7513-3902080 RM 28 04

OJSC “BELAZ” – MANAGEMENT COMPANY OF HOLDING
“BELAZ–HOLDING”
OPEN-CAST MINING DUMP TRUCKS

Of BELAZ-7513 series
BELAZ-7513, BELAZ-75135, BELAZ-75131,
BELAZ-75139, BELAZ-75137, BELAZ-7513А,
BELAZ-7513В
REPAIR MANUAL
7513-3902080 RM
REPUBLIC OF BELARUS
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28.04.2017
Manual is intended for drivers, technicians, and all persons operating and maintaining
dump trucks BELAZ.
Manufacturer is constantly busy on modernization of design of trucks and re-

serves the right for changes improving quality and increasing service life.
The most comprehensive information on all the modifications can be found at
the site of OJSC “BELAZ” – Management Company of Holding “BELAZ–HOLDING”
www.belaz.by
Please, send any comments regarding the design and operation of the dump
truck to the address: OJSC “BELAZ” – Management Company of Holding “BELAZ–
HOLDING”, General Design Engineer’s Office, 40 Let Oktyabrya Str., 4 Zhodino,
Minsk Region 222160, Republic of Belarus.
OJSC “BELAZ” – Management Company of Holding “BELAZ–HOLDING”
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CONTENTS
1 GENERAL ..................................................................................................................................................................................1-1
2 TECHNICAL SPECIFICATION OF DUMP TRUCKS ..................................................................................................................2-1
3 GENERAL INSTRUCTIONS AT REPAIRING .............................................................................................................................3-1
3.1 Disassembling .....................................................................................................................................................................3-1
3.2 Fault detection .....................................................................................................................................................................3-1
3.3 Assembling ..........................................................................................................................................................................3-2
4 SAFETY PRECAUTIONS AND FIRE-PREVENTION REQUIREMENTS WHEN REPAIRING THE DUMP TRUCK....................4-1
4.1 Safety Precautions ...............................................................................................................................................................4-1
4.2 Fire safety requirements ......................................................................................................................................................4-3
4.3 Safety precautions and warnings when performing welding operations ................................................................................4-3
5 ENGINE SYSTEMS ....................................................................................................................................................................5-1
5.1 Removal and mounting of the diesel generator ....................................................................................................................5-1
5.2 Connection of the engine KTA 38С (KTA 50C) with the traction generator of ГС525 type ....................................................5-3
5.3 Connection of the engine QSK45 with generator GTA22 (dump trucks with traction electric drive GE150AC
of “General Electric” Company..............................................................................................................................................5-6
5.4 Connection of the engine MTU with traction generator of single support type.......................................................................5-7
5.5 Repair and service of the cooling system ...............................................................................................................................5-11
5.6 Repair of the engine pneumatic starter system ....................................................................................................................5-14
5.7 Engine preheater troubleshooting ........................................................................................................................................5-14
6 TRACTION ELECTRIC DRIVE ...................................................................................................................................................6-1
6.1 General data on traction electric drive ..................................................................................................................................6-1
6.2 Description and operation of electric drive components........................................................................................................6-2
6.2.1 Electric machines .........................................................................................................................................................6-2
6.2.2 Electric apparatuses .....................................................................................................................................................6-3
6.2.3 System of fanning and cooling of traction electric drive .................................................................................................6-11
6.3 Repair of electric machines and apparatuses of traction electric drive ..................................................................................6-13
6.3.1 Repair of electric machines...........................................................................................................................................6-13
6.3.2 Ремонт аппаратов тягового электропривода ............................................................................................................6-19
7 ELECTROMOTOR-WHEEL ........................................................................................................................................................7-1
7.1 General information .............................................................................................................................................................7-1
7.2 Removal of electromotor-wheels ..........................................................................................................................................7-2
7.3 Disassembly of reduction gear .............................................................................................................................................7-4
7.4 Checking of the technical state of parts of motor-wheel reduction gear ................................................................................7-9
7.5 Assemblage of motor-wheel .................................................................................................................................................7-11
7.6 Running-in of the motor-wheel reduction gear ......................................................................................................................7-16
8 RUNNING GEAR ........................................................................................................................................................................8-1
8.1 Suspension ..........................................................................................................................................................................8-1
8.1.1 General data.................................................................................................................................................................8-1
8.1.2 Suspension cylinders troubleshooting ...........................................................................................................................8-6
8.1.3 Safety precautions at removal, repair and mounting of suspension cylinders on dump truck.........................................8-6
8.1.4 Removal of suspension cylinders from dump truck .......................................................................................................8-7
8.1.5 Disassembly of suspension cylinders............................................................................................................................8-8
8.1.6 Disassembly of central hinges of front and rear suspension..........................................................................................8-10
8.1.7 Removal and disassembly of transversal rods of front and rear suspension .................................................................8-12
8.1.8 Check– up of technical condition of suspension parts ...................................................................................................8-12
8.1.9 Assembly of suspension cylinders ................................................................................................................................8-16
8.1.10 Mounting of suspension cylinders on dump truck ........................................................................................................8-22
8.1.11 Assembly of central hinges of front and rear suspension ............................................................................................8-23
8.1.12 Assembly and mounting of transversal rods of front and rear suspension ...................................................................8-24
8.2 Front axle.............................................................................................................................................................................8-26
8.2.1 General information ......................................................................................................................................................8-26
8.2.2 Removal of front axle ....................................................................................................................................................8-26
8.2.3 Disassembly of front axle ..............................................................................................................................................8-27
8.2.4 Check-up of technical condition of front axle parts ........................................................................................................8-32
8.2.5 Assembly and mounting of front axle ............................................................................................................................8-33
8.3 Wheels and tires ..................................................................................................................................................................8-35
8.3.1 Removal of wheels from hubs.......................................................................................................................................8-35
8.3.2 Disassembly and assembly of wheels...........................................................................................................................8-37
8.3.3 Mounting of wheels on hubs .........................................................................................................................................8-40
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9 STEERING ................................................................................................................................................................................. 9-1

9.1 General information............................................................................................................................................................. 9-1
9.2 Possible failures of steering ................................................................................................................................................ 9-1
9.3 Removal of units of steering from dump truck...................................................................................................................... 9-3
9.3.1 Removal of steering column......................................................................................................................................... 9-3
9.3.2 Removal of steering gear ............................................................................................................................................. 9-4
9.3.3 Removal of flow amplifier ............................................................................................................................................. 9-4
9.3.4 Removal of collector .................................................................................................................................................... 9-4
9.3.5 Removal of filter ........................................................................................................................................................... 9-4
9.3.6 Removal of hydraulic cylinders of steering cylinder and pull-rod of steering trapezoid .................................................. 9-4
9.4 Disassembly of units of steering .......................................................................................................................................... 9-5
9.4.1 Disassembly of column of steering............................................................................................................................... 9-5
9.4.2 Disassembly of propeller shaft of steering.................................................................................................................... 9-6
9.4.3 Disassembly of batcher................................................................................................................................................ 9-7
9.4.4 Disassembly of flow amplifier ....................................................................................................................................... 9-8
9.4.5 Disassembly of collector .............................................................................................................................................. 9-12
9.4.6 Disassembly of the filter ............................................................................................................................................... 9-12
9.4.7 Disassembly of hydraulic steering cylinder ................................................................................................................... 9-13
9.4.8 Disassembly of pull-rod of steering trapezoid ............................................................................................................... 9-13
9.5 Inspection of technical condition of parts ............................................................................................................................. 9-14
9.6 Assembly of steering system units ...................................................................................................................................... 9-14
9.6.1 Assembly of steering column ....................................................................................................................................... 9-14
9.6.2 Assembly of propeller shaft of steering ........................................................................................................................ 9-16
9.6.3 Assembly of batcher .................................................................................................................................................... 9-16
9.6.4 Assembly of flow amplifier............................................................................................................................................ 9-17
9.6.5 Assembly of collector ................................................................................................................................................... 9-18
9.6.6 Assembly of the filter ................................................................................................................................................... 9-18
9.6.7 Assembly of hydraulic steering cylinder ....................................................................................................................... 9-18
9.6.8 Assembly of pull-rod of steering trapezoid ................................................................................................................... 9-19
9.7 Mounting of units of steering on dump truck ........................................................................................................................ 9-19
9.7.1 Mounting of column of steering with propeller shaft ...................................................................................................... 9-19
9.7.2 Mounting of batcher ..................................................................................................................................................... 9-20
9.7.3 Mounting of flow amplifier ............................................................................................................................................ 9-20
9.7.4 Mounting of collector.................................................................................................................................................... 9-20
9.7.5 Mounting of filter .......................................................................................................................................................... 9-20
9.7.6 Mounting of hydraulic steering cylinder and pull-rod of steering trapezoid .................................................................... 9-20
10 BRAKE SYSTEMS................................................................................................................................................................... 10-1
10.1 General information........................................................................................................................................................... 10-1
10.1.1 Service brake system................................................................................................................................................. 10-1
10.1.2 Parking Brake System ............................................................................................................................................... 10-2
10.2 Possible troubles of brake systems and methods of their removal ..................................................................................... 10-4
10.3 Repairing of brake systems ............................................................................................................................................... 10-4
10.3.1 Repairing of brake gears of front wheels .................................................................................................................... 10-4
10.3.2 Repairing of brake gears of rear wheels and parking brake system............................................................................ 10-6
10.3.3 Checking of technical conditions of parts of brake systems ........................................................................................ 10-10
10.3.4 Repairing of gears of the hydraulic actuator of brake systems.................................................................................... 10-11
10.4 Repair of brake gears of rear wheels on dump truck equipped with motor wheels 5GEB23 manufactured
by “General Electric” Company.......................................................................................................................................... 10-17
11 PNEUMATIC SYSTEM ............................................................................................................................................................ 11-1
11.1 General information........................................................................................................................................................... 11-1
11.2 Possible failures of pneumatic system and troubleshooting ............................................................................................... 11-1
11.3 Repairing of devices of pneumatic system......................................................................................................................... 11-2
12 ELECTRICAL EQUIPMENT..................................................................................................................................................... 12-1
12.1 Possible failures of electric equipment............................................................................................................................... 12-1
12.2 Troubleshooting and repairing of power supply system ..................................................................................................... 12-2
12.2.1 Troubleshooting and repairing of storage batteries .................................................................................................... 12-2
12.2.2 Repair and service of the alternator ........................................................................................................................... 12-4
12.3 Repair and service of external and internal illumination system ......................................................................................... 12-4
13 FRAME AND BODY................................................................................................................................................................. 13-1
13.1 Technical condition inspection of frame and body and defects imperfections definition ..................................................... 13-1
13.2 Preparation of frame and body for repair ........................................................................................................................... 13-2
13.3 Frame and body repair ...................................................................................................................................................... 13-3
13.3.1 Down hand welding ................................................................................................................................................... 13-4
13.3.2 Welding in vertical position......................................................................................................................................... 13-5
13.3.3 Welding in horizontal position .................................................................................................................................... 13-5
13.3.4 Welding in overhead position ..................................................................................................................................... 13-5
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13.4 Welding quality control and defects elimination ..................................................................................................................13-6

13.5 Body removal and setting...................................................................................................................................................13-8
14 DUMPING MECHANISM ..........................................................................................................................................................14-1
14.1 General information ...........................................................................................................................................................14-1
14.2 Dumping mechanism troubleshooting ................................................................................................................................14-1
14.3 Dismounting of the dumping mechanism units from dump truck .........................................................................................14-2
14.4 Disassembling of dumping mechanism units ......................................................................................................................14-4
14.4.1 Disassembling the dumping mechanism cylinder ........................................................................................................14-4
14.4.2 Disassembly of hydraulic distributor in the dumping mechanism .................................................................................14-4
14.4.3 Disassembly of dumping mechanism control unit........................................................................................................14-7
14.4.4 Disassembling of pump release automaton ................................................................................................................14-8
14.4.5 Disassembling of double way valve ............................................................................................................................14-9
14.5 Checking up of technical condition of dumping mechanism parts .......................................................................................14-10
14.6 Assembly of dumping mechanism units .............................................................................................................................14-10
14.6.1 Assembling dumping mechanism cylinder ..................................................................................................................14-11
14.6.2 Assembly of hydraulic distributor ................................................................................................................................14-12
14.6.3 Assembly of dumping mechanism control unit ............................................................................................................14-13
14.6.4 Assembly of pump release automaton ........................................................................................................................14-14
14.6.5 Assembling of double way valve .................................................................................................................................14-14
14.7 Mounting of dumping mechanism units onto dump truck ....................................................................................................14-14
14.8 Diagnostics of hydraulic system .........................................................................................................................................14-15
15 CAB, CAB EQUIPMENT AND FENDERING ............................................................................................................................15-1
15.1 General data ......................................................................................................................................................................15-1
15.2 Removing of cab, fendering and its repair ..........................................................................................................................15-2
15.3 Cab equipment repair.........................................................................................................................................................15-7
16 FIRE EXTINGUISHING SYSTEM .............................................................................................................................................16-1
16.1 Technical condition of fire-extinguishing system and trouble shooting ................................................................................16-1
16.2 Possible faults in fire-extinguishing system, reasons and their remedy...............................................................................16-2
16.3 Repair of fire-extinguishing system ....................................................................................................................................16-3
16.3.1 Disassembly of fire-extinguishing system with Remote Actuation of the Powder Line and Rear Axle Protection .........16-3
16.3.2 Repair of fire-extinguishing system units .....................................................................................................................16-4
16.3.3 Assembly of fire-extinguishing system ........................................................................................................................16-5
17 RUNNING IN OF DUMP TRUCKS AFTER REPAIRS ...............................................................................................................17-1
18 OPERATIONAL MATERIALS...................................................................................................................................................18-1
18.1 Fuel ...................................................................................................................................................................................18-1
18.2 Lubricants ..........................................................................................................................................................................18-1
18.3 Cooling Fluid ......................................................................................................................................................................18-2
18.4 Nitrogen .............................................................................................................................................................................18-2
18.5 Commercial Ethyl Alcohol ..................................................................................................................................................18-2
19 APPENDICES ...........................................................................................................................................................................19-1
19.1 APPENDIX А – Assembly protocol of engine КТА 38С (КТА 50С) with alternator ГС-525 (reference) ...............................19-1
19.2 APPENDIX B – Tightening torques of the most responsible threaded connections (reference) ..........................................19-2
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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 of 110 – 136 tones and their modifications, produced by
“BELAZ OJSC – Management Company of BELAZ–HOLDING”.
Manual includes:
– procedure for troubleshooting of units and assemblies mounted into dump truck;
– procedure for dismantling of defective units and assemblies from the vehicle and their disassembly;
– tables stating design and tolerance thresholds 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 new units and assemblies onto dump truck;
– list of activities for integrated testing of the dump truck after repairs;
– list of technical equipment required for servicing and repairing, as well as regulations for their applica-
tion in the process of units and assemblies repair.
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General
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Technical Specification of Dump Trucks
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2 TECHNICAL SPECIFICATION OF DUMP TRUCKS
Overall dimension of dump truck of BELAZ-7513 series are shown in figure 2.1, technical specification of
the dump trucks is given in table 2.1. Look more detailed information in Operation Manuals for corresponding
models.
Figure 2.1 – BELAZ-75131 dump truck. Overall dimensions
Dump trucks are equipped with engines “Cummins” or “MTU”, AC/DC traction electric drive, AC trac-
tion electric drive of “General Electric” GE150AС or of “Electrosila” КТЭ-136.
Table 2.1 – Dump Truck Specification

