 13.3), spline bushes 3, coupling sleeves 4;
– take out the sealing ring from the slots of each reducing ring;
– take off locking rings from spline bushes;
– take off cap 38 with lining, having unwrenched fastening bolts, take out the distance sleeve35;
– squeeze from the side of cap 38 the shaft of pump 37drive with bearing 18 and the distance bush 17;
– crimp from shaft 37 the bearing 18 and take out the distance bush 17;
– take out of case the gear of pump 36 drive the distance sleeve 17 and bearing 18;
– dissplint and unscrew the nut on shaft 25 of alternator drive, remove washer, gasket and sealing ring;
– take out pulley 30 from the shaft, extract key 29;
– take off cap 28 with packing ring, having unwrenched bolts of its fastening ;
– take off baffler 31;
– take off cap 23 with packing ring, having unwrenched bolts of its fastening;
– squeeze from side of cap 23 the shaft 25 of alternator drive with bearing 19, distance bush 27;
– crimp from the shaft 25 the bearing 19, take off distance bush 27;
– extract from case the gear 26, distance bush 24 and bearing 19;
– take off cap33, having unwrenched the bolts of its fastening;
– take off the reducing bushes 20 with packing rings from the both sides of countershaft 21;
– squeeze the countershaft 21 with bearing 19;
– crimp from the shaft 21 the bearing 19 and take off the key 32;
– extract from the case the bearing 19, the distance bush 22 and the gear of countershaft 34;
– dissplint and unscrew bolts of thrust washer 15 fastening;
– take off thrust washer with gasket;
– take off from drive shaft 44 the flange 11;
– take off the cap 16 of drive shaft with gasket, having unwrenched bolts of its fastening ;
– squeeze from cap 16 the collars 13;
– unscrew bolts and take off the motor speed transducer;
– unscrew bolts 40 and take off the cap with gasket;
– squeeze from cap 40 the collar 42;
– squeeze from the case from the side of cap 16 the drive shaft 44 with bearing 45 and distance rings 43
and 39;
– take off from the shaft the spacer ring39;
– crimp from the shaft 44 the bearing 45 and take off spacer rings 43;
– squeeze from the case the bearing12;
– extract from the case the drive gear 46 and spacer ring 14;
– take off pump НШ-10, having unwrenched bolts of its fastening;
– take off flange 7 of pump fastening, having unwrenched bolts of its fastening , with lining;
– take off spline bush 10 of pump НШ-10 drive;
– take off cap 49, having unwrenched bolts of its fastening, with lining ;
– extract the spacer ring 48;
– squeeze the shaft 47 with distance sleeve 9 and bearing 8;
– crimp from the shaft 47 the bearing 8 and remove distance sleeve 9;
– extract from the case the gear 6 ,bearing 8 and distance sleeve 9;
– squeeze the shaft 37 of pump НШ-100 drive with bearing 2 and distance sleeve 17;
– crimp from the shaft 37 bearing 2, remove distance sleeve 17;
– extract from the case the gear of pump 36 drive, bearing 2 and distance sleeve 17;
– dissplint and unwrench the nut on shaft 52 of fan drive, remove washer;
– take off flange –pulley 50 from shaft;
– take off cap 51, having unwrenched bolts of its fastening ;
– squeeze from cap the collar 53;
13-5
Power takeoff and cardan shaft
7513-3902080 RM
Table 13.1 — Nominal and maximum dimensions of the main parts of power takeoff of trucks
BELAZ–7514-10 and BELAZ–75145
+0,035 120,045
Diameter of the bearing holes of fan 120
drive shaft and motor speed trans-
ducer
+0,035
100 100,045
549Б – 4202026
Drive shaft:
External spline diameter 60 + 0,01 59,97 Steel 40Х НВ 321 – 375
−0,03
Spline thickness 9
− 0,09 8,8
549А – 4202020
Cement
Driving gear: −0,118 68,8 h 1,4 – 1,8
Length of the common tooth normal
69,154 Tooth face
−0,178
Steel 20ХН3А
НRС 59 – 65
+0,06 Tooth core
Width of spline cavities 9 9,20 НRС 26
13-6
Power takeoff and cardan shaft
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+0 , 5 26,80
Length of the common tooth normal 26,81
+ 0 ,3
549А – 4202088
Spline bush −0,3
Length of the common tooth normal 19,16
− 0, 5 18,60
Cement
h 0,7 – 0,9
+0,045 Steel 20Х
Width of spline cavities Tooth face
7 7,10 НRС 55 – 63
549А – 4202132-10
Coupling bushing +0,5
Length of the common tooth normal 19,16 285 – 321 НВ
+ 0, 3 19,35
Nitrogenize
Steel 40Х h 0,2 – 0,6
Length of the common tooth normal −0,3 Tooth face
25,8 25,10
− 0,5 HV 580
549А – 4202078
Cement
Gear of pump drive −0,098 h 1,4 – 1,8
Length of the common tooth normal 54,113 Tooth face
−0,158 53,80 Steel 20ХН3А
НRС 57 – 65
+0,06 Tooth core
Width of spline cavities 12 12,20 НRС 28 – 44
75125 – 4202068-10
Cement
Gear of pump drive −0,118 h 1,4 – 1,8
Length of the common tooth normal 84,265 Tooth face
−0,178 84,00 Steel 20ХН3А
НRС 57 – 65
+0,07 Tooth core
Width of spline cavities 14 14,20 НRС 28 – 44
13-7
Power takeoff and cardan shaft
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549А – 4202106-30
Countershaft +0,017
Diameter of bearing journal 30
+ 0,002 29,99 Steel 45 241 – 321 НB
549А – 4202108
Cement
Pinion of countershaft −0,098 h 1,4 – 1,8
Length of the common tooth normal 53,693
−0,158 53,40 Steel 20ХН3А
Tooth face
НRС 59 – 65
Width of key slots +0,065 Tooth core
6 6,10
+ 0,015 НRС 28 – 44
549Б – 4202128-30
Shaft of generator drive
Spline thickness 6
−0,048 5,90
13-8
Power takeoff and cardan shaft
7513-3902080 RM
−0,020 12,0
Width of key slots 12
− 0,075
751257 – 4202412
Shaft
Diameter of gear planting 50 + 0,008 49,97
+0,018 Steel 40Х НВ 241 – 285
Diameter of bearing journal 45
+0,002 44,99
75145 – 4202422
Cement
Gear −0,118 h 1,4 – 1,8
Length of the common tooth normal 84,615 Tooth face
−0,178 84,35 Steel 20ХН3А
НRС 59 – 65
+0,085 Tooth core
12 12,20 НRС 28 – 44
Width of key slots + 0,025
7521 – 4202422
Cement
Gear of fan drive −0,098 h 1,4 – 1,8
Length of the common tooth normal 53,553 Tooth face
−0,158 53,30 Steel 20ХН3А
НRС 59 – 65
+0,085 Tooth core
Width of key slots 12 12,20 НRС 28 – 44
+ 0,025
13-9
Power takeoff and cardan shaft
7513-3902080 RM
ized by means of push-button station on driving rest. Cramp control is realized by means of button station inte-
grated into the cramp handle.