BELAZ-7513А
BELAZ-7513В
BELAZ-75135
BELAZ-75131
BELAZ-75139
BELAZ-75137
BELAZ-7513
Parameters
Payload capacity, kg:

Equipped with tires 33.00-51, 36/90-51 110000 130000
Equipped with tires 33.00R51 136000
ENGINE
Model
КТTА38-С
Cummins
Cummins
КТА38-С
Cummins
Cummins КТА50–С MTU12V4000
QSK 45
Type Diesel, four-stroke, V-shaped, with electronic control system, gas turbine super charging
and intermediate charged air cooling
TRACTION ELECTRIC DRIVE
AC AC AC AC
Model AC/DC AC/DC AC/DC
GE150AС КТЭ-136 GE150AС КТЭ-136
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Technical Specification of Dump Trucks
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Continuation of table 2.1
BELAZ-7513А
BELAZ-7513В
BELAZ-75135
BELAZ-75131
BELAZ-75139
BELAZ-75137
BELAZ-7513
Parameters
RUNNING GEAR
Frame Welded, made of high-strength steel, side girders of box section are connected by cross-
beams
Front and rear wheels suspension Pneumohydraulic , dependent
Wheels Diskless, with split rims 24.00-51/5,0
Tires Tubeless, pneumatic

Dimensionality of diagonal tires 33.00-51 HC 58 36/90-51 HC 58
tire inflation pressure, MPa 0,61 ± 0,025 0,6 ± 0,025
Dimensionality of radial tires 33.00R51 
tire inflation pressure, MPa 0,725 ± 0,025 “Bridgestone” tires
0,7 ± 0,025 “Belshina” tires
STEERING
Hydraulic drive Hydrovolumetric with two independent circuits
Emergency drive By pneumatic hydroaccumulators
BRAKE SYSTEMS
Service brake system Brake mechanisms are of disk type with automatic clearance adjustment between the linings
and the disk. The drive is hydraulic, separate for front and rear wheels. Power source is the
pump, power storage devices are pneumatic hydroaccumulators
Parking brake system The brake mechanisms are of disk type, constantly closed. Hydraulically controlled spring
drive
Auxiliary brake system Electric braking by traction electric motors in generator mode
Reserve brake system The parking brake system and operable circuit of the service brake system are used
ELETRIC EQUIPMENT
Type of connection Single-wire type, negatives of current sources and consumers are connected to “mass”. Un-
derbonnet lights and portable lamp socket are connected by two wires
Current DC, 24 V
Storage batteries 6СТ-190А, series connection
CAB AND BODY
Cab All-metal, two-seated, hermetic, thermo-and-noise insulated. It meets ROPS requirements. It
is equipped with two sun visors, double-blade electrical windshield wiper, heater-conditioning
unit, windshield washer, hooks and seats. Rear view mirrors are located at both truck sides
Body Welded structure of bucket type, provided with protection visor over cab. Body floor is heated
by exhaust gases. It is equipped with a device for fixing the body in the raised position and
provided with rock ejectors
DUMPING MECHANISM
Type of mechanism Hydraulic
Cylinders Telescopic, three-staged
Pump Axial-piston pump of varying capacity
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3 GENERAL INSTRUCTIONS AT REPAIRING

3.1 Disassembling
Sectors and shops, carrying out repair of dump trucks BELAZ, should be equipped with load-lifting me-
chanisms, pull adaptations and other devices providing an opportunity of removal, disassembling and installa-
tion of any gear and unit on a dump truck, and also their installation on assembling benches and their removal
from assembling benches after testing.
During disassembling and repairing of a dump truck it is recommended to organize three-stage washing
which includes:
– external washing of dump truck before disassembling;
– washing of removed and partly disassembled units and gears;
– washing of parts of disassembled units and gears.
To prevent ingress of moisture to the engine system and to the gears of traction electric drive, the exter-
nal washing of the dump truck should be performed with the gaiters installed on the dump truck.
Disassembling of gears and units which have been removed from a dump truck, is necessary to per-
form on special benches or supports providing the highest possible access to disassembled parts.
At disassembling of the units having transition fit in joint, it is necessary to use removers, mandrels, ac-
commodations, drill drifts and hammers made of copper.
At disassembling of bearing mount assemblies the force at a release of bearings should be applied on a
face-end of an outer ring in case of a release of the bearing from the case and to a butt of an inner race in
case of removal from the shaft.
Parts which have passed combined processing on the factory – manufacturer, are not subjected to can-
nibalization when disassembling.
Besides it is necessary to remember, that any disassembling and assembling of unit or an aggregate
even if it did not expose to repair, results to drop of its operating cycle owing to violation of joints and interposi-
tion of the earned surfaces of mating parts. Therefore, disassembling of aggregates and units is necessary to
perform only in the event that it is caused by emergency after determine the probable cause and method of its
removal. To provide the correctness of assembling and setting of parts on the places it is necessary to provide
cerite-top, marking with a color or drawing of marks on mated parts when disassembling a unit.
WARNING: DO NOT REMOVE AND DISASSEMBLE ELEMENTS OF PNEUMATIC AND HYDRAULIC SYS-
TEMS, WHICH ARE UNDER PRESSURE.
Releasing the pressure in the hydraulic drive is to be performed by loosening the locking needles on the
brake valve as doing in the pneumatic system and pneumatic start-up system by opening valves on the receiv-
ers (three valves), as the shut-off valve on the air pneumatic start-up system tank pnevmostarternogo start to
be opened.
3.2 Fault detection

At fault detection monitoring of parts is carried out first of all an external examination, if necessary - with
application of the measuring tool.
At visual inspection presence of visible damages, such as cracks, holes, breaks, fins, nick, risks,
scratches, sags, twisting, hoggings, color tarnishing, shell, spandings and other damages of mechanical and
corrosive character and deformation of parts must be determined.
For control parts dimension use special measuring tools: caliper gages, depth gages, gear tooth gages,
micrometers, indicating hole gages. Adjustment of the instruments should be performed using standard rings.
If required use special measuring instrument along with the standard instrument. Dimensions of parts should
be controlled in the sections and directions of maximum wear.
Monitoring of threads is made by visual inspection, inspection of interfaces by a part with a suitable
thread or in responsible cases by the threaded impassable gauges.
All cavities of lubricating systems, cooling system, and also the units working under pressure are neces-
sary to be tested on leakproofness before assembling.
Parts and units subjected to balancing, are necessary to balance.
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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 elim-
inate hit of a mud, dust, water, emulsion and abrasives on assembling parts.
The site for the assembly should not be near the place of works, causing over-contamination: near the
welding places, machine tools and particularly grinding machines. Avoid the use of open compressed air - air
streams used to clean parts near the site where the assembly is carried out as a stream of air can carry conta-
minator over several meters.
Before sending for assembly the parts should have no corrosion, dirt and scale; chips and dirt in all dead
openings, pockets and borings are not allowed. The corrosion-resistant coating used at parts storage, should
be removed.
The mated, mounting surfaces and lead-in chamfer should not have dents, nicks, scratches and other
damages.
Oil passages and openings in the parts should be properly cleaned, washed under pressure and blown
through by compressed air. After cleaning, rinse the parts thoroughly in the diesel fuel, or mineral spirits and dry.
Parts of hydraulic devices (casings, sleeves, spool-valves, etc.) after treatment are to be rinsed in the
working fluid. It is not recommended to wipe the parts of hydraulic devices before assembling with rugs in order
to avoid clogging of channels and sticking of spool-valves. After the unit assembly install temporary plastic plugs
into the channels to eliminate the possibility of contamination.
Parts are to be assembled immediately after cleaning, since even a short period of storage in ambient
environment conditions can cause corrosion and deposition of dust suspended in the air on the parts.
During assembling, mated surfaces and technological facets are necessary to smooth out, not disturbing
admissible sizes.
When Installing the parts and components it is allowed to use hammers and key drivers made of non-
ferrous metals and alloys. It is recommended to press-fit bearings on the hydraulic presses with special man-
drels or by mechanical devices.
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 С. Package is moved of only from
0
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.
Special attention during assembly should be paid to alignment and absence of skews
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.
ATTENTION: IT IS STRICTLY FORBIDDEN TO STRIKE ON THE BEARING RING BY THE HAMMER
When mounting bearings on shafts, their heating in oil till 80 – 90 С, for exclusion of closed bearings
0
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). Rubber parts are to be replaced.
Before setting sealing rubber rings, fluoroplastic cups and protective washers are to be washed in the
working fluid. While assembling fittings with rubber seals watch for undercuts, bites and twisting.
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Safety precautions and fire-prevention require-ments when repairing the dump truck
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4 SAFETY PRECAUTIONS AND FIRE-PREVENTION REQUI-

REMENTS WHEN REPAIRING THE DUMP TRUCK
4.1 Safety Precautions
When mounting, operating, servicing and repairing the dump truck, operators and maintenance person-
nel should undergo obligatory training courses for safety engineering, learning safe methods and modes of
work, observance of general safety precautions prescribed for transport vehicles, and to follow the “Unique
safety regulations to be observed in open-cast mining of mineral deposit”, “Safety Precautions for Surface Coal
Mining Applications”, the ’’Operational regulations of consumer’s electric equipment’’, the ’’Safety regulations
of consumer’s electric equipment’’ and the “Rules of arrangement and safe operation of pressurized vessels’’
and “Operating Manual for radial and cross-ply tires designed for mining and industrial application”.
Drivers and service personnel are to be provided with overalls, safety shoes, protective caps, glasses, and
other personal safety means.
Companies using trucks have to provide safety labor conditions, work out directions on maintenance and
repair, stipulated written admission to carry out operations with advanced safety requirements as well as the op-
erations related to servicing the fire-extinguishing system.
Besides, observe also the following requirements conditioned by the design of the dump truck:
4.1.1 Maintenance and repair of dump trucks must be performed by technical personnel familiar with the
dump truck design, rules of its operation, safety and fire precautions.
4.1.2 Towing of defective dump truck should be carried out by special recovery tractor. In case of dump
truck towing when fastening the bumper, it is required to unbrake the parking braking system gear.
4.1.3 Before dump truck servicing and repairing it is necessary not to allow spontaneous dump truck
movement. Parking brake system shall be applied and recoil stops should be laid under wheels.
Servicing and maintenance are to be performed only with the stopped engine, with the exception of
operations on adjustment of traction electric drive, foreseen in Instruction for traction electric drive ad-
justment.
ATTENTION: TRACTION ELECTRIC DRIVE WORKS UNDER LIFE-THREATENING VOLTAGE. NON-
FULFILMENT OF SAFETY REQUIREMENTS MAY CAUSE CURRENT SHOCK OF LETHAL CASE.
4.1.4 Before leaving the cab make sure that the truck is stopped by applying parking brake, and the
reverser switch and electric drive control switch are set to “Off” mode.
4.1.5 At servicing and repairing the dump truck, if raising of a body is required, it is necessary to unload
it and to fix it in the raised position by special rope, the two ends of which should be inserted into ears on axle
case and fixed with towing pivots. Stuck load is allowed, but it should be no more than 3% of payload. Opera-
tions with raised and loaded body stopped with rope with the speed of fair wind of more than 6,5 m/s, are not
allowed.
ATTENTION: STOPPING ROPE IS DESIGNED ONLY FOR STOPPING UNLADEN BODY.
ATTENTION: IF THE BODY IS STOPPED IT IS FORBIDDEN TO LOWER IT APPLYING FORCE.
It is forbidden to stand near the dump truck with the body being lifted in order to avoid injuries with the
load.
It is forbidden to leave the cab at the body being raised and lowered.
It is forbidden to begin operating with raised body.
4.1.6 To secure safety during assembly, adjustment, maintenance and repair works the dump truck is
equipped with ladders, feet boards, banisters and level grades.
When working without guard rails and handrails, use safety belt and pick and place ladders (access
boards) and supports. Thereby safety requirements are to be observed.
4.1.7 When moving along ladders and zones (fenders, bonnets), hold on to handrails available on the
ladders, fenders, bonnets and cab, so that there were constantly three points of support (two hands and one
leg or two legs and one hand). Clean the ladders and working zones of dirt, snow and ice.
Move along ladders always facing the dump truck.
4.1.8 It is prohibited to jump off the truck.
4.1.9 It is prohibited to go up and down the ladder having any instruments or other objects in hands. To
lift and lower instruments and other objects use hoisting devices that secure safety of these operations.
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When performing works from ladders and working zones it is not allowed for servicing personnel to
stand under them.
4.1.10 When use hydraulic jacks, hoists, and also other elevating means to lift the dump truck, it is ne-
cessary 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.
4.1.11 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.
4.1.12 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 and its modifications is made automatically after scheduled shutdown of the engine during 80 s.
4.1.13 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.
4.1.14 Make sure that there is no gas under pressure in suspension cylinders and pneumo-and-hydraulic
accumulators, it is necessary to open charging valves prior to their disassembly. When checking the level of oil
in oil intake of suspension cylinder, control plug should be unscrewed slowly as the gas inside the chamber
may be under the pressure. During this operation do not stand in front of the plug.
4.1.15 Before charging the suspension cylinders and pneumo-and-hydraulic accumulators spaces with
gas, make sure that the charging unit is in good order and that the marking on the compressed gas cylinder is
correct. The gas cylinder must bear a yellow inscription NITROGEN ("A3OT") and should carry a brown circu-
lar marking strip.
ATTENTION: IT IS STRONGLY PROHIBITED TO CHARGE THE SUSPENSION CYLINDERS AND PNEUMO-
HYDRAULIC ACCUMULATORS WITH OXYGEN, AS THIS WILL CAUSE AN EXPLOSION!
4.1.16 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.
ATTENTION: IT IS STRICTLY FORBIDDEN TO DISMANTLE AND MOUNT WHEELS WITH EXCESSIVE AIR
PRESSURE IN THE TIRES.
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.
4.1.17 Open the expansion tank cap of the cooling system only when the engine is cold, since the cooling
fluid in the warmed-up engine is under pressure.
4.1.18 It is necessary to remember, that low-freezing cooling liquid is toxic and may cause poisoning if
the rules of sanitary are violated.
4.1.19 When servicing and repairing a storage batteries remember, that electrolyte, having got on a
body, can cause strong burns.
4.1.20 It is strongly prohibited to make alternation in the design of electrical equipment schemes without
consultations with manufacturer.
4.1.21 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.
4.1.22 It is forbidden to perform repairing, to disassemble an armature, to perform welding jobs in sys-
tem of pneumatic start and the pneumatic system of a dump truck which are under pressure. The pressure re-
lease in system of pneumatic start is made through the valves of condensate drain, thus the shut-off cock on
air vessels should be opened.
4.1.23 Adjustment and operation of system of pneumatic start and pneumatic system with out-of-order
manometers and the broken seals on safety valves are forbidden.
4.1.24 Maintenance of air vessels, manometers, safety valves, armatures (including engineering survey
and repair) should be performed according to the requirements and the orders given in “Rules of Arrangement
and Safe Operation of Pressurized Vessels” (ПБ 10-115-96).
4.1.25 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 forbidden.
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4.2 Fire safety requirements

To avoid fire on the dump truck, observe the general fire requirements in handling inflammables, and al-
so the following requirements:
4.2.1 Check constantly the impermeability of fuel and oil pipelines in the engine system, steering gear,
dumping mechanism and service brake system.
4.2.2 Clean constantly the dump truck from inflammables: leaks of combustive-lubricating materials, coal
dust and elsewhere.
4.2.3 Do not leave the dump truck when the engine starting preheater is operating.
4.2.4 Dump trucks must be equipped with fire extinguishing system. Use combined fire extinguishing
system for fire fighting, previously shutdown the engine.
IT IS FORBIDDEN TO USE SOLUTION LINE FOR A FIRE EXTINGUISHING OF ALIVE ELECTRICAL EQUIP-
MENT AND FUEL AND OIL OVERFLOWS. IT IS FORBIDDEN TO USE A POWDERED LINE IF THERE ARE PEOPLE.
4.2.5 IT IS FORBIDDEN TO OPERATE DUMP TRUCK WITH MALFUNCTIONS OF FIRE FIGHTING SYSTEM
AND FIRE EXTINGUISHERS. MAINTENANCE OF FIRE FIGHTING SYSTEM MUST BE PERFORMED WITH STRICT
OBSERVANCE OF DIRECTIONS GIVEN IN THE PART “FIRE FIGHTING SYSTEM”.
4.2.6 In order to prevent ignition accumulating in the engine cooling system of gases it is forbidden to use
open fire when checking a level of a cooling liquid in the expansion tank.
4.2.7 It is forbidden to use open fire when examining the storage batteries.
4.3 Safety precautions and warnings when performing welding operations

4.3.1 Prior to carry out welding jobs directly at assembled dump truck it is necessary to disconnect sto-
rage batteries, disconnect as positive as negative power cables from batteries terminals.
4.3.2 When carrying out welding jobs in order to avoid fire emergency make sure there are no combus-
tive materials (fuel, oil) near welding site (chassis elements, ground), prevent drop of smelt to flammable parts
(hoses, cables, etc.).
4.3.3 The “ground” wire of the welding unit shall be connected to the part or unit to be welded at the dis-
tance of not more than 0,6 metres from the welding place so that no current would pass through the wires and
cables of the traction electric drive control, payload and fuel consumption control system, video survey system,
cylinders of the hydraulic system and suspension, bearings of the ШСЛ of the central levers and rods, bearings
of the wheel hubs, bearings and toothings of the wheel gearings of the power-wheel reduction gear.
Special attention shall be paid to prevention of passing the current through the bearings in the traction
alter-nator or power-wheel motors, because it would cause their damage and premature failure.
4.3.4 Never fasten the “ground” wire of the welding:
– unit to the hydraulic system components (pumps, hydraulic cylinders, distributors, pipelines, oil tank, etc.);
– on the main units of payload and fuel consumption control system, video survey system.
The connection place shall be cleaned from paint and rust. To provide reliable contact of the “Ground”
cable with the surface to be welded.
4.3.5 When performing welding operations close to electronic units of payload and fuel consumption
control system, video survey system certain units are to be dismantled.
4.3.6 When carrying out welding jobs disconnect switches of control circuits and auxiliary circuits in the
control cabinet. When carrying out welding jobs near electrical wires and cables take measures to prevent
them of damage.
Don’t take out any control boards as well as disconnect sockets of traction electrical drive control system
since this may damage contact and cause system failure.
Welding jobs, tied with power cabinet, are to be performed in presence of specialist on traction electrical
drive; prevent drop of smelt into cabinet.
4.3.7 When carrying out welding jobs at dump truck, equipped with electronic system of the engine con-
trol, observe following rules to avoid damage of electronic parts:
– prior to starting welding disconnect all the sockets, connecting circuits of control, power, alarm system
and engine and dump truck data transfer;
– it is not admitted to fasten “ground” cable to the bracket of the Engine Electronic Module (ECM) or to
the ECM directly;
– if necessary to carry out welding jobs at attached engine units or parts directly mounted on the engine,
these units or parts are to be dismounted;
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If it is impossible to dismount units and parts, then prior to welding disconnect all the sockets connected
to ECM. If there are several ECM disconnect all the modules.
4.3.8 When connecting engine circuits to electrical circuit of dump truck ( as after welding as at dump
truck assembly) observe following directions:
– all the socket, connecting circuits of power, control, alarm system and engine and dump truck data
transfer are to be arranged before storage batteries connection;
– when connecting storage batteries connect negative terminal first and then do positive;
– never set key in the key-lock in working position before storage batteries are connected;
– disconnect sockets connecting circuits of dump truck and the engine (for troubleshooting, for example)
only without of key in the key-lock and when “ground” of dump truck is switched off.
4.3.9 It is forbidden to carry out the welding jobs near to the fuel and oil tanks, charged pneumohydraulic
accumulators and pipelines, connected to them; near gas cylinders of fire fighting system, near suspension cy-
linders charged with gas and filled with oil.
4.3.10 It is forbidden to perform welding jobs in system of pneumostart and the pneumatic system of a
dump truck which are under pressure. The pressure release in pneumatic system of a dump truck is made
through the valves of condensate drain, installed in a receiver.
4.3.11 It is not allowed to perform welding jobs, when hydraulic system pipelines 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 is made automatically after scheduled
shutdown of the engine during 80 s.
4.3.12 When carrying out welding jobs prevent drop of smelt to chrome surfaces of dump truck units
(suspension cylinders, cylinders of hydraulic system, etc).
4.3.13 It is forbidden to carry out the welding jobs at wheel rim, when it is in assembly with tire.
4.3.14 When carrying out welding jobs at the cab equipment take measures to prevent inflammation of
cabin upholstery and noise insulation parts.
4.3.15 Prior to carry out welding jobs near boxes with storage batteries pay special attention to obser-
vance of fire-prevent rules and take necessary precaution measures.
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5 ENGINE SYSTEMS
Service and repair of the engine systems includes removal and mounting of the engine, traction genera-
tor, failed units and systems, as well as outer engine systems. Inspections of malfunctions, repair of the engine
units and systems look in the documentation, supplied with the engine and its systems or do in the manufac-
turer’s web site.
5.1 Removal and mounting of the diesel generator

For the removal of the diesel generator it is necessary:
– place the dump truck on the even horizontal platform, brake it by parking brake system and lay under
all wheels the stops;
– lift the body in the extreme upper position and lock it by special rope, which both ends take into lugs
on the axle housing and fix by tow pivots (Look section “Body” in Operation Manual);
– drain oil, coolant and fuel from systems;
– remove front and rear hoods from dump truck;
– disconnect hoses and pipelines of the engine external systems;
Place tags with marks at all the hoses, pipelines and wire harnesses of electrical equipment as removal
performing; during assembling perform connecting in accordance with marks.
– disconnect and remove the radiators set;
– disconnect and remove pipelines of traction electric drive cooling system from the generator and fan;
– disconnect output wires of the traction generator and remove wire harnesses, cabled over the traction
generator;
– disconnect the cardan shaft from the hub of the fan impeller;
– remove the longitudinal beam and unscrew the attachments of under engine frame to the shock ab-
sorbers;
– disconnect diesel generator from the frame;
– fasten diesel generator behind under engine frame (Figure 5.1), lift by cock and slowly move forward
along dump truck motion and place onto the rest;
Figure 5.1 – Fastening diagram of the dump truckс diesel generator
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Perform mounting of diesel generator on the chassis in reverse sequence.

When mounting the upper part of the vibroinsulators rubber pad should be situated near the dump truck
frame spar. The flatness tolerance of the upper surfaces of four vibroinsulators should not exceed 1,5 mm, it
should be adjusted by gaskets, placed between lower vibroinsulator fittings and bracket of dump truck frame.
Not more than two gaskets are to be placed under one vibroinsulator. The adjustment can be performed by se-
lection of vibroinsulators by height.
In case of the traction generator failure the dismantling can be performed without engine removal.
When mounting the fan impeller set it directing the letter “B” towards to setting point.
Removal and mounting of the traction generator.