Stand-turner (figure13.7) is intended for turning of power takeoff body under assemblage. The turn is re-
alized under the rotation of handle 8 of reducer 2;
– built up to the countershaft 21 (see figure 13.3) the bearing 19 up to the stop into the face of shaft
shoulders;
– mount the semicircular key 32 into the slot of countershaft 21;
– mount into the case the pinion gear of countershaft 34;
– insert the countershaft, assembled with key, into the power takeoff case cavity and having united the
pinion gear slot with key, put the gear on to the shaft against stop;
– insert bearing 19, pressed onto the countershaft, into the case cavity;
– install into the reducing sleeve20 the gasket and, having united the slots in reducing sleeve and case ,
install reducing sleeve into the case flush with case face;
– install cap of countershaft 33 and fasten by bolts with washers;
– install onto the shaft the distance sleeve 22;
– mount bearing 19 into the case opening and built up onto the countershaft 21 and into the case;
– install into the reducing sleeve 20 the gasket, having united the slots at the reducing bush and case,
mount reducing bush into the case hole flush with the case face;
– mount onto the generator drive shaft 25 the distance sleeve 24 and built up the bearing 19 flush with
shaft face;
Figure 13.6 — Stand СБ-50 for dismantling and assembling of power takeoff:
13-10
Power takeoff and cardan shaft
7513-3902080 RM
1 – hydrostation; 2 – cantilever support; 3 – carriage; 4 – cramp with hydrocylinder; 5 – idler support; 6 – power takeoff; 7 – hom-
ing support
Figure 13.7 —Stand -turnerСБ-9 for dismantling and assembling of power takeoff:
1 – pan; 2 – reducer ; 3 – left tenon; 4 – power takeoff; 5 – right tenon; 6 – frame; 7 – tap; 8 – handle
– mount on the shaft of generator drive, assembled with bush and bearing, into the case hole of the
power takeoff and press bearing;
– mount on the cap 23 rubber ring and , having united cap holes with case holes, fasten cap by bolts
with washers;
– mount on the splines of generator drive 25 shaft the pinion gear of generator drive 26 shaft, introduc-
ing it into the engagement with gear of countershaft 34;
– mount on the shaft of generator drive the distance bush 27;
– mount bearing 19 on to the shaft of generator drive and press the bearing onto the shaft and into the
case up to stop into the distance bush 27;
– built up onto the shaft of generator drive the reflector 31up to the stop into bearing;
– mount on the cap 28 rubber ring and , having united cap holes with case holes, fasten cap by bolts
with washers;
– mount key 29 into the slot of generator drive 25 shaft and , having united the slot in the driving pulley
30with key, mount pulley on shaft up to stop;
– fasten the pulley on shaft by castellated nut with washer, previously having placed on the shaft the
rubber ring, and the lining under washer, and stop the nut on shaft by splint;
– press up to stop on to the shaft of fan 52 drive the bearing 59and fasten by stop ring , having put the
ring into the slot on shaft;
– place the key into the slot of fan drive shaft;
– place the gear of fan 57 drive shaft into the case opposite the hole under plant;
– insert the shaft of fan drive, assembled with bearing and key, into the hole of takeoff case and press
the bearing into case, having united the gear groove with the key on shaft ;
– place onto the takeoff case in series the lining and cap of fan 60 drive shaft, having united the holes,
and fasten cap by bolts with washers;
– place into the bearing 55 groove the stop ring;
– put gear 57 up to stop into the face of fan 52 drive shaft;
– place onto the fan drive shaft the spacer bush 56, bearing 55, assembled with the stop ring, and press
bearing up to the stop;
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Power takeoff and cardan shaft
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13-12
Power takeoff and cardan shaft
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13-13
Power takeoff and cardan shaft
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– put the technological plugs into the holes for pump plant and gauge of rotational speed;
– join the cardan shaft of stand to the flange of drive shaft of power takeoff and fasten by bolts with
washers ;
– unwrench the drainage magnetic plug and wrench instead of it the drain cock of stand;
– unscrew filter plug and fill the oil ТАП-15В into the power takeoff up to the level of locating hole and
screw plug;
– switch on stand and realize the power takeoff running in. See modes of running in at the table13.3.
During the running-in control the lack of leaks along places of joints, along body parts, along threaded
and sealing joints, along drain and filling plugs, along breathers and clearance seals. Under oil leaks detection
along threaded joints it’s permitted to mount fasteners on sealant.
The noise level during the running-in should not exceed under the measurement on the distance (150 + 10)
mm:
– 98 dB on the mode 1;
– 105 dB on the mode 3.
Under that the external noise level on the place of measurement shouldn’t exceed 86 dB.
The oil temperature at the running-in shouldn’t be more 75 0С.
After the running-in drain off the oil from the power takeoff.
13-14
Power takeoff and cardan shaft
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13-15
Power takeoff and cardan shaft
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13-16
Power takeoff and cardan shaft
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Table 13.5 —Nominal and maximum dimensions of the main parts of cardan shafts
Dimensions, mm
Number, part designation and con-
Material Hardness
trolled variables
Nominal Maximum
540–2208049-11
Flange yoke: 50+0,012 50,05
Bearing hole diameter -0,027
5+0,09 5,15
Width of spline slots +0,03
53205–2205030-10
Cross: Cement
Tenon diameter 33,635-0,016 33,60 h 1,8 — 2,2 mm
Steel 20ХГНТР
61 — 66 HRCэ
Size on tenon faces
143-0,04 142,9
DIESEL FUEL AND KEROSENE FOR PARTS WASHING ARE NOT USABLE AS THEY ARE BADLY EVAPO-
RATED OR LEAVE A LAYER ON THE PARTS SURFACE WHICH MIXED WITH LUBRICATION AND VIOLATE ITS
STRUCTURE!
13-17
Power takeoff and cardan shaft
7513-3902080 RM
needles so that they will be fully covered by lubricator, besides lubricate operation edges of glands);
– put on the cross pins 1 (see figure 13.9) end seals 3;
– insert into the one of flange-yoke 2 holes the needle bearing 5, introduce one cross pin 1 into the
yoke hole, where there is no bearing, and the other insert into the inserted bearing. Under inserting of needle
bearings into the yokes orient the bearings so that slot on the bearing face will on the same line with threaded
yoke holes. Such bearing orientation is required for bearing caps 6 installation;
– mount on the cross pin and insert into the flange-yoke the second hinge bearing;
– mount bearing caps 6 and mount under bolts 18 locking plates 19. Tighten and stop bolts of caps fas-
tening, having bent the whiskers of locking plates on the bolt head panes. Bolt tightening torque should be
25 – 32 N.m;
– similarly assemble with cross the second flange-yoke 2, sliding yoke 9 and spline yoke 16;
– mount the mantle rings 15 to the spline shaft 14;
– check up assembled hinges for angular rolling. Piston throw under the turn on full angle should be
smooth, without jamming;
– lubricate spline part of the joint of sliding yoke 9 and spline yoke 14 by lubricant
Литол-24 and insert the spline yoke into the sliding yoke.
Each bearing should be packed by self-tightening packing 4, mounted into the bearing hoop. Face pack-
ing hasn’t protective hoop. Spline joint is protected by packing 11.
Under the cardan shaft assemblage it’s necessary to install the hinge lubricators so that they were di-
rected to one side and positioned under the angle 30 – 60 degree to the axe of cross pins. The hinge yokes
under the rotation of them around crosses in both sides should be smoothly rotated.
UNBALANCE (CHANGE OF MUTUAL PARTS POSITION), BENDING OF CARDAN SHAFT, PARTS WEAR-
OUT, WEAKENING OF SHAFT AND NEEDLE BEARINGS FASTENING, WEAR-OUT OF MOVABLE SPLINE JOINT –
ARE THE REASONS OF VIBRATION, KNOCKING, REDUCING OF CARDAN SHAFT SERVICE LIFE WHICH LEADS
TO ITS DESTRUCTION.
13-18
Dumping mechanism
7513-3902080 RM
14 DUMPING MECHANISM
14.1 General
Dumping mechanism for BELAZ-7514-10, BELAZ-75145 dump trucks is of hydraulic type and is
electro-hydraulically driven, ensures raising and lowering of the body and makes it possible to stop body in
any intermediate raised or lowered position. It comprises three gear-type pumps НШ100А-4 __ 19, 20, 22 (pic-
ture 14.1) and pump НШ10В-3 __ 21, two three-stage telescopic hydraulic cylinders 7, hydraulic control dis-
tributor 1, control valve 8, hydraulic distributor 16, auxiliary hydraulic distributor 5, oil tank, solenoid valve 14
preventing spontaneous body raising on the move and oil piping system.
Dumping mechanism is actuated from the cab by electric switch available on the control board.
Dumping mechanism in BELAZ-75131, BELAZ-75132 dump trucks ensures body raising and
lowering, makes it possible to stop body in any intermediate raised or lowered position. Mechanism is
equipped with hydraulic drive of progressive type with electro-hydraulic actuation. It comprises two three-stage
telescopic hydraulic cylinders Ц1 and Ц2 (picture 14.2 а), control board ПУ, control unit БУ, oil pumps Н1- Н3,
oil tank and interconnecting oil piping.