For the generator removal it is necessary:
– place the dump truck on the plane horizontal ground, brake it by parking brake system and put under
all wheels supports;
– lift the body in the extreme upper position and lock it by special rope, which both ends take into lugs
on the axle housing and fix by tow pivots;
– disconnect the cardan shaft from the hub of the ventilation wheel;
– disconnect and remove cooling pipes of the traction generator and motor- wheels;
– disconnect power cable from the terminals of the traction generator;
– disconnect and remove pneumatic starter and oil pump from the engine block.
– through hole in the flywheel housing, formed after the pneumatic starter removal, turn off one of adap-
ter fastening bolts of the generator rotor to the flywheel (position 5 figure 5.6);
– with the help of the barring gear, turning the flywheel, turn off rest bolts (12 pieces);
– remove split-pins, turn off nuts and remove bolts 3, connecting the starter adapter and generator
casing;
– turn off bolts fastening generator to the under engine frame;
– with the help of the fastening device lift the generator by the 1 – 5mm and move it behind;
– after having enough gap between generator casing and starter adapter remove generator and place it
onto support ;
– remove rotor adapter from rotor generator, having turned off bolts 7 (18 pieces).
During removal pay attention to the gaskets under generator supports between rotor and rotor adapter,
between flywheel and rotor adapter.
Figure 5.2 – Fastening diagram of the traction generator
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5.2 Connection of the engine KTA 38С (KTA 50C) with the traction generator of
ГС525 type
Lift engine, remove transportation arms and instead of it to install the arms 75125-1001150, fixing their
be eight times bolts S123 3/4" 10UNCx2,5" with spring lock washers. The bolts tightening torque is of
(380±20) N.m. It is supposed to use arms, acting with the engine, together with plates 75125-1001079.
At the lifting and travel the engine and also generator should be in horizontal position.
Install the underframe on the stand. Lower on it engine and bolts with springs and washers. Tighten two
bolts М18-6gх80 with spring washers on the front engine support by torque (280±10) N.m.
Tighten four bolts М20х1,5-6gх60 with plane spring washers on the rear engine arms by torque
(380±10) N.m.
In the case of necessity install under rear engine arms no more than four adjustment gaskets
75145-1001448.
In the engine accompanying documentation should be specified size (С) axial (horizontal) movement of
the engine crank shaft .
It is necessary to check this size. Turn off three bolts strengthening starter to the flywheel casing and
two bolts strengthening starter to the arm. Take off starter and arm supporting starter. Turn off four bolts and
take off oil pump. Turn off the arm of the oil pump and others bolts. Take off the cover opening access to the
crank shaft.
The device, crowded to the crankshaft web move out the engine crankshaft in the end position up to the
stop and hold in this position. In front of the engine where possible near to the crankshaft to install indicator
and expose on the “0”. Then displace the crankshaft in the reverse side up to the stop and holding it to fix the
indicator indices. This is axial(horizontal) movement (backlash) of the engine C crankshaft which must be
С=0,305 – 0,508 mm.
Displace the crankshaft in the extreme front position and install on the former place the engine cover
Install and fasten adapter of the stator 3 (75145-1001102, Figure 5.3) with sixteen bolts 4 (1/2"
13UNCх1,5") with spring washers to the fly-wheel casing of the engine 2, previously having installed four bolts
М16х1,5-6gх75 in the holes of the stator adapter (to two with each side ) near rear engine arms. To fasten six-
teen bolts by torque of (110±5) N.m.
By test ruler measure in fourth points: 3 and 9, 6 and 12 hours of
the clock dial distance between disk face of the elastic coupling (sur-
face Ж) and stator adapter, fixed on the engine (surface И). To find
mean value (Д1+Л).
Determine the size: A1=Д1+Л–1/2C.
Move the generator in the horizontal position. Take off from en-
gine four covers. With the adjustment help to install the front end of the
generator rotor coaxial the stator (around). The shaft generator to move
out in the limit position. The indicator to install in front. near to the gene-
rator axle and install it on the«0». Then move the generator shaft in the
underside to stop and holding it fix value of the indicator. This size (Е)
is the axial (horizontal) movement of the generator shaft.
Е=0,8 – 1,4 mm.
Move the generator shaft in the end rear position. With the help
of the straight edge measure in four points accordingly: 3 and 9, 6 and
12 hours of the clock dial the distance between the generator case 1
(Figure 5.4, surface И1) and the rotor flange 2 (surface Н).
Find an average value. It is size "Г1".
Define size Гпр=Г1–1/2Е.
Measure in the adapter of the rotor 75145-1001104 size "K"
(Figure 5.5) between adjoining surfaces Ж1 and Н1.
Figure 5.3 – Connection of engine with traction alternator engine

1 – engine flywheel; 2 – engine flywheel jacket; 3 – adapter of stator; 4 – bolts
А1, Л, Д1 – sizes; И, Ж – surfaces
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Calculate an amount of adjusting shims 5 (75145-1001428 and 75145-1001429), necessary for deriving
the size "P" between adjoining surfaces Н (look Figure 5.4) and Н1 (look Figure 5.5).
Р=А1+Гпр–M–K.
At setting adjusting shims the size of the typed package should not exceed the size "É", and this va-
riance 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 torque (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).
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".
Define size В1=F+1/2Е.
Obtained size В1 necessarily should be less the size А1. The maximum difference of these sizes
П=А1–В1 should not exceed 1,5mm.
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.
Screw in the adapter of the rotor generator two technological studs in points accordingly 3 and 9 hours
of a hour dial. Move the generator forward along axle.
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
axles. Technological studs should enter the corresponding bores of the disk of an elastic clutch.
Figure 5.4: Figure 5.5:

1 – generator body; 2 – generator shaft; 1 – generator body; 2 – rotor body; 3 – bolt М24х160;
Г1 – size И1, Н – surfaces 4 – generator rotor; 5 – adjustment gaskets;
И1, Ж1, Н1 – flatness; F, К, Р, М – sizes
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Install two technological layer pads of equal width (3 – 5 mm) in points accordingly 3 and 9 hours of a
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 5.3 and 5.5. Tighten four
bolts the torque 10 – 20 N.m, thus displacing the generator in the necessary horizontal direction.
Adjust overlapping generator axles and the engine in a vertical plane, measuring by a probe a spacing
between the case of the generator and the adapter of the stator in points accordingly 6 and 12 hours of the
hour dial and mounting 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.
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.
Remove the lifting tackle of the generator.
Release four fastening bolts in points accordingly 3 and 9 hours of a hour dial and to delete two technol-
ogical layer pads. 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.
Install the bolts fastening the stator adapter to the generator body (16 pieces, four of which are installed
preliminary). Under six bolts to install a visor bracket and to tighten all bolts the torque (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
access cover to turn an engine flywheel through everyone 30 and tin stall bolts М16-6gx70 (12 pieces) with
0
lock washers from two sides of the engine in access cover simultaneously. Mark the first torqued bolt and to
tighten bolts the torque (220±10) N.m.
Tighten four bolts М30x2-6gx70, fastening generator claws to the underframe, the torque
(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 indicator. 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.
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 5.6) of the rotor adapter. Expose the indicator on "zero".
0
The barring gear to turn crankshaft of the Diesel-generator set on 360 , registering an outrun on the indicator.
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-
0
generator set, to turn an engine flywheel on 180 and again to manufacture process of assembly.
Test tightening torque of the bolts fastening the adapter of the stator to the generator body and cotter of
them.
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. Install on the place access covers from two sides of the en-
gine.
Additional indications.
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 torque (44±3) N.m.
Install the starter motor and to fix three basic bolts to the fly-wheel casing of the engine by the torque
(220±10) N.m. Tighten two bolts, fastening the starter motor to the bracket by the torque (44±3) N.m. Connect
the hoses connected to the starter motor, on the former place. Fix oil injected pump on the bracket.
Install four covers on the generator, closing air ports in the generator.
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Figure 5.6 – Diesel-generator assembly:

1 – generator body; 2 – visor bracket; 3, 5 – bolts; 4 – engine fly-
wheel casing; 6 – generator rotor;
F – size of the pads thickness; Т – surface metering of the radial
runout
5.3 Connection of the engine QSK45 with generator GTA22 (dump trucks with
traction electric drive GE150AC of “General Electric” Company
Perform coupling and centering of the engine

QSK45 with generator GTA22 in accordance with men-
tioned earlier centering of the engine КТА 38С with ge-
nerator ГС525 paying attention to further procedures:
– if necessary place adjusting gaskets 7
(figure 5.7) 7513-1001428 (4pcs., as more as possible),
7513-1001429 (3pcs., as more as possible.),
7513-1001446-10 (3pcs., as more as possible),
7513-1001447 (3pcs., as more as possible),
7513-1001448 (1pcs., as more as possible);
– tightening torques for bolts 1 and 5 should be set
from 130 up to 165 N.m., as for bolts fastening rear
brackets to the traction generator tightening torques
should be set from 940 up to 1160 N.m.;
– axial movement of generator rotor 10 should be
set within thresholds of 0,354 – 0,656 mm.
Figure 5.7 – Assembling of diesel-generator:

1, 5 – bolts; 2 – engine flywheel; 3, 7 – adjusting gaskets; 4 – hous-
ing of the engine flywheel; 6 – stator adapter; 8 – generator body;
9 – rotor adapter; 10 – generator rotor
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5.4 Connection of the engine MTU with traction generator of single support type
General requirements.
1. Hit in the engine and the generator of extraneous subjects (bolts, nuts, rags) is not supposed.
2. It is categorically forbidden to leave open internal cavities of the engine without supervision. After all
the necessary operations are finished in the internal cavities, immediately close all the hatches and uncovered
cavities.
3. The mated surfaces on the engine as well as the generator and an underframe are to be carefully
cleaned of lubricants, paint, dirt, burrs.
4. When lifting and moving the engine, as well as the generator should be in the horizontal position.
5. When tightening bolts which fasten the engine with the generator mark the first tightened bolt: make
a mark on a bolt head.
Mounting of the engine.

1. Lift the engine, remove transportation brackets, mount brackets 75302-1001150, having fastened
them by 12 bolts М16-6gx50 (202123) with spring washers. Tightening torque for bolts should be set from
130 up to 165 N.m.
2. Install the underframe onto the stand. Lower the engine onto it and start a screw of bolts with spring
washers.
3. Tighten eight bolts М20-6gx55 (340035) with spring washers with torque of 260 – 320 N.m. on the
front engine support.
4. Tighten four bolts М20-6gx55 (340035) with flat and spring washers with torque of 260 – 320 N.m.
on the rear engine brackets.
5. If when centering the generator rests on the frame install under rear engine brackets no more than
four adjusting gaskets 75145-1001448.
Size of the engine A1.

1. Support documentation contains size of the axial movement of the engine crankshaft (C).
2. Size С should be checked. For that take off the cover, which allows access to the crankshaft.
3. Using appliance, pressed to the crankshaft web move out the engine crankshaft to the extreme posi-
tion up to the stop and hold it in this position. Install indicator in front end of the engine crankshaft as possible
as near to its axis and expose it at “zero”. Then displace the crankshaft in the reverse side up to the stop and
holding it fix the indicator indices. This is axial (horizontal) movement (backlash) (C) of the engine crankshaft; it
should be within thresholds of 0,3 – 0,5 mm.
4. Displace the crankshaft in the extreme front position and install on the former place the engine cover.
5. Set the stator adapter on the engine 75137-1001102 and fasten it by sixteen bolts М12-6gx38
(201543) with spring washers, preliminarily having installed eight bolts
М16x1,5-6gx100 (372662) in the upper part of the engine, and four bolts
M20-6gx55 (340035) close to rear engine brackets (two at each side). Tighten
bolts with torque of 54 – 67 N.m.
6. Using calibrating ruler and depth probe measure in four points: 3 and
9, 6 and 12 hours of the clock dial distance between faces of elastic coupling
disk (surface Ж) and stator adapter, fastened on the engine (surface И, figure
5.8). Determine average value – size (Д1+Л).
7. Define the engine size.
А1=Д1+Л–0,5С;
Where С – axial (horizontal) movement (backlash) (C) of the engine
crankshaft; А1 – is to be measure finally.
Figure 5.8 – Size of the engine А1:

1 – engine flywheel; 2 – housing of the engine flywheel; 3 – stator adapter; 4 – bolts;
А1, Л, Д1 – sizes; И, Ж – surfaces
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Generator size Гпр.

1. Set the generator in the horizontal position. Take off four covers from the generator. Using appliance
set the front end of the generator rotor coaxially to the stator with accuracy of +5 мм. Then move the generator
shaft to the extreme position. Install indicator in front end of the rotor shaft as possible as near to its axis and
expose it at “zero”. Then displace the generator shaft in the reverse side up to the stop and note the obtained
value. This is axial (horizontal) movement (backlash) (Е=0,8 – 1,4 mm) of the generator shaft.
2. Measure backlash (E) of the generator, which shaft after movement should be in free condition (not
pressed by the appliance).
3. Displace the generator shaft to the extreme rear position.
4. By calibrating ruler and depth probe measure in four points: 3 and 9, 6 and 12 hours of the clock dial
distance between generator body surface И1 and rotor flange (surface H) with accuracy of +0,1 mm. Deter-
mine average value – size (Г1) (figure 5.9).
5. Preliminary size of the generator is
Гпр=Г1–0,5Е;
Where Е – axial (horizontal) movement (backlash) mm.
Figure 5.9 – Preliminary size of the generator Гпр:

1 – generator body; 2 – shaft of generator
Г1 – size; И1, Н – surfaces
The size of the generator B1.