Dumping mechanism is actuated from the cab by electric switch on the control board.
14-1
Dumping mechanism
7513-3902080 RM
14-2
Dumping mechanism
7513-3902080 RM
Picture 14.2 b – Functional hydraulic diagram of dumping mechanism in BELAZ-75131-50 dump truck:
А1 – control board; А2 – control unit; А3 – drain filter; Р1-Р4 – distributors; КП1-КП3 – relief valves; К1 – valve; КР1 – reduction
gear; Ц1, Ц2 – hydraulic cylinders;
Ф1-Ф3 – filters; ДР – throttle; Н1, Н2 – pumps;
I – hydraulic line of the steering system II – hydraulic line from pneumatic hydraulic accumulators
14-3
Dumping mechanism
7513-3902080 RM
Table 14.1 __ Major faults of the dumping mechanism; their causes and remedy
Fault and its cause Trouble shooting Remedy
Body fails to rise If the switch is positioned at “raise” and steering hydraulic sys-
tem fails to function (“zero effect of steering”), and the body
fails to rise then control valve for the dumping mechanism is to
be examined, and if the steering wheel obeys, i.e. steering hy-
draulic system functions, then hydraulic distribution valves of
the dumping mechanism are to be inspected
Insufficient operating liquid content in the To add operating liquid up to
Level is to be checked through eyelets
oil tank the marking
Solenoid hydraulic distribution spool Operating liquid flows in the drain line of the hydraulic distribu- To eliminate chocking or to re-
valve УИС (device preventing spontane- tion valve УИС place hydraulic distribution
ous body raising) chocked up in opened valve
position
Power supply from switch to solenoid
Steering functions with the body raising procedure activated.
hydraulic distribution spool valve is inter- To restore power supply circuit
Power supply circuit is to be checked for intactness
rupted
Raising spool of solenoid spool hydraulic Operating liquid in the piping from solenoid spool hydraulic dis- To cleanse out or to replace
distribution valve chocked up tribution valve to face chamber of raising spool of spool hy- solenoid spool hydraulic distri-
draulic distribution valve features no pressure bution valve
Raising spool of hydraulic distribution Piping leading to face chamber of the raising spool is to be dis- To cleanse out or to replace
spool valve chocked up connected and spool travel is to be checked by torque of hydraulic distribution spool
(400±50) Nm. Spool stroke makes up (18±0,5) mm. valve
Excessive pressure of operating liquid in Piping is to be disconnected from face chamber of the lowering
face chamber of the lowering valve spool. Raising procedure is to be initiated. If the body is being To clean up or to cleanse out
raised, this implies that hydraulic drain line leading from face hydraulic drain line
chamber of the spool valve to the oil tank is clogged up
Lowering valve chocked up Piping is to be disconnected from face chamber of the lowering To cleanse out or replace con-
valve and valve stroke is to be checked by torque of (60±10) trol valve of the dumping
Nm. Valve stroke makes up 1,5 — 2 mm. mechanism
Supporting valve at the drain spot does
Operating liquid pressure is to be measured in the hydraulic To replace the supporting
not ensure operating liquid pressure of
line of the steering system. It shouldn’t be less than 0,7 MPа valve
0,7 — 1 MPa
Overflow control valve in dumping Operating liquid features low pressure in delivery hydraulic line To cleanse out or to replace
mechanism chocked up in opened posi- leading from control valve to head end of the hydraulic cylin- control valve of the dumping
tion ders mechanism
Operating liquid is not supplied into suc- Shutter in the oil tank is closed, transportation plugs in the To open the shutter and to re-
tion pipe-line pumps haven’t been removed move the plug
Body lifts slowly
Low capacity of pumping Lifting is being effected slowly but body is held in neutral posi-
tion. Body spontaneously lowers down at the speed of To replace pumps
(600±50) mm/h
Excessive leakage of operating liquid
Body spontaneously lowers down from neutral position at the To replace control valve of the
from control valve of the dumping
speed of (600±50) mm/h dumping mechanism
mechanism
Spool valve of the auxiliary hydraulic dis- Piping leading to the face end of the spool of additional hydrau-
To cleanse out or to replace
tribution valve chocked up lic distribution valve is to be disconnected and spool valve
auxiliary hydraulic distribution
stroke is to be checked by torque of (400±50) Nm. Spool
valve
stroke makes up (18±0,5) mm
14-4
Dumping mechanism
7513-3902080 RM
14-5
Dumping mechanism
7513-3902080 RM
Table 14.2 __ Major faults in the dumping mechanism, their causes and remedy
14-6
Dumping mechanism
7513-3902080 RM
14-7
Dumping mechanism
7513-3902080 RM
Picture 14.4 — Appliance for removal and mounting of the dumping mechanism cylinders:
1 – loader fork; 2 – cross-member; 3 – bracket; 4 – axis; 5 –dumping mechanism cylinder, bracket; 6 – ball support; 7 – support
bracket; 8 –longitudinal bracket; 9 – pin; 10 – nut; 11 – handle; 12 – jaws; 13 – insert; 14 – chain; 15 – grab
14-8
Dumping mechanism
7513-3902080 RM
14-9
Dumping mechanism
7513-3902080 RM
14-10
Dumping mechanism
7513-3902080 RM
14-11
Dumping mechanism
7513-3902080 RM
14-12
Dumping mechanism
7513-3902080 RM
14-13
Dumping mechanism
7513-3902080 RM
14.4.1.6 Disassembly of solenoid distribution valve of body raise interlock in the dumping
mechanism
Disassembly of solenoid distribution valve of body raise interlock is to be effected in the similar way to
disassembly of solenoid distribution control valve.
14-14
Dumping mechanism
7513-3902080 RM
14-15
Dumping mechanism
7513-3902080 RM
14-16
Dumping mechanism
7513-3902080 RM
14.4.2.4 Disassembly of relief valve in hydraulic distribution valve of the dumping mechanism
Disassembly of relief valve in hydraulic distribution valve of the dumping device is to be effected in the
following succession:
- to unscrew cover 7 (picture 14.14);
- to remove spring 5 and valve 4 out of housing 1.
14-17
Dumping mechanism
7513-3902080 RM
Table 14.3 — Design and tolerance limit dimensions of major parts in dumping mechanism
549-8603164-10
Cylinder rod 30 micromicron 12 micromicron 40Х steel HRC 47 — 54
thickness of chrome coating
Hydraulic distribution valve:
clearance between spool and bore in
housing 0,009 0,035
7520-8607254
Valve: 32-0,009 31,965 40Х steel HRC 56 — 62
belt housing -0,020
549Б-8607240
Housing:
opening diameter
60+0,03 60,05 45 steel HRC≥46,5
549Б-8607232-10
Overflow valve 32+0,060 32,06 20 steel HRC 56 — 62
belt diameter +0,025
549Б-8607235
Lowering servovalve: 10-0,13 9,965 20Х steel HRC 57 — 63
belt diameter -0,27
549А-8606198
Pusher: 5-0,04 4,8 35 steel HB 241 — 285
outer diameter -0,12
549Б-8606198
Pilot: 10-0,005 9,97 20Х steel HRC 57 — 63
belt diameter -0,015
14-18
Dumping mechanism
7513-3902080 RM
Table 14.4 — Design and tolerance limit dimensions of major parts in dumping mechanism
Cylinder:
ДПРНМ band
7519-8603183
2x165НД
7519-8603184
Бр ОЦС
7519-8603185
4-4-2,5
7519-8603186
7519-8603188
549-8603130 pipe
30 micromicron 12 micromicron 45 steel HRC 47 — 54
thickness of chrome coating
549-8603134-10 pipe
30 micromicron 12 micromicron 40Х steel HRC 47 — 54
thickness of chrome coating
549-8603164-10
Cylinder rod 30 micromicron 12 micromicron 40Х steel HRC 47...54
thickness of chrome coating
5132-8606423 Clearance in match-
Sleeve: 10+0,015 ing Cementing
sleeve-spool 20Х steel h 0,7 — 0,9 mm
inner diameter
0,01 — 0,02 57 — 63 HRCэ
not more
75132-8606456 Clearance in match-
Spool: ing Cementing
belt diameter 10,00 spool - sleeve 20Х steel h 0,7 — 0,9 mm
0,01 — 0,02 57 — 63 HRCэ
not more
78211-4612015 Clearance in match-
ing
Housing:
sleeve-spool ВЧ 50 cast iron 150 — 190 НВ
spool opening 25+0,027 0,005 — 0,020
not more
78211-4612042 Clearance in match-
Spool: ing Cementing
belt diameter 25,00 sleeve-spool 20Х steel h 0,7 — 1,0 mm
0,005 — 0,020 56 — 61 HRCэ
not more
78211-4617122
Valve: Operating surface of the valve must be 40Х steel 43,5 — 49,5 HRCэ
scratch- and damage-free
14-19
Dumping mechanism
7513-3902080 RM
14-20
Dumping mechanism
7513-3902080 RM
14-21
Dumping mechanism
7513-3902080 RM
lowering spool driven by spring should come back to original position and whole operating liquid stream should
flow into drainage through chamber VII.
At least five switch-overs are to be performed.
Chamber IV is to be plugged. If operating liquid is being supplied into chamber X from pressure generat-
ing source featuring capacity of 120 l/min, and control pressure is being created in chamber III, operating liquid
pressure in chamber IX should amount to (2,5±0,5) MPa.
Chambers IX and X are to be connected to high-pressure pumping plant. Z, B, VI, VII, VIII, XI chambers
are to be plugged and I, II and III chambers are to be attached to gauging tank.
14-22
Dumping mechanism
7513-3902080 RM
14.6.1.6 Assembly of solenoid distribution valve of body raise interlock (dumping mechanism)
Assembly of solenoid distribution valve of body raise interlock is to be effected in the similar way to as-
sembly of solenoid distribution control valve.
Testing of solenoid distribution valve for body raise interlock.
When solenoid is activated and simultaneously operating liquid is supplied into chamber Д, operating
liquid must flow into drainage through chamber С.
Not less than five switch-overs are to be effected.
14.6.2 Assembly of dumping mechanism units in BELAZ-75131, BELAZ-75132 dump
trucks
14.6.2.1 Assembly of dumping mechanism cylinders
Assembly of dumping mechanism cylinders in BELAZ-75131, BELAZ-75132 dump trucks is to be ef-
fected in the similar way to assembly of dumping mechanism cylinders in BELAZ-7514-10, BELAZ-75145
dump trucks.
14-23
Dumping mechanism
7513-3902080 RM
CAUTION: THROTTLE BORES OF SPOOL ARE TO BE SITED FROM SLEEVE 14 COVER SIDE.
- to place spring 6;
- to place semi-assembled spring cover into bore on housing 10 and to secure using cover 4 with screws
18 complete with washers 17;
- to place hydraulic distribution valves 19, 20 on housing 10 and to secure with screws 21 complete with
washers 22;
- to place cocks 11 and nipple 16.
Testing of dumping mechanism control unit is to be effected in the following succession
- to create pressure 4 — 20 MPa in channel Р (picture 14.16), drainage is to be carried off from chamber
Т1 into tank and by connecting manometer with measuring limit of 10 MPa to chamber М, when solenoids are
deactivated, reduction pressure is to be set at (3±2) MPa using screw 1 (see picture15.6);
- channels X, Y, Z must be open for leakage evaluation and measuring: 0 — 100 sm³/min pressure in
chamber Р (10±1) MPa;
- by connecting manometers to chambers X and Y, one is to check distribution valve 20 performance,
activating its magnets by turns and waiting for the moment when
pressure value reaches (3±0,2) MPa in chambers X and Y;
- performance of distribution valve 20 is to be checked
when pressure value of 16 — 20 MPa is supplied (through throttle
1,5 mm in diameter) to chambers А and В;
- magnet activation should lead to pressure reduction in
chambers down to 0 – 0,5 MPa. Drainages Т and Т2 at this mo-
ment should be connected to tank and pressure Р should not be
used.
14-24
Dumping mechanism
7513-3902080 RM
14-25
Dumping mechanism
7513-3902080 RM
pressure (2,5±0,5) MPa in turns in chambers Y1 and X1, drainage must be provided through chambers В1 and
А1 accordingly. Break-loose pressure on spool should not exceed 0,65 MPa. Operating liquid is to be supplied
into chamber P2 at discharge rate not less than 100 l/min, drainage is to be done from chambers Т1, Т2. To
obtain control pressure (2,5±0,5) MPa in turns in chambers Y2, X2, drainage from chambers Т1, Т2 should
stop and should be provided through chambers В2 and А2 accordingly. Break-loose pressure on spool should
not exceed 0,65 MPa.
Mounting of dumping mechanism cylinders into dump truck is to be effected in the following succession:
- to place anti-backtracking supports under wheels of front and rear axes of dump truck;
- to lift body by crane thus body floor being in horizontal position. To place technological stands between
frame and lifted body;
- to place spacer bushings 8 into cylinder cover;
- to place appliance for removal and mounting of cylinders (see picture 14.4) onto cylinder and to secure
it safely;
- to place cylinder onto lower frame support;
- to place hold-down cover 13 of cylinder head and to secure it with screws 14;
- to match cylinder cover with body ears;
- to place pin 9 complete with spacer bushings 8, cover 4 and to draw up screws 5 (spacer bushings
should travel symmetrically);
- to screw in lubricators 6 and 17 into cylinder cover and head;
- to grease articulated spherical bearings with Litol-24 lubricant through lubricators until lubricant shows
up from underneath glands;
- to place cover 12 of cylinder head;
- to connect oil piping to lower cylinder supports.
Assembly of dumping mechanism cylinders in BELAZ -75131, BELAZ-75132 dump trucks is to be ef-
fected in the similar way to assembly of dumping mechanism cylinder in BELAZ -7514-10, BELAZ-75145 dump
trucks.
14-26
Cab, cab equipment and empennage
7513-3902080 RM
Figure 15.1 – Mounting of cab and empennage of trucks BELAZ -75131, BELAZ-75132:
1 – left wing; 2 – front bonnet; 3 –rear bonnet; 4 –right wing; 5 –left rear wing; 6 – bolt of cab fastening; 7, 11 –plates; 8 – pad of
cab fastening; 9 – bracket; 10 –bolt
15-1
Cab, cab equipment and empennage
7513-3902080 RM
Empennage grounds of the truck are made of special steel sheet (with effect «antislip») in thickness of 3
to 4 mm.
During the operation on the parts of empennage and cabin as a result of weather or mechanical impact
the following defects can be emerged :damage of antirust coating, cracks, breaks, dents, bends, weakening of
threaded joints, breakage of rubber pads of cab fastening.
Zones of empennage or cab where the coloration is damaged or there is a corrosion, it’s necessary to
clean and paint opportunely for preserving them from the further corrosion trouble.
Cabs and empennages of trucks BELAZ -7514-10, BELAZ-75145 are differ in form, operator seat and
screens.
15-2
Cab, cab equipment and empennage
7513-3902080 RM
The empennage is taken off by means of any pull adaptations, which are appropriate in load capacity
and meet safety requirements. Left and right wing are removed by
turns as an assembly with brackets. At that it’ s necessary previously
to cut off the bolts with nuts, by which the empennage is fastened to
the frame.
The diagram of cabin fastening is shown at the figures 15.4
and 15.5.
Figure 15.4 –Diagram of cab fastening under the removal from trucks
BELAZ-75131, BELAZ-75132:
1 – truck cab; 2 – ring-bolt; 3 – pull adaption (with 4 hooks)
15-3
Cab, cab equipment and empennage
7513-3902080 RM
Figure15.5 – Diagram of cab fastening under the removal from trucks BELAZ-7514-10, BELAZ-75145:
1 – truck cab; 2 – pull adaption
- disconnect the pipes to the drive valves of service and parking brakes, previously having made mark-
ing on clamps, fastened on both ends of cutoff point (if marking is absent);
- disconnect the hoses of cab heater from the heat exchanger;
- disconnect the air pipe-line from the square of pneumo-cushioned seat powering (for trucks BELAZ-
75131, BELAZ-75132);
- disconnect the hoses of conditioner (if it’s installed);
- cut off bolts (see figures 15.1 and 15.2) with nuts, by which the cab is fastened to the beams of rest;
- for joining of pull adaptation (for trucks BELAZ-75131, BELAZ-75132) screw into the holes, located on
the cab roof, four ring-bolts (ring-bolts are put into kit of spare
parts);
-remove cab and place it onto the special stand.