1. Measure in the rotor adapter 75137-1001104 size (K) between adjacent surfaces R1 and H1 with ac-
curacy of +0,1 mm (figure 5.10).
2. Calculate the quantity of gaskets 75145-1001428, 75302-1001428, 75145-1001429, 75302-1001429,
75302-1001446 and 75302-1001447 needed to get the size (P) between the adjacent surfaces of H and H1.
P = A1 + Гпр – K,
where K – to be measured, A1 – the engine size in mm, Гпр - preliminary generator size in mm.
When installing the gaskets size of selected package must not exceed the size P and the difference of
sizes should not exceed 0,5 mm.
3. Place the package of gaskets onto the shaft of the generator rotor and press by the adapter. Screw
eighteen bolts M24x2-6gx100 (340925) or M24x2-6gx75 (340931). Gradually and alternately tighten the bolts
with torque of 470 to 580 Nm. Lock bolts by bendable plates which are preliminarily placed under bolts.
4. Using the appliance set the front end of the generator rotor coaxially to the stator with an accuracy of
5 mm.
5. By calibrating ruler and depth probe measure in four points: 3 and 9, 6 and 12 hours of the clock dial
distance between mating surfaces of the generator body (surface И1) and rotor adapter (surface Ж1) with an
accuracy of +0,1 mm. Determine the average value.
This is size (F).
6. Determine the size of the generator.
B1 = F + 0,5 E
where F – finally measured, E – axial movement of the shaft of the generator in mm.
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The resulting generator size B1 should necessarily be smaller

than the engine size A1. The maximum difference between these
sizes.
П = A1–B1 should not exceed 1,5 mm.
7. Determine the quantity of gaskets N, mounted on the engine
flywheel surface Ж. Еhe quantity of gaskets is to be chosen with an
accuracy
N = П + 0,1
where П – the difference between the size of the engine A1 and
generator size B1; +0,1 tolerance to the size П.
Figure 5.10 – Generator Size B1:

1 – bolt, 2 – rotor adapter, 3 – generator housing, 4 – gaskets, 5 – generator
shaft
Installation of the generator.
1. Remove from the engine the covers closing technological hatches, from left and right sides of the
flywheel housing.
2. Screw in two technological studs into the adapter of the generator rotor in points accordingly 3 and 9
hours of clock dial.
3. Move the generator forwards along its axis.
4. Turn the engine flywheel so that two dowels on the elastic disk are opposite to bores for dowels in the
adapter of the generator rotor as bores in the flywheel are opposite to the engine technological hatches.
5. Cautiously shift the generator to the engine as it is possible more precisely having matched their
axes. Technological studs should enter the corresponding bores of the disk of flexible coupling.
6. Install two technological layer shims of equal thickness (3 – 5 mm) in points accordingly 3 and 9 hours
of a clock dial; bolt four bolts from above and from below layer shims from each side between generator body
(surface И1) and stator adapter (surface И), tighten four bolts with torque of 10 – 20 N.m., moving generator to
necessary horizontal direction.
7. Adjust matching of generator and the engine axes in vertical plane, measuring by a probe the gap be-
tween the case of the generator and the adapter of the stator in points accordingly 6 and 12 hours of the clock
dial and mounting adjusting shims under each claw of the generator until the variance in gaps occurs no more
than 0,1 mm. The gap in point of 12 hours should differ in the smaller side, than in point of 6 hours.
8. Bolt but do not tighten, four bolts with flat and spring washers fastening the claws of the generator to
the under-motor frame.
9. Remove the lifting tackle of the generator.
10. Release four fastening bolts in points accordingly 3 and 9 hours of a clock dial and remove two
technological layer shims. Check the gap in the points 6 and 12, which should not be changed when removing
the lifting tackle.
11. Install the rest bolts fastening the generator body to the flywheel housing, tighten the bolts
М16x1,5-6gx100 (372662) with torque of 140 – 170 N.m, tighten bolts М20-6gx55 (340035) with torque of
260 – 320 N.m. The gap П between mating planes should be equal to zero.
12. Remove technological studs. Using shaft rotating device, placed in the technological hatch of the
engine, rotate engine flywheel each 30 and install bolts (12 pces.) М16-6gx70 (340486) with spring washers
0
from both sides of the engine into the technological hatches simultaneously. Mark the first bolt to be tightened
and tighten bolts with torque of 130 – 165 N.m.
13. Tighten four bolts М30x2-6gx105 (340901), fastening generator claws to the under-motor frame with
torque of 940 – 1160 N.m.
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Validation of assembly.
1. Inspection of engine backlash (figure 5.11)
Remove a cover of the engine manhole. Move the crankshaft of the diesel-generator backwards up to
stop. In front of the engine, whenever possible closer to the crankshaft install the indicator and set it on "zero".
Shift the crankshaft forwards up to stop and, holding it fix the reading of the indicator. Compare obtained value
with value mentioned in the attached documentation for the engine and with obtained one as a result of mea-
suring of the size (C). These values of size (C) should coincide with size mentioned in the engine documenta-
tion with the accuracy of ±0,13 mm.
2. Inspection of the generator radial whipping
Fix dial gage over thread М14х1 made in the case of the adapter in a point of 3 or 9 hours of a clock di-
al. Set the indicator leg onto surface Т of the rotor adapter. Expose the indicator on "zero". Using barring gear
0
turn crankshaft of the Diesel-generator by 360 , registering whipping using the indicator.
Preferable value of whipping is of 0,08 mm. The maximum
permissible value of whipping is of 0,13 mm. If value of whipping
exceeds 0,13 mm, it is necessary to perform disassembly of the
0
Diesel-generator, to turn the engine flywheel by 180 and to per-
form assembly again.
3. Test tightening torque of the bolts (372662), fastening the
adapter of the stator to the generator case and splint them.
4. Test tightening torque of the bolts (340486) installed
through engine access covers, fastening the adapter of the gene-
rator rotor to the engine elastic coupling. Install back access cov-
ers from two sides of flywheel housing.
5. Register all the results of assembly measuring in the log-
book for certain dump truck.
Figure 5.11 – Diesel-generator assembly:

1 – flywheel housing; 2, 4 – bolts; 3 – generator case; 5 – generator shaft
П – size of shims thickness;
Т – surface metering of the radial whipping
Additional indications.
1. Check the fastening of hatches, which were re-

moved from the engine during the assembling of diesel-
generator.
2. Install on the generator four covers, closing air ports
in the generator.
Figure 5.12 – Finite-size circuits of diesel-generator

Д1 + Л – 1/2C = F + 1/2Е
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5.5 Repair and service of the cooling system

Index of a normal operation of the engine cooling system is maintenance of temperature of a coolant in
0
nominal limits 70 – 95 . 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 coolant;
– 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 shutters or their drive gear;
– failure of a water pump.
Washing of the cooling system, replacement of a coolant is necessary for carrying out according to the
use specification of the engine and indicatings of a maintenance manual of the dump truck.
Drain of coolant.
To drain coolant quickly and completely from the system, it is necessary to remove plug from the exten-
sion tank of the respective circuit and open valves. After liquid draining to put the plugs into their position and
leave the valves opened. For complete draining of coolant from the cab heater radiator to open both valves on
pressure and drain pipelines.
As practice shows after coolant draining from the engine through the all above mentioned valves, full
drain from the upper part of thermostat boxes and water pipes accordingly, connecting thermostats with the
radiator, is not performed due to engine design features. As thermostat valve in locked position shut off her-
metically bypass hole in the body and don’t let the coolant come for drain. For full draining of coolant from
thermostat boxes it is necessary to disconnect water pipes from them and through the opening holes to strip or
drain it by means of thermostats boxes disassembling on connector.
It is possible to install plugs instead of valves in the cooling systems.
When filling the system with coolant it is necessary to turn out plug at outer shroud of start up preheater
and release air from the system.
Removal and installation of the radiators blocks.

– before removal of the radiators blocks from the dump truck it is necessary to drain the coolant from
cooling system through drain cocks, as well as fuel from fuel heater;
– disconnect and remove with the help of the hoisting device front bonnet;
– disconnect pipelines and hoses from blocks of radiators, cooling and fuel system, hoses of heater;
– loosen the clamp fastening sealant to the fan housing ;
– disconnect the pneumatic switch of the drive gear of radiators shutters from the air supply line;
– disconnect electrical cables from temperature sensors;
– turn off bolts fastening the radiators shutters and remove them;
– turn off bolts fastening the radiators block to frame brackets;
– install on blocks of radiators the ring bolts attached to spare parts kit.
Using the hoisting device and fastening cable fasten each radiators block of and disconnect from both
sides links fastening radiators block;
– remove each radiators block from the dump truck and install it on a jamb
– unscrew bolts and remove fan housing from block of radiators.
Setting of the radiators blocks on the dump truck is to be performed in inverse sequence.
Disassembly of radiators block.

Mount and fix radiators block on the assembly and disassembly of the radiators (Figure 5.13).
Disassembly of the radiators block is carried out in the following sequence:
– turn nuts of the bolts of radiators fastening to each other to move apart them, to take out distance
sleeves from racks;
– fasten in succession radiators and to remove them from the stand;
– disconnect upper and lower radiators tank, turn fastening bolts to radiator racks and strips. Remove
upper and lower radiators tank, two linings, four strips;
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– disconnect the upper and lower radiators frame, turn off nuts and the bolts connecting two frames,
racks of the radiator and strip through the prorate in an average part of the radiator. Remove two frames, two
linings, four racks, four strips.
Assembly of radiators blocks is to be performed in inverse sequence.
Figure 5.13 – The Stand–turner for assembly–disassembly of the radiators block:

1 – frame; 2 – stopper; 3 – reducer; 4 – front support; 5 – front bracket; 6 – rear bracket; 7 – rear support
Repair of radiators.
After disassembling inspect the radiators thoroughly.
The following imperfections may be found:
– leakage in soldering spots;
– leakage of pipelines and tubes;
– damage of tanks and cooling plates;
– clogging of pipelines and tanks with debris and scale.
Leakage test can be launched after outside cleaning of radiator surface and removal of scale which can
hide the defects.
The test is carried out using pressure air in water bath (see Figure 5.14). All in-and out– pipes should be
plugged with rubber sealing while one of the branch pipe must be chosen to deliver 0,2 MPa pressure air. Test
lasts 5 minutes.
To detect inoperative pipes located inside the radiator inspect each pipe individually. For this purpose
remove upper and lower tanks, place the radiator core into the water bath, blank off one of the pipe’s end and
connect the other to pressure air hose making use of device shown on Figure 5.15.
Figure 5.14 – Installation diagram for

the radiators tests:
1 – feeding compressed air cock; 2 – manome-

ter; 3 – pressure air control cock; 4 – air receiver ;
5 – condensate sink cock; 6 – hose; 7 – water bath;
8 – radiator
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Figure 5.15 – Tube test on the tightness:

1 – radiator tube; 2 – tip; 3 – rubber plug; 4 – hose
for air delivery
To eliminate detected leakage of the radiator use leaden solder alloy (POS-30 or POS-40). The pipes
whose soldering is problematic or impossible are subject to replacement or alternatively solder them from the
both ends to 10 mm depth. Note that you may choke not more than 1,5% of the pipes.
The radiators that have been subject to soldering should be flushed off with alkaline solution and subse-
quent rinsing with hot water till complete removal of the solution.
Straighten cooling plates so that they wouldn’t contact each other.
Repaired radiator after sub-assembling with the tanks must be tested for leakage as described above within 5
minutes.
One demountable radiator 1 (figure 5.16), which consists of thirteen cooling elements 5 united by upper
and lower tanks, is installed instead of two-row installation of radiators (four radiators in two rows) in cooling
system of BelAZ-75131 and BelAZ-75139 trucks from October, 2015.
To repair the radiator element 5 unscrew nuts 4, extract washers 3 and gaskets 2 and remove the ele-
ment. After repair put the section back into the radiator.
Figure 5.16 – Demountable radiator:

1 – radiator; 2 – gaskets; 3 – washers; 4 – nuts; 5 – radiator element
Adjusting shutters plates position.

This is achieved by changing length of a rod free end or placing it into other opening in a lever. To ad-
just, disconnect the rod (from the one end only), unscrew locking nut, rotate the fork 0,5-1 revolution and lock
the nut. Put the rod in it’s place.
Open and close the shutters checking the plates for proper adjacency.
When opening the plates should get opened completely and when closing they should adjoin tightly.
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Pneumatic switch repair.

At the tightness violation of the pneumatic switch it is necessary to replace joint rings.
For disassembly of pneumatic switch it is necessary:
– to turn off bolts and to remove cover 1 (figure 5.17);
– to extract from the case 2 piston 4 together with rod 7;
– to remove the retaining ring 5 and to disconnect stock
and piston;
– to remove joint rings.
Perform assembling in inverse sequence.
Before assembly ring gaskets and body work surface to
grease with lubricant ЦИАТИМ-221. After assembly the bucket
with rubber rings should displace freely without jams in both di-
rections
Test the assembled switch for air tightness under pressure
of 0,4 МPа. Supply air serially in both cavities. The air pressure
decrease should not exceed 0,05 МPа during 5 minutes.
Figure 5.17 – Pneumatic switch:

1– cover; 2 – case; 3, 6, 8 – joint rings; 4 – piston; 5 – retaining ring; 7 – rod
5.6 Repair of the engine pneumatic starter system

ATTENTION: SYSTEM DISMANTLING AND ITS ELEMENTS( PNEUMATIC STARTER, SHUT-OFF COCKS,
COCKS OF RESET OF A CONDENSATE, ETC.), REMOVAL OF AN ARMATURE AND PIPE DUCTS, ALSO HOLDING
OF PREVENTIVE AND WELDING OPERATIONS IT IS SUPPOSED TO MANUFACTURE DISASSEMBLY OF SYSTEM
AND ITS ELEMENTS ONLY AFTER AIR PRESSURE DECREASE IN SYSTEM UP TO ATMOSPHERIC. AIR REMOVAL
FROM SYSTEM IS MADE THROUGH COCKS OF RESET OF A CONDENSATE, THUS SHUT-OFF COCKS OF AIR-
SLAKED BULBS SHOULD BE OPEN.
Features of design, operation maintenance and repair of pneumatic starter are given in the manuals
supplied by manufacturer of pneumatic starter.
5.7 Engine preheater troubleshooting

Possible problems of engine preheater and its troubleshooting are specified in table 5.1.
Table 5.1 – Possible problems of engine preheater and its troubleshooting
Trouble and its symptom Possible reason Troubleshooting

Preheater fails to start because of no Electromagnetic valve filter is clogged Wash or replace filter, blown down with
fuel delivery compressed air before mounting
Electromagnetic valve fails to open (no Check reliable connection of wire lugs to
click heard in working position) terminals and serviceability of 2A fuse. Re-
place fuse if needed
Nozzle centre orifice is 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 is 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
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Glow plug does not operate Control board check spiral is burnt Replace spiral
Glow plug spiral is burnt Replace glow plug
Glow plug spiral heat is insufficient Check connection of wire lugs to terminals.
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 is insufficient be- Charge storage batteries
cause of low motor speed
Nozzle orifice is choked Disassemble nozzle, wash parts in diesel
fuel and clean orifice. Check assembled
nozzle for spray cone
Air intake blower screen or outlet pipe is Clean outlet pipe or air intake screen
clogged with dirt
Carbon deposit in combustion chamber Disassemble and eliminate carbon deposit in
combustion 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 nozzle.
insufficient delivery of fuel Increase fuel consumption by turning fuel
pump pressure-reducing valve screw
Fuel pipelines are leaky Eliminate leakage
Electromagnetic valve fails to shut off Dirt is got under check seat Screw valve out of base, wash in diesel fuel
fuel feed and blow down with compressed air
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6 TRACTION ELECTRIC DRIVE

Dump trucks depending on the model can be equipped with AC/DC GE150AC manufactured by “General
Electric” or one КТЭ-136 manufactured by OJSC “Electrosila”.
Technical description, maintenance and repair of traction electric drives GE150AC and КТЭ-136 are
given in the documentation attached to the equipment by manufacturer when shipping.
Current chapter contains information about AC/DC traction electric drive.
6.1 General data on traction electric drive

Traction electric drive of dump trucks is intended for:
– creation of regulated traction forces on driving wheels of dump truck by transformation of mechanical
power of diesel engine to electric power, and also for automatic regulation of electric power and its reconver-
sion to mechanical power;
– creation of regulated braking powers on driving wheels at standard and forced electric braking.
At standard electric braking force is formed at expense of regulated transformation of kinetic energy ac-
cumulated by dump truck during driving, in electric power. Transformation of kinetic energy is carried out by
shifting of traction motors in generator operation mode and creation of braking torques on their shafts. Electric
power oscillated by electric motors is transformed in brake resistors into thermal energy with consequent dif-
fusing in circumambience.
Forced electric braking operation is carried out for raising of braking efficiency at dump truck speeds be-
low 20 – 25 km/h and for providing full shut–down of dump truck. Braking powers at forced electric braking op-
eration, except for specified for standard electric braking operation, are formed at expense of additional power
consumption from diesel–generator set.
The electric drive is intended for operation in two modifications of dump truck distinguished by reduction
ratio of electric motorized wheel reducer.
The electric drive comprises following principal components:
– traction synchronous alternator which is rotated by engine. Stator winding of traction alternator con-
sists of two electrically not connected three–phase windings, each of which is connected in star. On stator of
traction alternator is situated single–phase self–excitation winding that is connected through external adjuster
and slip rings to exciting winding, placed on its rotor;
– two direct–current traction motors of electric motorized wheels with series excitation, forced pressure
ventilation and built–in sensors of rotary speed and monitoring of thermal condition;
– two power three–phase bridge incontrollable rectifier to which input cramps stator three–phase wind-
ings of traction alternator are connected;
– setting of ventilated brake resistors with individual brake resistors for each traction motor and common
motor–fan;
– current regulator of excitation of traction alternator, which power part represents half–controlled sin-
gle–phase bridge rectifier to which input cramps self–excitation winding of traction alternator is connected, and
to output its exciting winding is connected;
– common current regulator of excitation of traction motors (adjuster of smooth field reduction of electric mo-
tors). Power part of adjuster comprises steered three–phase zero rectifier, powered in parallel circuits, containing
anode group of one of power rectifiers and two sequentially joint exciting windings of traction electric motors;
– power switching equipment consisting of contactors, providing power circuits commutation, circuits of
excitation and reversing of traction motors.
Except for listed electric machines, settings and apparatuses basic components of electric drive com-
prise automatic control system (САУ), which comprises two subsystems: system of program control (СПУ) and
system of automatic regulation (САР). Adjusters of alternator excitation and electric motors are also included in
САУ subsystems.
The automatic control system is intended for control of power switching equipment and of operation
modes of system of automatic regulation.
The system of automatic regulation is intended for forming of traction and braking performances of dump
truck by means of comparison of assigning signals and feedback signals acting from sensors of electric and
mechanical parameters. It is intended also for regulating of exciting currents of traction alternator and traction
motors in function of error signals between specified signals.
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Besides, system of automatic regulation executes functions of guard of electrical equipment from emer-
gency operation modes.
The signalling of electric drive operation is carried out by indication devices – indicating lamps located
on control panel in cab, and indicators on front panels of blocks with microelectronic elements.
Indicators on front panels of blocks are intended for diagnosing operation of blocks, other devices of
system of automatic regulation and of some aggregates and devices of electric drive. In particular, indicators
signal about receipt of source voltages on inputs of blocks with microelectronic elements, about operation of
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
basic 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 accepta-
ble values of voltage and current of power circuit, shorting of power circuit on body of dump truck, short–circuit
of power rectifier, skidding of electric motorized wheels and others.
6.2 Description and operation of electric drive components

6.2.1 Electric machines
Traction alternator.
On dump trucks non–collector one–basic or two–point traction alternator is installed. Alternator is in-
tended for power supply of traction motors through rectifying installation, and also for power supply of exciting
winding of alternator rotor through system of automatic regulation.
Description, operation, maintenance and repair of traction alternator look in the operation Manual, sup-
plied by manufacturer.
Traction electric motor.

On dump trucks direct–current traction electric motors are installed. Electric motors are intended for
drive gear of wheels of dump truck as part of alternating–direct–current electric drive.
Description, operation, maintenance and repair of traction electric motor look in the operation Manual,
supplied by manufacturer.
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6.2.2 Electric apparatuses
6.2.2.1 Control cabinet 75131–2112010–31

The cabinet is intended for rectification of AC voltage, commutation and protection of power circuits and
circuits of excitation of traction alternator, traction electric motors, mounting of ventilated brake resistors, and
also automatic regulation of exciting currents of traction alternator and traction electric motors in composition of
electric drive.
The control cabinet has four demountable cargo bolts and is fastened on dump truck in horizontal plane with six
bolts М16.
The control cabinet has frame modification with one–sided maintenance of electrical equipment located
in it, contains four consistent doors with sealants and locks. On rear wall of cabinet there are glands for input of
power cables. The control cabinet consists of four chambers. Arrangement of electrical equipment in chambers
of control cabinet is shown in figure 6.1.
In first chamber following units are located:
– power contactors KM4, КМ5, КМ6, КМ7;
– contactor КМ8 and automatic switch QF1 of circuit of excitation of alternator;
– contactor КМ3 of excitation of traction electric motors;
– relay of maximum current KА1, КА2;
– thyristors VS1, VS2, БУT5.2 and diodes VD3, VD4 of adjuster of excitation of traction alternator;
– resistor R8 of degaussing of alternator and diode VD20 of circuit of additional charging;
– measuring shunts RS1, RS2.
In second chamber there are power gate blocks БСВ1 and БСВ2, which comprise power rectifiers UZ1,
UZ2, blocking off diodes VD1, VD2, thyristors VS6–VS8 of adjuster of excitation of traction electric motors and
thyristors VS4, VS5 of protection of skidding of electric motorized wheels.
The second chamber is executed as air pit providing opportunity of operation of power semiconductor
devices located in it, both with natural, and with forced cooling. In the last case take–in of air for fanning is per-
formed through branch pipe with filters from front side of cabinet. Blowout of air is carried out into air pipe–line,
connected to flange on rear wall of cabinet.
In third chamber following units are located:
– blocks of reinforcement of power БУМ–5.3 and thyristors control unit БУT–5.2;
– contactor КМ9 of turning on of circuits of initial excitation of traction alternator;
– power contactors KM1, КМ2;
– resistor R15.
In fourth chamber following units are located:
– control cabinet;
– automatic switches SF1–SF3, QF2 of control circuits and auxiliary circuits;
– contact clamps XT1, XT2 for connection of external low–current circuits of cabinet control;
– unit БУ–1.3, clamps XT5, XT3;
– module of high voltage sensors МВС-01.
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6-4
Figure 6.1 – Location of electrical equipment in the control cabinet 75131-2112010-31

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6.2.2.2 Contactors
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 6.2). Magnet-
ic system is of two–bobbin type. Twirl of armatures 2 and 8 occurs on shafts 4 fixed in pads, shock absorbing
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 snap-
ping 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 6.1.
Figure 6.2 – Electromagnetic contactor МК–6:

1 – base ring; 2, 8 – armatures; 3 – spring; 4 – shaft; 5 – clinch; 6 – interlock con-
tact; 7 – pad contact; 9 – clinch snapping; 10 – chamber
Table 6.1 – Technical data of contactor МК–6

Contact pieces of principal circuit (closing): Retractable coil:
number of contact pieces 1 voltage:
rated voltage, V 220 rated, V 24
rated current, А 400 retractable (concerning nominal), % 7 – 11
Interlock contacts: resistance, Ohm 8,2
number of contact pieces (closing and unlocking) 4 (2+2) power, W 70
voltage, V 110 Insulance, MOm:
current, А: in cold condition 100
powered up at 110 V 25 in heated condition 20
disconnected at 110 V 2,5 at test on moistureproofness 1,0
nominal (on heat) 10 Weight, kg 6
Information on the electromagnetic contactors СТ 1115 manufactured by “SHALTBAU” (КМ1-7 see

figure 6.1) look in the User’s Manual С20/08-М.ru on the manufacturer’s site (http://www.schaltbau-
gmbh.com/).
6.2.2.3 Ventilated brake unit VBU2x600

VBU designed to convert electrical energy generated by the traction electric motors in the mode of dump
truck electric brake to the thermal one aiming to disperse it over the environment.
It is electrodynamic brake resistor with forced air cooling.
VBU consists of an axial fan blower 1 (figure 6.4) and two groups of four resistors sections 7 in each.
Fan and resistors are interconnected by means of branch-pipes 4, 5 and two tapes 3. Equalizing of the cooling
air stream is performed via air duct 9. All the parts and components of the unit are assembled over the
framework 2. The fan electromotor is powered from the resistor R4 belonged to the first group of resistors.
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Figure 6.4 – Ventilated brake unit:

1 – fan; 2 – framework; 3 – tape; 4, 5 – branch-pipes; 6 – panel; 7 – resistors section; 8 – power cable; 9 – air duct; 10, 15, 16, 17,
19 – bolts; 11 – washer; 12 – suspension pad; 13 – insulator; 14 – nut; 18, 20 – screws
Technical description is given in the table 6.2
Table 6.2 – Technical data of УВТР 2х600

Sort of current direct
Amount of banks of resistors 4x2
Resistance of the VBU, Ohm 2x1,05
Resistance of each section, Ohm 0.25
Thickness of fechral tape, mm 1.4
P designed, KWt 2x600
о
The maximum temperature of tape, С 800
Weight, kg 655
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The fan comprises ВС electromotor 3 (ДПТВ-16,25-02 или ЭТВ-20М3Л) (Figure 6.4) and the fan impel-
ler 5 mounted on the key 6 of the electromotor shaft armature. The impeller is secured on the shaft by nut 7,
which is locked from loosening by washer 8.
The electromotor is installed in the internal space of the housing 2; in the front part it is centered by the
housing as in the rear part – by means of support 11. The gap between the faces of the housing 2 and support
11 should be of 1 – 1,5 mm; the gap is to be set before tightening the bolts 19 using rings 12 (for electromotor
ДПТВ-16,25-02 only). Locking the electromotor in the housing is performed by means of bolts 16, screw 9 and
the bracket 4 (screw and the bracket are actual only for electromotor ДПТВ-16,25-02). The bolt and screw in
their turn are being locked by nuts 17 and 10, respectively. For the electromotor ЭТВ-20М3Л additionally the
dowel 20 is mounted (Figure 6.4a).
The fan unit is mounted on rubber shock absorbers to reduce vibration loads on the VBU parts and as-
semblies.
Figure 6.4 – Fan 75139-2126004 (electromotor ДПТВ-16,25-02):

1, 15, 16 – bolts; 2 – housing; 3 – electric motor; 4 – bracket; 5 – fan impeller; 6 – key; 7, 10 14, 17 – nuts; 8 – a washer;
9 – locking screw; 11 – support; 12 – rings; 13 – connecting receptacle
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Technical performances of electromotors is given in the table 6.3.