15-4
Cab, cab equipment and empennage
7513-3902080 RM
For removal of cab windshield unscrew nuts 6, extract screw 3 and take off clamps 2, take out cam
bushing 4 and , pushing by hand onto the screen top, squeeze it out (this operation would be better realized
the two together in order to prevent the glass drop at the moment of its outcome from aperture).
7513-3902080 RM
and press it tightly to the window aperture, the other brings the sealing edge beyond the glass border;
- insert the cam bush by means of mandrel (figure 15.9) into the compactor slot along the whole length;
-mount clamps.
Removal and mounting of rear screen and immovable side screen of the cab should be realized simi-
larly.
15-6
15-7
Cab, cab equipment and empennage
7513-3902080 RM
15-8
Cab, cab equipment and empennage
7513-3902080 RM
The brake mechanism is checked up by the single lifting of load with mass 10+0,5 kg, at that the clear
fixation of load in any point of motion, as under the lifting so under the sinking, should be provided. Smooth-
ness of motion is controlled under the load of mass 6+0,5 kg. The load move should be uniform , without jerk-
ing, jamming, gnash and clicks. Effort on the handle of window raiser (на плече 85+2 мм) under the lifting of
load with mass 6+0,5 kg should be not more 20 N.
Replacement of the volute spring of window raiser is realized in the following way:
- take off handle 24 (see figure 15.11) of window raiser;
- take off dutchman 29;
- take off spring 4 (figure15.13),having released it from capture;
- replace spring and mount it in the reverse order.
15-9
Cab, cab equipment and empennage
7513-3902080 RM
Operator seat – pneumo-cushioned, with the devices of seat height control, lengthwise movement, turn-
ing and back fixation (figure 15.14).
The lengthwise movement of seat is realized by means of handle 1. The handle should be turned left,
put the seat to the necessary position and release handle.
The regulation of turn and fixation of seat back 8 is realized by handle 6. Under the handle turn to the
upper position the back is put to the front position.
The seat pad is regulated and fixed on height and slope by the handles 2 and 4 . Under the turning of
handle up the pad takes the extreme upper position. Byturn turning of handles is provided the slop of seat pad.
Seat shell has two threaded holes 9 of size 7/16" for fastening of lap belt. The fastening bolts are in-
cluded into the kit of lap belt
For checking of serviceability of pneumatic cushioning system it’s required under the operative motor to
bring out the seat from the nominal static position by pushing or lifting it up. After the loading stop the seat
should be returned to the original position (size 150 mm), at that after the lifting up the noise of air outlet from
pneumodistributor should be heard.
The arrangement of pneumatic cush-
ioning system is shown at the figures 15.15
and 15.16.
The mechanism of pneumatic cush-
ioning is powered from the pneumosystem
receiver, mounted at the seat 3 rest (fig-
ure15.14). It consists of pneumoballon 6
(see figure15.15),pneumo distributor 3,
shock absorber4, upper 1 and lower 2
arms and buffer 5.
15-10
Cab, cab equipment and empennage
7513-3902080 RM
Under the operative motor the air from the pneumosystem receiver intakes to the canal I (figure 15.16)
of air distributor. Under the loading on the seat the upper and lower arms (figure15.15) are turned. At that the
arm 10 is turned(figure 15.16). The zone of insensitivity of air distributor is 4-120. Under the lifting of the seat
down the pivoted element 4 opens the valve 8,
joining canal I with canal II (receiver of pneumo-
system with pneumoballoon).The swap of bal-
loon is carried out. Nominal static size of air bal-
loon 150 mm. Under achievement of such posi-
tion the arm 10, turning pivoted element 4,
closes valve 8, stopping the air supply to the
balloon. Under the shifting of operator seat up
the pivoted element of air distributor opens the
second valve, joining canal II with canal III. The
air from the pneumoballon passes to atmos-
phere. So the effect of pneumo-cushioning is
achieved. Buffer 5 (figure 15.15) limits the mini-
mal height position of seat, the shock absorber 4
reduces the fluctuations, emerging under the
seat shifting up and down.
Under the non-operative system it’s re-
quired to dismantle it. For that cut off the pipe of
air supply to the air distributor from receiver,
take off the rest with pneumoequipment from the
truck, check the state of pipes of air supply be-
tween pneumoapparatuses, the state of pneu-
moballon (hermeticity).Having dismantled the air
distributor, check the state of rubber washer 11
Figure 15.16 – Air distributor:
on the valve 8 (figure15.14). In case of washer
1 – knee; 2 – slide; 3 – collar; 4 – rotary element; 5 – cap;
damage it should be changed. The washer 6 – lining; 7 – body; 8 – valve; 9 – stop; 10 – arm; 11 – rubber washer
should be pasted into its cage on valve. Under I – canal communicating to receiver; II – canal of air supply to
the falling out of washer from the cage – the pneumoballoon; III – canal communicating to atmosphere(figures in
system is not operative. After the trouble- brackets are marked on body)
shooting and assemblage of the system, check
up repeatedly its serviceability.
Cab heater - fluid, as a heat carrier the motor cooling fluid is used. The hot fluid passes from the ther-
mostat head through the plug stopcock and rubberized fabric hose into the heat exchanger and flows out of it
into the inlet pipe of motor. The cold air, delivered by two fans, passing through the heated exchanger, is
heated and enters the cabin. The amount of supplied into the cabin external air is regulated by shutter. The
shutter can be mounted so that only the external air, or the part of external air together with cab air, or only the
inner air will be entered the cab.
The hot air from the heater is supplied onto the windshield by the one fan, and by the other – to the zone
of operator feet and to the left and right side door windows.
The fans of the heater are connected into the network through two switches according to the double-
mode circuit for separate engagement into the work and control of their productiveness and hence of air tem-
perature at the cab.
Stopcock of the heater connect, mounted on the discharge pipe, gives the opportunity to reduce the
amount of hot liquid, entried into the heat exchanger, or fully overlap the entry on summer period. On the run-
down pipe the stopcock is not mounted.
Under the connect of aluminium heat exchanger to the cooling system the pressure and rundown pipe
lines can be connected to any exchanger pipe junction.
For air purification, supplied into the cab through heat exchanger, the paper filter, which should be peri-
odically cleaned from dust and dirt, is mounted outside on the front cab side wall.
The repair of heater is realized by replacement of worn components: radiator, electric motors, rotor and
rubberized fabric hoses.
For change of electric motor (figure 15.17) it’s required:
- unscrew bolts 8 and extract from heater cage 7 the electric motor 14 with the fan rotor 9;
15-11
Cab, cab equipment and empennage
7513-3902080 RM
- unscrew the screw of rotor fastening (it’s not shown at the figure) and take off the rotor from the motor ;
- unscrew nuts 15 and take off from the motor the disk 11.
Under the mounting of motor the fan rotor should be rotated without jamming.
15-12
Cab, cab equipment and empennage
7513-3902080 RM
15-13
Cab, cab equipment and empennage
7513-3902080 RM
Windshield washer – consists of polyethylene pot for fluid and pump with electric motor, mounted at
this pot. The pump is joined by hoses with two jets.
Under switching of pump the fluid passes through hoses into jets and splits by them on screen. At the pot
cap there is a hole which provides the pressure equalization in it under the pump operation. The direction of fluid
jet is regulated by turn of the ball at the plastic jet in order to the flush is directed into the upper zone of section,
describing by the brush of windshield wiper.
15-14
Cab, cab equipment and empennage
7513-3902080 RM
For avoidance of filter and jets clogging, it’s necessary to flood the pot only by filtered fluid and clean pe-
riodically the jets. As the operational fluid for windshield washer it’s required to use special antifreezing fluids
mixed with water in proportion according to application instructions of this fluid.