To pour lubricant to the bearings of the fan ЭТВ-20М3Л when servicing it is necessary to unscrew plugs
16 (Figure 6.4a) in the pipes 1 and 5 to the drainage holes of the outer bearings covers. Press in grease till old
one is displaced and new grease appears through greasers 14 mounted in pipes 2 and 7 connected to the
pressure holes of the outer bearings covers. Let the electromotor run for two – three shifts of the truck opera-
tion with open drain holes to let the excessive grease outlet, then close holes using plugs 16.
Figure 6.4a - Fan 75139-2126004-01 (ЭТВ-motor 20M3L):

1, 2, 5, 7 – pipes; 3, 18, 21 – bolts; 4 – housing; 6 – electric motor; 8 – support; 9 – fan impeller; 10, 13 – washers; 11 – key;
12, 19, 22 – nuts; 14 – greaser; 15 – end-tip; 16 – plug; 17 – connecting receptacle; 20 – dowel
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Table 6.3 – Technical data of electric motor
Type of engine 4 – poles DС motor with serial oscillation

ДПТВ-16,25-02 ЭТВ-20М3Л
(75139-2126004) (75139-2126004-01)
Nominal output, kW 16,25
3
Productivity, m /s (3100 rpm.) 7,8
Rated voltage, V 210
Rated current, А 90
Nominal rotary speed, rpm 3100
Number of brush–holders 8 16
Mark of brushes ЭГ4 ЭГ-74
(ЭГ84М, ЭГ841К)
Sizes of brush, mm 12,5х25х40 10х12,5х35
Maximum permissible height of brush, mm 20 25
Force of pressure to brush, Н 4,6 – 6,1 3,2 – 3,8
Resistance of the electromotor windings relatively to 20 – cold condition. 10 – cold condition.
the housing, at least, МОм 2,5 – heated condition. 3 – heated condition
The resistors section comprises eight resistors sections interconnected by buses. The resistor 4 (Fig-
ure 6.5) is made of multiply curved flat fechral tape. Two outputs are soldered (riveted) to the tape ends. To
provide rigidity to the structure there are side frames 5 mounted at both sides made of non-combustible ma-
terial; they are strapped together by rods 8, insulated pipes 7. The curved parts of the tape are fastened to the
rod by means of steel holders 1 and 2.
Resistor, held by steel holders is attached to the rods through ceramic insulators 9 and gaskets 10,
which in their turn are pressed by springs 12 for compensating thermal expansion of insulators.
Figure 6.5 – Resistor section:

1, 2 – holders; 3, 13, 14 – nuts; 4 – resistor; 5 – side frame; 6 – bolt; 7 – pipe; 8 – rod; 9 – insulator; 10 – gasket; 11 – washer;
12 – spring
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6.2.2.4 Running control unit

The running control unit is intended for turning on of circuits of traction mode. It is installed on grounding
of floor of cabin from below.
The control unit consists of case 4 (figure 6.6) in which are fixed cam elements 1 and shaft 21 with cams
17. On shaft bar 13, which is connected by pull–rod to drive gear of fuel delivery control is installed. Cams
have figurate excisions for cam elements control.
By pressure accelerator pedal bar 13 is pivoted and pivots shaft 21 with cams 17. If at turning movement
of shaft roller of cam element gets in excision of washer contact pieces 11 become insulated, and on contrary,
contact breaking occurs at hit of roller on protuberance of washer.
The spacing in contact pieces 11 of cam elements in open mode should be (7 ± 3) mm.
Overlapping of rollers of cam elements with washers is made by conveyance lath 3 in axial direction of
shaft.
Regulating of extreme positions of bar and pull–rod of drive gear of running control unit is shown in Op-
eration manual of dump truck.
For adjustment change the length of running control unit link, having reached actuation of circuits of trac-
tion electric drive at the engine speed of (900+100) rpm.
Figure 6.6 – Running control unit:

1 – cam element; 2, 7, 23 – bolts; 3 – lath; 4 – case; 5 – wiring harness; 6 – sealing ring; 8, 12 – covers of manholes; 9 – contact
bolt; 10 – screw; 11 – contact bridge; 13 – bar; 14 – lock washer; 15, 20 – covers of bearings; 16 – ring; 17 – cam; 18 – insulating washer;
19 – bearing; 21 – shaft of cam drum; 22 – bracket
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6.2.3 System of fanning and cooling of traction electric drive
System of fanning and cooling is intended for maintenance of optimum temperature operation mode of
components of traction electric drive.
The system of input of cooling air ensures input of air from least dusty zone of dump truck and through
cyclones built on power cabinet air cleared of foreign admixtures on suction air duct flows 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.
The rest 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 rear axle housing.
The cooling fan of traction electric motors.

Fan wheel in assembly consists of front disk 20 (figure 6.7) and rear disk 15. Between disks on bolts 17
aluminum blades 16 (24 units) are installed. Fastening of vanes is carried out by nuts 18. Plates 19 are in-
tended for locking of nuts.
Fan wheel with hub 5 is installed on key 3 on conic shank of shaft of rotor of traction alternator 2. Hub is
landed on shaft of alternator with tightness and tightened by round split nut 6 with torque 882 – 980 H.m. From
unscrewing nut is arrested by bolts 9, which are among themselves stopped by splint–wire 10.
Housing of fan 4 is fixed on end bracket of traction alternator. Gasket 1 between traction alternator 2 and
housing of fan 4 and gasket 13 between cover 8 and housing of fan 4 are installed with adhesive 88 СА
ТУ 38.105.1760.
Fan wheel in assembly with hub is dynamically balanced. Unbalance should not exceed 18 g.cm in
plane of front disk and 52 g.cm in plane of rear disk. Positional relationship of components is arrested by pins 7
(2 pieces).
Technical condition of product of fan is determined in operation by:
– external examination;
– hearing (noise of operations, vibration).
External examination makes it possible to reveal fault and emersion of cracks of housing with air main
pipe–line 4 or covers 8, fault or wear of gasket 11. By hearing noise of operation and vibrations violation of ba-
lancing fan wheels can be detected.
Repair of cooling fan of traction machines.

Repair of cooling fan of traction machines consists in welding up of cracks, replacement of gaskets in
case of fault or wear, replacement of fan wheels.
Disassembly of fan is to be performed as follows:
– lift and lock body;
– unscrew bolts of propeller shaft fastening from hub of fan wheel 5 and disconnect propeller shaft;
– unscrew bolts 14 of cover 8 fastening and remove cover and gasket 13;
– unscrew nuts 12 and remove gasket 11;
– unsplint and turn off bolts 9;
– turn off nut 6;
– by device squeeze fan wheel in assembly with hub;
– take out key 3 of rotor chase of alternator;
– if necessary unscrew bolts of housing 4 fastening and remove housing and gasket 1.
ATTENTION: IT IS FORBIDDEN TO PERFORM DISMOUNTING OF FAN WHEEL ON COMPONENTS AS THUS

POSITIONAL RELATIONSHIP OF DETAILS OF BALANCED PACKAGE IS DISTURBED, THIS AT CONSEQUENT AS-
SEMBLY RESULTS IN INCREASE IN UNBALANCE OVER SPECIFIED NORMS AND OWING TO THAT TO HEIGH-
TENED VIBRATION OF ALTERNATOR AND DECREASE OF RESOURCE OF ITS BEARINGS.
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Assembly of fan is to be performed as follows:

– place on end bracket of traction alternator 2 housing with air main pipe–line 4 and gasket 1 and fix it with
bolts. Gasket is to be set on adhesive 88 СА ТУ 38.105.1760, bolts – on sealant Унигерм 9 ТУ 6-01-1326;
– mount in rotor chase of alternator key 3;
– press, screwing up nut 6 (torque 882 – 980 N.m) fan wheel in assembly with hub 5 on conic shank of
rotor of alternator. Before landing of wheel with hub on conic shank of rotor reseat and test firmness of fit of ta-
per of rotor to nave boss, surface of fit should be not less than 75 % of all surface of taper;
– lock nut 6 by bolts 9 and splint bolts with splint–wire 10;
– place gasket 11 between hub and cover 8 and tighten nut 12;
– mount cover 8 with gasket 13 to housing of fan 4 and fix with bolts 14. Gasket 13 is to be installed on
adhesive 88 СА.
Figure 6.7 – Cooling fan of traction electric motors:

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

6.3.1 Repair of electric machines
Repair of electrical machines (traction generator and electromotor) look in the Operation Manual, which
is supplied by manufacturer.
Repair should be performed by qualified specialists in the workshops equipped necessary tools. Disas-
sembly and assembly of electric machines (traction alternators and electric motors) should be performed with
application of standard instruments and special devices.
6.3.1.1 Repair of traction alternators

The principal causes triggering violation of serviceability of alternator are drop of insulance of windings,
breakdown of insulation of winding on case, excessive arcing under brushs and heightened heat of slip rings,
heightened heat or collapse of bearing.
Besides, reasons of violation of serviceability of alternator can be arrangement of soldered connections of
stator winding in frontal part or outputs of winding, and also arcing of outputs of coils or webs between coils of
poles of rotor, arcing or abruption of connective tire between exciting winding and slip rings. Elimination of majori-
ty of listed failures and faults needs disassembly of alternator and replacement or repair of its components.
Repair of alternator is executed by highly skilled mechanics in special locations equipped with necessary
equipment for holding of maintenance jobs.
Before unhooking of alternator from diesel engine lay gaskets (to fill in spacing) between lower poles of rotor
and stator sheets, lift brushes and envelop slip rings with pressboard, disconnect electric cables and harnesses
from alternator and snug, tie up them with help of rope to frame of dump truck with purpose of prevention from faults
at removal and mounting of alternator.
The order of dismounting and wiring of traction alternator on chassis of dump truck, alignment of traction
alternator with engine is explained in "Systems of engine» chapter.
The order of maintenance:
– remove alternator from underframe and install it on jamb;
– clear external surface of alternator, unhooked from diesel engine, of dust and dirt, blow alternator out-
side and inside with dry clean air, clear external surface of assembly unit and parts of pollution.
Air for dusting of separate parts and of alternator as a whole should be dry, cleared of ectogenic admix-
tures and moved under pressure of 0,18 – 0,2 МPа, hose for dusting should not have metal nosepiece.
Clearing of contact or other metal and insulated surfaces of alternator is to be produced by clean dry
pileless napkins (if necessary moistened in benzine or spirit) at powered exhaust ventilation.
For removal of dirt, which is densely stuck to component of alternator, use rigid hair brushes, and wood
or fibre scratchers.
A T T E N T I O N : IT IS STRONGLY FORBIDDEN TO PERFORM CLEARING OF LOW–PURITY SURFACES
OF COMPONENTS AND ALTERNATOR BY CAUSTIC SUBSTANCES.
– clear surfaces of windings, slip rings, brush device of pollution and dust. For removal of stuck dirt it is
necessary to use rigid hair brushe, 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 tripoliphos-
phate of GOST 13493.
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".

0
It is supposed to apply to flushing out of alternator in assembly cleaning solution "Лабомид–101" or

"Лабомид–102";
– after clearing or flushing out produce drying at temperature of 130 – 150 С before restoring required
0
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.
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Insulance of circuits of alternator regarding to case and between windings is to be measured with me-
gohm meter by voltage on 1000 V.
At doing so level of insulance should be:
– not less than 10 MOm in practically cold condition before mounting on dump truck new or past operat-
ing repair and factory repair of alternator;
– not less than 1,0 MOm at stator windings and not less than 0,5 MOm at armature coils\ in practically cold
condition in operation and before putting of dump truck into operation after long parking (more than 15 days);
– not less than 1,0 MOm at stator windings and not less than 0,5 MOm at armature coil in heated condition.
For measurement of insulance of circuits of alternator in assembly concerning case connect output of
gear "GROUND" with any unpainted part of case of stator, and output "CIRCUIT" – to one of output leads «1N,
1U, 1V, 1W» (circuits of first star of stator winding). Winding of other star «2N, 2U, 2V, 2W» and self–excitation
winding should be connected to grounded case. After measurement disconnect winding «2N, 2U, 2 V, 2W»
from case.
Then connect winding of first star « 1N, 1U, 1V, 1W » to grounded case; connect output "GROUND" of
gear to any unpainted part of case, and output "CIRCUIT" – to one of output leads «2N, 2U, 2V, 2W». After
measurement disconnect all outputs from case.
For measurement of insulance of self–excitation winding concerning case connect output "GROUND" of
gear to any unpainted part of case, and output "CIRCUIT" – to one of output leads of self–excitation winding.
At measurement of insulance of rotor in assembled alternator concerning case lift all brushes (or lay in-
sulating spacers under brushes) and connect output "GROUND" of gear with shaft of rotor, and output "CIR-
CUIT" – to one of slip rings.
At measurement of insulance of circuits of brush–holders in assembled alternator concerning case lift all
brushes and connect output "GROUND" with any unpainted part of case of stator or end bracket, and output
"CIRCUIT" – serially to nosepieces of wires "F1" (circuit of brush–holders of one slip ring) and "F2" (circuit of
brush–holders of other slip ring).
In case of detection of insulance decrease due to moistening, perform drying of insulation of windings.
Drying is to be performed by:
– blowing off through alternator of dry hot air (for example, from hot–air heater or special defroster);
– external heating up (for example, in furnace or drying chamber).
Produce measurement of insulance during drying every 30 minutes, and at installed one – every hour.
During drying by both modes value of insulance is depressed owing to evaporation of moisture, then
raises. At kickdown of insulance drying should not stop. After reaching the installed insulance drying should be
continued for 2 – 3 hours more.
At drying by blowing off with air its temperature should be no more than 120 – 130 С. During drying
0
cover of access hatches should be enclosed.

For drying by external heating up dismantle alternator, disassemble it and place separately stator and
rotor in ventilated drying chamber or furnace. Temperature in drying chamber or furnace should be no more
than 100 – 110 С. During drying temperature should be raised for not more than on 10 С within one hour.
0 0
Before drying of insulation blow alternator (and its components) with compressed air to clear disposable
sections of stator, rotor, brush–holders, suspenders and their insulators of dust, oiling and other pollution. At
drying stator winding and rotor heat gradually (raise temperature for not more, than on 10 С within one hour).
0
At sweeping heating up variance in fixed time of heat and in coefficients of linear expansion of winding and ac-
tive steel, and also constructive parts of alternator, can cause faults (ruptures) of insulation.
The requirements to assembled alternators.