Removal and montage of the windshield washer is shown at the figure 15.20.
The repair of windshield washer is realized by replacement of worn components: pump with electromo-
tor, pot, jets and hoses.
Windshield wiper –consists of electric motor, links, and arms with brushes, fastened on the front cab
board. Removal and montage of arms and brushes of windshield wiper are shown at the figure 15.21.
Figure 15.21 –Removal and montage of arm and brush of windshield wiper:
1 – brush; 2 – drive of wiper; 3 – arm; 4 – nut; 5 – link
The repair of windshield wiper is realized by replacement of worn components: electric drive(or electric
drive as assembly with electric engine), brush, arm (or arm as assembly with brush).
For change of arm with brush unscrew nut 4 and take of it from the axe cone. Place the new arm with
brush and fasten it by nut.
For change of electric drive take off the link from axe of the drive, having unwrenched nut and taken off it
axe cone, unscrew 3 bolts, fastening the drive to bracket and cut off cord assemblies. Replace the drive and
assemble it in reverse order.
Conditioner. On customer demand the truck is equipped by block chladone system of air conditioning
with location of compressor on engine, air cooling block (evaporator)at the cab behind the operator seat, con-
denser block on the back cab side wall. The conditioner units are joined between them by elastic pipes of
chladone-resistant rubber.
Charging of conditioner, its putting into operation, repair are realized in accordance with operation man-
ual for this conditioner by specialists of the conditioner firm-supplier or their regional representatives.
After the performing of all working concerning repair or change of faulty parts, place the cab and em-
pennage. The montage is realized in reverse order.
15-15
Cab, cab equipment and empennage
7513-3902080 RM
Replacement (removal) of movable and immovable door windows is realized in the following way:
- take off door, having unwrenched bolts 4 (figure 15.22), fastening it to the loop and put it onto lazy
board for avoidance of lacquer coating damage and confort of further operations performing (all operations can
be performed without door removal);
15-16
Cab, cab equipment and empennage
7513-3902080 RM
- take off the inner door handle 21 and handle of lock drive 5, having unwrenched bolts 6 (figure 15.23);
- take off lining 23 holders and dutchman 22;
- take off the holder of door window frame 14, having unwrenched screws 13;
- take off movable window 16 with frame 12 and packing 17;
- take off immovable window with packing 11;
- replace windows;
- assemble the door in reverse order.
After assemblage the movable window should smoothly without jam opens and closes, and compactors
of door windows are abutted without gaps to the windows .
Replace the lock drive and door lock in the following way :
- take off door handle21 and handle of lock drive 5, having unwrenched screws 6;
- take off the lining 23 holders and dutchman 22 (figure 15.23);
- unscrew screw 20 and take off lock 19;
- unscrew the stud of handle 10fastening and take off external handle 4;
- unscrew screws 7 and take off the door lock drive 8 with link 9;
-replace the lock and install it in reverse order.
Operator’s seat – cushioned, with devices of height seat control, lengthwise movement, turning and
back fixation (figure 15.24).
15-17
Cab, cab equipment and empennage
7513-3902080 RM
Replacement of cab heater, windshield wiper and windshield washer is realized analogously as on the
trucks BELAZ-75131, BELAZ-75132.
15-18
Frame and body
7513-3902080 RM
Frames used on dump trucks and bodies of a welded construction are characterized by tall longevity at
operation in the close conditions of maintenance.
For security long and a fault-free operation of the basic bearing components of a construction of a dump
truck observe service regulations. Do not suppose overload of the dump truck. While in service a dump truck
periodically inspect availability index of product of a frame and a body.
Imperfections detected at checks (cracks, holes, dog-legs) frames and bodies in due time eliminate.
The frame manufactured of high-strength low-alloy steel 10ХСНД with the following mechanical proper-
0
ties: a ultimate strength σВ = 540 МPа, a yield stress σТ = 400 МPа, impact strength at a minus 70 С not less
2
аН = 30 N.m/sm .
The body manufactured of high-strength, antiwear alloyed steel 18ХГНМФР with the following mechani-
cal properties: a ultimate strength σВ = 1100 МPа, a yield stress σТ = 1000 МPа, impact strength at a minus
40 0С not less аН = 30 N.m/sm2.
Both steel quality are characterized by good weld ability any kinds of a welding.
For deriving a qualitative welded connection at repair quality of used electrodes and preparation of a
surface to a welding has the important value. With this purpose apply electrodes such as Э-46А or Э50А. Ap-
plication of these electrodes allows to provide a necessary ultimate strength of a weld seam (a ultimate
strength should be not lower σВ = 420 МPа).
Electrodes should be stored in a dry heated location with temperature not below plus 16 0С and a rela-
tive humidity of air no more than 60 %. Directly ahead of use electrodes should be calcinated on a condition
specified on packaging.
Before calcination to test rods of electrodes on absence of a rust by collapse of a coverage on 1 –2 elec-
trodes of each brand. Presence of a rust is not supposed.
To transport the calcinated electrodes to a work station and to store them in carefully closed container,
guarding against moistening and pollution.
16-1
Frame and body
7513-3902080 RM
Figure 16.1 – Location of the most loaded sections of a frame of dump trucks BELAZ-75131, BELAZ-75132
(are shown by arrows):
1 – first cross bar; 2 – second cross bar; 3, 7 – spars; 4 – fourth cross bar; 5 – rear cross bar; 6 – third cross bar
Figure 16.2 – Location of the most loaded sections of a frame of dump trucks BELAZ-7514-10, BELAZ-75145
(are shown by arrows):
1 – first cross bar; 2 – second cross bar; 3, 7 – spars; 4 – fourth cross bar; 5 – rear cross bar; 6 – third cross bar
16-2
Frame and body
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Figure 16.3 – Location of the most loaded sections of a body of dump trucks BELAZ-75131, BELAZ-75132
(are shown by arrows)
16-3
Frame and body
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Figure 16.4 – Location of the most loaded sections of a body of dump trucks BELAZ-7514-10, BELAZ-75145
(are shown by arrows)
16-4
Frame and body
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– precisely to define an occurrence of cracks. At a development of cracks on parent metal in both ends
bore viaholes in diameter of 6 – 8 mm;
– to prepare a crack under a welding for what to delete from a zone of a crack metal with simultaneous
shaping a facet, having provided an angle of disclosing of 30 – 45 grades, obtunding of crimps of 0 – 2 mm,
and a spacing between crimps of 2 – 6 mm. Removal of metal to manufacture on all length of a crack , using
for this purpose arc-air cutting (melting-down of parent metal by a coal electrode and a blowing its jet of com-
pressed air). Application of oxygen cutting is possible, however it is less efficient and has wider heat-affected
zone. With the help polishing machine to manufacture a square-wave stripping of crimps, to clear of slag and
sparks places of a welding. At presence on sections of repair of colour and lubrication to burn their paring knife
and to smooth out a metal sweeper or polishing machine.
Operation of clearing of a surface from pollution is obligatory, otherwise it is impossible to receive the
qualitative welded connection safely working in conditions of reversal loads.
16-5
Frame and body
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Figure 16.9
ATTENTION:
1 AT THE INCREASED WIDTH OF THE ELECTRODE OSCILLATION THE AXLE OF THE CONCAVE CAMBER
THAT RESULT IN THE INSUFFICIENT FUSION OF THE RADICAL IS GAINED.
2 AT SMALL WIDTH OF THE ELECTRODE OSCILLATION THE AXLE OF THE CONVEX CAMBER THAT RE-
SULTS IN THE INCOMPLETE FUSION AT THE GASKET OF THE FOLLOWING STRATUM ON BOTH EDGES OF THE
AXLE IS GAINED.
Graphic representations of the specified welds are reduced in Figures 16.10 and 16.11.
Figure16.12
16-6
Frame and body
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Figure 16.15
Figure 16.16
16-7
Frame and body
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Figure16.17
At welding up of a defective section blanking of adjoining sections of parent metal should be provided.
After welding up of cracks and reparations of imperfections from slag and metal sparks should be
smoothed out as heat-affected zone.
For a reinforcement of repair places if necessary, it is recommended to weld on additional mouldings and
ribs. Thus, for prevention of the further collapse it is necessary to be guided by the following rules:
– terminations of ribs are necessary for issuing a gradient junction to the basic part (Figure 16.18). Tran-
sition sections are expedient for treating at polishing machine;
Figure16.18
– mouldings on spars and cross bars of frame and body should have a waste in the shape «dovetail » or
not rectilinear shape, instead of are cut off across. The welding across a staging and side members of spars
(Figure 16.19) is not supposed;
Figure16.19
– the moulding should fit to a reinforced detail densely. The welding welds should be smooth
("stretched"), without interruptions, are treated at polishing machine with a gradient junction to the basic part.
After repair and heat-affected zone it is necessary to paint weld seams colour.
16-8
Frame and body
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16-9
Frame and body
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Figure 16.21 – Body removal and setting scheme of the dump trucks BELAZ-75131, BELAZ-75132
Figure 16.22 – Body removal and setting scheme of the dump trucks BELAZ -7514-10, BELAZ-75145
The mass of frames and bodies of dump trucks is specified in Table 16.1.
16-10
Frame and body
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16-11
Frame and body
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16-12
Fire-fighting System
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17 FIRE-FIGHTING SYSTEM
17-1
Fire-fighting System
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17-2
Fire-fighting System
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Table 17.1 — Possible faults in the fire-fighting system, their causes and remedy
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17-4
Fire-fighting System
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17-5
Fire-fighting System
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– to check powder line tank for availability of extinguishing powder. If necessary to fill in tank with pow-
der through filling neck. Powder should in no case feature lumps exceeding 2 mm to avoid clogging up of pow-
der line channels;
– to check solution line tank for availability of calcium chloride solution. To check solution consistency
which should comply with consistency stated in table 17.3. If necessary to fill in tank with solution through any
opening in the tank. Solution should feature no mechanical particles exceeding 2 mm.
17-6
Running in of Dump Trucks after Repairs
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In the initial period after repairing dump truck, surfaces of repaired assemblies coming into friction need
time for grinding-in and lubrication modes should get to standard. Good grinding-in of part faces ensures reli-
ability and handsome life service of assemblies and systems.
After mid-life repair one is to run in loaded dump truck for not less than 50 km.
Following restrictions are being imposed for the running-in period:
– maximum traveling speed is not to exceed 35 km/h;
– dump truck is to be operated on roads with hard pavement;
– dump truck payload is to make up 75% from rated load.
Before running in of dump truck after repairs are over it is required:
– to check by external examination operating condition of dump truck, paying special attention to tighten-
ing of all outer threaded joints (fastening of diesel alternator, wheels, suspension parts and assemblies, steer-
ing, braking systems, U-joint shaft, power take-off box and electric plants);
– to check oil level in the engine, in oil tank for combined hydraulic system, in motor wheel reduction
gears, power take-off box, to check fuel availability in the fuel tank, coolant availability in the engine cooling
system, availability of viscous lubrication on friction units;
– to check intactness and functioning of supervision gauges, pilot lights, lighting system, warning lights,
acoustic warning system;
– to check adjustment of fuel supply drive. Drive adjustment should allow maximum and minimum rota-
tion speed of engine in idling mode (ventilator is off). Checking-up is to be effected in recommended engine
operating temperature modes;
– to check intactness of power supply system for low-voltage installations. Hand in voltage indicator if
-1
engine rotation speed makes up 800 min and higher, should reside in green area (26 – 28,5 V). If indicator
hand is in red or yellow areas while engine is running, this points to malfunctioning of power supply system;
– to check on the spot steering system operation by turning steerable wheels both ways from one out-
ermost position into the other;
– traveling at speed of up to 5 km/h to do two turns from one outmost position into the other. Hydraulic
system should ensure smooth, jerk and vibration free turning of steerable wheels. Minimum turning radius ac-
cording to the track of front outer wheel should comply with data stated in technical specification;
– to do not less than three series of vehicle pull ups applying electro-dynamic, service brakes and mov-
ing backwards in the following succession:
– traveling at speed of 35 – 40 km/h to decelerate dump truck up to speed of 10 km/h applying electro-
dynamic brake;
– to pull up dump truck applying service brake;
– to engage reversing and to move backwards for not less than 20 m;
– to bring dump truck to full stop;
– to accelerate dump truck up to speed of 35 – 40 km/h after full stop;
– to check functioning of service brake system by braking up empty dump truck going straightforward
from initial speed of 20 – 25 km/h. Service brake system should ensure simultaneous braking of all wheels
without skidding effect. Checking-up of steering system, service and electro-dynamic brake systems on the
move is performed on even horizontal area featuring hard dry paving without any dents and slopes. Area di-
mensions should ensure safety of the whole procedure;
– to check performance of parking brake system. Parking brake system should ensure dump truck im-
mobility at grade of 16%;
– to check performance of dumping mechanism by raising empty body twice or thrice and by interlocking
it in raised position once. Unloading mechanism should ensure smooth jerk- and jamming free raising and low-
ering of body and its locking in any intermediate position. At the end of body raising a pilot lamp should turn
ON thus warning about emergency level of oil in steering tank. Spontaneous body lowering at speed of
0,01 m/min is allowed when switch is positioned at “neutral”;
– to check all hydraulic systems for leakage. Spraying-out or leaking of lubricant, oil, fuel, braking fluid,
coolant or gas out of any unit, assembly or through joints is not allowed. Oily spots and single drops not sub-
ject to dripping down at gland seals on reduction gears, on upper sealing of suspension cylinder sealing and
on breathers are not a defective feature.
18-1
Running in of Dump Trucks after Repairs
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18-2
Operation materials
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19 OPERATION MATERIALS
At maintenance of dump trucks to apply only recommended brands of operation materials which quality
should prove to be true the deed.
19.1 Lubricant
The lubrication diagram of dump trucks BELAZ-75131, BELAZ-75132 is reduced in Figure 19.1, the list
of used greases in Table 19.1, a lubrication diagram of dump trucks BELAZ-7514-10,
BELAZ-75145 It is reduced in Figure 19.2, the list of used greases in Table 19.2, the list of equivalent
brands of oils in Table 19.3.
Doubling greases (substitutes) are authorized to be applied only at absence of the basic brands.
At transition to other brands of greases former should be deleted completely. Commixing of different
brands of greases is not supposed.
Before a filling of oil in capacity to clear fuses of a dust and muds. A filling of aggregates to manufacture
from oil-dispensing columns. A used oil to merge from warmed-upaggregates. After an oil drain to clear mag-
nets of drain plugs.
At each disassembly штекерных joints of their pad it is recommended to grease only with lubricant
Литол-24 as at smearing by other lubrications it is not ensured required current distributor. Lubricant is plotted
by a thin stratum on a metal part of the plug pads.
19-1
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.1
о
Ftont wheels of hubs bear- Above minus 40 С Lubricant Литол-24 The order of a filling look in
ings о
Above minus 50 С Lubricant Лита the head « Running gear
1 о
2 7 kg (front axle)
Above minus 40 С Substitude:
Фиол-2
о
Suspension cylinder of Above minus 40 С Lubricant Литол-24 To grease through greasers
__ spherical bearings 8 1,12 kg up to an exit of lubrication
о
Above minus 50 С Lubricant Лита from pressure-relief valves
о
The central hinges of a Above minus 40 С Lubricant Литол-24 To grease through greasers
suspender of a front axle о
Above minus 50 С Lubricant Лита up to an exit of fresh lubrica-
__ 2 0,3 kg
and a rear axle tion from under compres-
sions
Hinges joint of cardan shaft Lubricant №158М To grease through greasers
of the drive gear of pumps up to an exit of fresh lubrica-
12 2 0,08 kg
of an integrated hydraulic tion from under sealings
system
о
Sline joint of cardan shaft Above minus 40 С Lubricant Литол-24 To grease through a greaser
of the drive gear of pumps up to an exit of lubrication
of an integrated hydraulic о from a bore in stub
11 Above minus 50 С Lubricant Лита 1 0,03 kg
system
о
Above minus 40 С Substitude: Фиол-2
19-2
Operation materials
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amount lubri-
cation point
positions in
figure 19.1
19-3
Operation materials
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amount lubri-
cation point
positions in
figure 19.1
о
Cock of the cab heater Above minus 40 С Lubricant Литол-24 To grease preliminary having
о cleaned (autumn)
__ Above minus 50 С Lubricant Лита 1 0,002 kg
о
Above minus 40 С Substitude: Фиол-2
о
Lock of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
__ Above minus 50 С Lubricant Лита 2 0,01 kg
о
Above minus 40 С Substitude: Фиол-2
о
Hinges axle of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
__ Above minus 50 С Lubricant Лита 6 0,09 kg
о
Above minus 40 С Substitude: Фиол-2
о
Lock drive of the cab door Above minus 40 С Lubricant Литол-24 To grease at repair
о
__ Above minus 50 С Lubricant Лита 2 0,02 kg
о
Above minus 40 С Substitude: Фиол-2
о
Racetracks of the gear of Above minus 40 С Lubricant Литол-24 To grease at repair
conveyance of the driver- о
__ Above minus 50 С Lubricant Лита 2 0,006 kg
seat
о
Above minus 40 С Substitude: Фиол-2
о
Pneumatic starter bearings Above minus 40 С Lubricant Литол-24 To grease at repair
о
__ Above minus 50 С Lubricant Лита 6 0,12 kg
о
Above minus 40 С Substitude: Фиол-2
19-4
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.2
о
Rear wheels hubs bear- Above minus 40 С Lubricant Литол-24 The order of a filling look in
ings о the head « Running gear
3 Above minus 50 С Lubricant Лита 2 7 kg
(front axle) »
о
Above minus 40 С Substitude: Фиол-2
о
Spherical bearings of sus- Above minus 40 С Lubricant Литол-24 To grease through greasers
__ pension cylinder о 8 1,12 kg up to an exit of lubrication
Above minus 50 С Lubricant Лита
from pressure-relief valves
19-5
Operation materials
7513-3902080 RM
amount lubri-
cation point
positions in
figure 19.2
о
The hinge of an eyelet of Above minus 40 С Lubricant Литол-24 To grease through a greaser
6 the central bar of a rear о 1 0,15 kg up to an exit of fresh lubrica-
Above minus 50 С Lubricant Лита
suspension tion from under sealings
Hinges of cardan shaft of Lubricant №158М To grease through greasers up
5 the drive gear box of a 2 0,08 kg to an exit of lubrication from
power takeoff under compression
о
Slotted joint of cardan shaft Above minus 40 С Lubricant Литол-24 To grease through greasers up
of the drive gear box of a о to an exit of lubrication from
5 Above minus 50 С Lubricant Лита 1 0,03 kg
power takeoff stub hole
о
Above minus 40 С Substitude: Фиол-2
Hinges of a transversal rod Above minus 40оС Lubricant Литол-24 To grease through a greaser
10 of a suspender of a rear о 2 0,24 kg up to an exit of fresh lubrica-
axle Above minus 50 С Lubricant Лита tion from under sealings
о
Steering link hinges Above minus 40 С Lubricant Литол-24 To grease through greasers up
о to an exit of lubrication from
4 Above minus 50 С Lubricant Лита 2 0,1 kg under compression
о
Above minus 40 С Substitude: Фиол-2
Steering hydraulic cylinder Above minus 40оС Lubricant Литол-24 To grease through greasers up
of steering о to an exit of lubrication from
2 Above minus 50 С Lubricant Лита 4 0,2 kg under compression
о
Above minus 40 С Substitude: Фиол-2
о
Barrels of spindle pins Above minus 40 С Lubricant Литол-24 To grease through greasers
15 о
4 1,2 kg up to a floturning of lubrica-
Above minus 50 С Lubricant Лита tion from pressure-relief
valves
о
Bearing parts of cylinders Above minus 40 С Lubricant Литол-24 To grease through greasers
of dumping mechanism о up to an exit of lubrication
11 Above minus 50 С Lubricant Лита 4 0,22 kg from spacings
о
Above minus 40 С Substitude: Фиол-2
Shafts of end support bear- Above minus 40оС Lubricant Литол-24 To grease through greasers
ings of body о up to an exit of lubrication
8 Above minus 50 С Lubricant Лита 2 0,12 kg from spacings
о
Above minus 40 С Substitude: Фиол-2
Bearings of the electromo- Lubricant Литол-24 To grease through greasers
__ tor of the cooling fan of 2 0,03 kg
brake setting
Pull pads and connective Lubricant Литол-24 To grease metal surfaces with
panels of wires of a low- a thin stratum at everyone re-
__ voltage electrical equip- 20 0,04 kg pair
ment
о
Clips of accumulator bat- Above minus 40 С Lubricant Литол-24 To grease with a thin stratum
teries о at setting batteries
__ Above minus 50 С Lubricant Лита 4 0,12 kg
о
Above minus 40 С Substitude: Фиол-2
Traction alternator bear- Lubricant Литол-24 At repair to put in pawn I skin
14 1
ings СГД 89/38-8 lubricant
Traction alternator bear- Lubricant Литол-24 At repair to put in pawn I skin
14 2
ings СГД2 89/38-8 lubricant
Traction alternator bear- Lubricant Литол-24 At repair to put in pawn I skin
14 1
ings ГСН-500 lubricant
о
Traction engine bearings Above minus 40 С Lubricant Литол-24 At repair to put in pawn I skin
ДК 722Д о lubricant
__ Above minus 50 С Lubricant Лита 4 1 kg
о
Above minus 40 С Substitude: Фиол-2
о
Running and breack con- Above minus 40 С Lubricant Литол-24 At repair to put in pawn I skin
trollers bearings lubricant
__ 0,04 kg Lubricant Лита 4
о
Above minus 40 С Substitude: Фиол-2
19-6
Operation materials
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amount lubri-
cation point
positions in
figure 19.2
19-7
Operation materials
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19.2 Fuel
Fuel is applied to the engine in accordance with GOST 305-82 following marks:
- Л-40 (summer) - at temperature of ambient air 0 0С and is higher;
- 3-35 (winter) - at temperature of ambient air the minus 20 0С and is higher;
- 3-45 (winter) - at temperature of ambient air the minus 35 0С and is higher;
- A (arctic) - at temperature a minus 50 0С also it above agrees recommendations of a maintenance
manual of the engine.
19-8
Operation materials
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19.5 Nitrogen
Nitrogen gaseous engineering (GOST 9293-74) is applied for cylinders charging of a suspender and
pneumohydraulic accumulators of a working braking system and steering. Gaseous engineering nitrogen is de-
livered in steel seamless cylinders under pressure (15 + 0,5) МPа. Bulbs coloured in black color, on the upper
part of a bulb the inscription "Nitrogen" of yellow color is put.
19-9
Operation materials
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19-10
Appendix
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APPENDIX А
(reference)
Assembly protocol of engine КТА 38С (КТА 50С) with alternator ГС-525
1. Engine dimensions
1.1 Size of crankshaft axial movement (backlash) С __________________
1.2 Size А1 __________________
2. Alternator dimensions
2.1 Size of shaft axial movement (backlash) Е __________________
2.2 Size Г1 __________________
2.3 Size Гпр __________________
2.4 Size of rotor adapter К __________________
2.5 Size of fan wheel М __________________
2.6 Size for selection of gaskets Р __________________
2.7 Number of alternator adjusting gaskets
S=2 mm __________________
S=0,5 mm __________________
2.8 Size F __________________
2.9 Size В __________________
3. Assembly
3.1 Size П __________________
3.2 Number of engine adjusting gaskets
S=0,3 mm __________________
S=0,1 mm __________________
4. Results of assembly correctness check-up
4.1 Axial movement of crankshaft of diesel generator __________________
4.2 Radial runout of alternator rotor adapter __________________
4.3 Conclusion __________________________________________________________
________________________________________________________________________
________________________________________________________________________
Executor _______________________
Name, signature
Supervisor _________________________
Name, signature
20-1
Appendix
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APPENDIX B
(reference)
20-2
Appendix
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20-3
Appendix
7513-3902080 RM
APPENDIX C
(reference)
20-4
Appendix
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20-5
Appendix
7513-3902080 RM
20-6