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

Sequence of inspection of technical condition of alternator parts:
– after disassembly of alternator is to be blown through with clean compressed air and cleared of pollu-
tion of its components, pay special attention to parallax purity of surfaces of coils of poles;
– test condition of insulation of stator in cold condition by visual inspection and megohm meter. Insula-
tion should not have cracks, stratifications, coalification, mechanical damages and pollution. Insulance should
be not less than 10 MOm (it is measured after drying in drying chamber by megohm meter on 1000 V).
At mechanical injury of insulation of frontal parts and tires of stator winding produce insulating of
damaged place (tires of stator winding – by ribbon ЛСЭП–934 ТПЛ 0,13х20 GOST 13184–78 and ribbon
ЛЭС 0,1х20 GOST 5937–81, coils – by polyamide film ПМ–A 40х20 ТУ6–19–121–85 and ribbon ЛЭС
0,1х20 GOST 5937–81). Cut insulation in place of its fault, and edges should be cut off on taper. Overlap
new insulation sequentially from one edge of cut section to another densely, without folds, blanking of 1/2
width. Each stratum of insulation should be varnished. General width of overlapped stratums should be not
less than width of basic insulation. At insulance in cold condition less than 10 MOm produce drying insula-
tion by external heating. After drying it is necessary to cover surface of stator winding with enamel KO–935.
At impossibility of restoring of damaged sections of insulation, at detection of breakdown of insulation on
case, and also if insulance gauged at temperature 100 – 110 С (after drying), less than 1,0 MOm send stator
0
on major repair;
– test by visual inspection condition of soldered joints of stator. There should not be faults and traces of
excessive heating (change of color of enamel). At fault detection and traces of excessive heating test quality of
brazing of stator winding by method of power failure. Places of unsoldering are to be soldered.
At impossibility to solder winding in conditions of garage deliver stator on major repair;
– test by visual inspection and tap test condition of grooving chocks of stator. There should not be
cracks, having chopped off and slackenings of chocks (rattling sound at tap test by hammer at length more
than one third of length of chocks). Replace damaged chocks;
– enamel internal surfaces of stator (except for contact areas of outputs of winding). Surfaces, covered
with enamel, should be equal (without rolls and smudges). Use enamel KO–935 ТУ16–50.4.021–77;
– wash out bearing, internal and external sealing rings, internal and external bearing cap with kerosene,
white spirit or diesel fuel with help of hair brush and napkin. Examine condition of bearing. Replace bearing at
presence of cracks, wears, strain of separator, shelling–out, indents on tracks of rolling and rollers, cracks of rings;
– test by visual inspection condition of rotor. At fault of shaft and flange send rotor for major repair;
– test condition of insulation of coils of poles in cold condition by visual inspection and megohm meter.
There should not be cracks, stratifications, mechanical damages and pollution. Insulance should be not less
than 10 MOm. Measurements are to be produced by megohm meter on 1000 V.
Cracks, spallings and places of surface blankings of insulation of poles and slip rings are to be removed
with help of epoxide composition of cold curing, which consists of hundred parts of epoxidian pitches ЭД–20
GOST 10587–84, fifteen parts polyethylene–polyamine ТУ6–02–594–80, twenty five parts of oligoether–
acrylate 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 С (after drying), less than 0,5 MOm, deliver rotor on major repair. Before sending on repair remove bear-
0
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 brushes is to be defined by
measuring by probe light slot between ruler and slip ring. Development under brushes 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.
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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 brushes in cartridge clips;
– test retorque fastening of brush–holders to suspenders, suspenders to insulators, insulators to brack-
ets 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 brushes. Again installed brushes 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 brushes is installed. Install only brushes of brand, which is specified in certificate of alternator.
Brushes 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 brushes 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
housings, and also in weld seams with consequent square–wave stripping. Smooth out weld seams flush with
parent 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).
Testing of alternators after repair.

After repair and assembly works carry out following trials of alternator:
– measure insulance of windings in cold condition by megohm meter;
– measure by method of voltmeter and ammeter the resistance of windings to direct current in practi-
cally cold condition. Resistance of windings to direct current, shown to temperature of 20 С, should not dif-
0
fer from shown in certificate more than on 10 %;

– test electric strength of insulation of windings concerning case of alternator and between windings
within one minute at voltage Uисп. of frequency of 50 Hz (voltage at trial is to be applied to each winding se-
rially, other winding and case of stator or rotor should be grounded):
Uисп. = 2U + 1000, V
Where U for stator windings is equal to greatest voltage of alternator at durating condition of power, for
exciting windings and autoexcitation U is equal to rated voltage of these windings.
After trial cover external surface of alternator with enamel ПФ–115 GOST 6465–76 (modification УХЛ)
or enamel MЛ–12 GOST 9754–76 (modification Т), and also cover greaser and screw of external bearing cap
with red enamel ГФ–92ХС GOST 9151–75.
In case of storage necessity produce rust–preventive treatment of alternator.
The joint of alternator with diesel engine.

At joint of alternator and its centre–drilling with diesel engine:
– inspect spacing between poles of rotor and stator on shaft of poles probe in length not less than 400
mm and width no more than 5 mm;
– open external bearing cap and measure radial clearance in bearing which should be not less than 0,06
mm and no more 0,22 mm;
– install and fix external bearing cap;
– test spacing between brush–holders and working surface of slip ring (under midpoint of brush–holder);
– test on fit on color the surface of conic end of shaft (alternator СГД2) and half–couplings. If imprint is
less than 75 % of mating, or unfitting is present produce mutual abrading of shaft and half–coupling by means
of emery powder;
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– test operation of alternator in time of running–in of diesel engine idling at rheostatic trials. Bearing
should work without knock with uniform noise, and surface of abrading of brushes to slip rings before turning
on of loading of alternator should be not less than 75 % of cross–section. After inspection of operation blow
internal surfaces of alternator with dry compressed air.
After rheostatic trials of dump truck alternator should meet following requirements:
– slip rings should have smooth working surface without traces of flashing off, without burnings and dirt;
– radial runout of working surface of slip rings in hot condition should be not more than 0,08 mm;
– brushes 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.
6.3.1.2 Repair of traction electric motors

The principal reasons for violation of serviceability of traction electric motors are: drop of insulance of
windings, breakdown of insulation of windings on case, spring coil closure in windings, transfer on collector of
electric arc, violation of commutation (heavy sparking under brushes, violation of glossy surface of collector,
burning of crimps of brushes), 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 ne-
cessary 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 ectogenic
admixtures and move under pressure of 0,18 – 0,2 MPa, hose for blowing should not have metal nosepiece.
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 dirt, densely stuck to components of electric motor, use rigid hair brushes, and also wood
or fibre scratchers.
ATTENTION: IT IS STRICTLY FORBIDDEN TO PRODUCE CLEARING OF LOW–PURITY SURFACES OF
COMPONENTS AND ELECTRIC MOTOR WITH CAUSTIC SUBSTANCES.
Clearing and drying of electric motor which has arrived on repair and its components from operation pol-
lution is to be carried out in washing mounting by washing fluid according to recommendations, specified in
Operation manual;
– measure insulance of circuits with purpose of detection of sections with reduced insulance (the insul-
ance of windings should be not less than 1,0 MOm);
– test outrun of collector in cold condition which should be not more than 0,04 mm.
Insulance of circuits of electric motor concerning case and between windings should be measured me-
gohm meter by voltage of 1000 V.
Level of insulance should be:
– not less than 10 MOm in practically cold condition before mounting on dump truck of new or passed
operating repair and factory repair of electric motor;
– not less than 1,0 MOm in practically cold condition in maintenance and before lead of dump truck in
maintenance after long parking (more than 15 days);
– not less than 1,0 MOm in heated condition.
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For measurement of insulance of circuits of electric motor in assembly concerning case connect output
"GROUND" of gear to any unpainted part of case of magnetic system, and output "CIRCUIT" – serially to
nosepiece of one of wires "Д1" or "Д2" (circuit of principal poles) and "А1" or "В2" (circuit of additional poles,
brush–holders and armatures).
For measurement of insulance of circuits of additional poles and brush–holders in assembled electric mo-
tor concerning case lift all brushes (or to lay insulating spacers under brushes) and connect output "CIRCUIT" of
gear with nosepiece of one of wires "А1" or "В2", and output "GROUND" of gear – so, as at measurement of in-
sulance of circuits of electric motor in assembly. For measurement of insulance of circuit of additional poles in as-
sembled electric motor concerning case disconnect wire going from brush–holder to additional pole and connect
output "CIRCUIT" of gear with nosepiece of wire "В2", and output "GROUND" of gear – so, as at measurement of
insulance of circuits of electric motor in assembly.
For measurement of insulance of circuit of brush–holder in assembled electric motor concerning case lift
all brushes (or to lay insulating spacers under brushes), disconnect wire going from brush–holder to additional
pole, and connect output "CIRCUIT" of gear with nosepiece of wire "А1", and output "GROUND" of gear –
same as at measurement of insulance of circuits of electric motor in assembly.
For measurement of insulance of separate pole in assembled magnetic system concerning case discon-
nect it from other poles and connect output "CIRCUIT" of gear with one of output leads of coil, and output
"GROUND" of gear – same as at measurement of insulance of circuits of electric motor in assembly. For mea-
surement of insulance of separate brush–holder in assembled electric motor or in assembled magnetic system
concerning case disconnect it from other brush–holders and connect output "CIRCUIT" of gear with case of
brush–holder, and output "GROUND" of gear – same as at measurement of insulance of circuits of electric mo-
tor in assembly.
For measurement of insulance of armature in assembled electric motor concerning case lift all brushes,
short–circuit collector of armature thin copper noninsulated wire or tire, and connect output "CIRCUIT" of gear
with any plate of collector (wire or tire), and output "GROUND" of gear to armature shaft.
For measurement of insulance between windings in assembled electric motor connect one of outputs of
gear with any of nosepieces of wires "Д1" or "Д2", and other output – to any of nosepieces of wires "А1" or "В2".
After measurement of insulance unload winding (windings) association to lead–out wires of windings (to
plates of collector) grounded wire, and also remove from collector of armature copper wire (tire).
In case of detection of drop of insulance owing to its moistening carry out drying of insulation of windings
(as in assembled electric motor, and separately armature or poles of magnetic system) by one of methods,
shown for alternator.
Before drying of insulation blow electric motor (and its components) with compressed air to clear dis-
posable sections of armature and magnetic system, brush–holders and their fingers of dust, oiling and other
pollution.
0
At drying, winding should be heated gradually (raise temperature no more, than on 10 C within one
hour). At sweeping heat variance in fixed time of heat and in coefficients of linear expansion of winding and ac-
tive steel, and also constructive parts of electric motor, can cause faults (ruptures) of insulation.
In time of drying covers of access hatches should be closed, and sampling of insulance should be per-
formed by megohm meter with voltage of 500 V.
At each disassembly of electric motor produce washing of bearing mount assemblies and full relubrica-
tion. Type of lubrication and its amount is specified in Operation manual and lubrication charts.
The requirements to assembled electric motors.

After assembly electric motors should meet following requirements:
– working surface of collector should be without pollution combustive–lubricating and paintwork mate-
rials, without burrs, agnails and other mechanical damages. Facets on crimps of collector bars should be by all
working part of collector, grooves between collector bars should be depth 0,5 – 1,5 mm and without pollution,
binding on cuff of collector should be without mechanical damages;
– brushes should be preliminary smoothed, local spalling of crimps at contact area of brushe of its cross–
section should be not more than 10 %, pressure gears of brush–holders should be lowered on brushes;
– identification mark and arrangement of wires should match to wiring scheme of joints of electric motor;
– armature should be twirled manually without jam, in bearings there should not be knocks at extreme
positions of armature;
– in electric motor there should not be ectogenic subjects.
After assembly install electric motor on test–bed and apply no–load tests during 30 – 40 minutes at rota-
ry speed 500 – 600 rpm with purpose of validation of assembly and wear–in of brushes on collector.
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Bearings should work without knocks with uniform noise, and contact area of abrading of brushes to col-
lector after running–in should be not less than 75 % of its cross–section. After validation of assembly and
wear–in of brushes on collector blow internal surfaces of electric motor with dry compressed air.
After maintenance produce trials of electric motor. Test methods, sequence of execution of operations
and technical requirements should match GOST 2582.
At trials of electric motor it is necessary to be guided by following rules:
– resistance of windings to direct current in practically cold condition should not differ from values,
shown in certificate of electric motor more, than on 10 %;
– trials on heightened rotary speed should be carried out at rotary speed exceeding on 25 % greatest rotary
speed, within two minutes at idle running of heated electric motor;
– trial of electric strength of spring coil insulation of windings should be carried out at heightened voltage
on 50 % over nominal within 5 minutes;
– outrun of collector on heated electric motor should be no more than 0,04 mm, and variance between
outrun in cold and hot condition should be no more than 0,02 mm;
– insulance of all windings concerning case of electric motor and between windings in heated condition
should be not less than 1,0 MOm;
– trial of electric strength of insulation of windings concerning case of electric motor and between windings
should be carried out within one minute with test voltage Uисп of frequency of 50 Hz
Uисп. = 2U + 1000, V
– inspection of commutation, rotary speed and reversing should be carried out only at replacement of
poles or armatures, pay attention to presence of necessary gaskets in straps of brush–holders intended for
mounting of neutral.
At trial of electric motor there should not be circular fire and mechanical damages. Collector and brush–
holders after trial should be suitable to further operation without clearing and any reparation.
After trials electric motor should meet following requirements:
– collector should have smooth from bright up to dark brown color working surface without traces of flash-
ing off from transfers of electric arc, without burnings, filter sludging of copper and pollution;
– contact area of wear–in of brushe to collector should be not less than 75 % of its cross–section and
should not have double smooth surface;
– brushes should not have one–sided development of edges, traces of burning, fault and traces of ex-
cessive heating of current carrying wires;
– collector should not have traces of violation of welding of waste of sections in risers;
– bindings should not have cracks, stratifications and burrs;
– insulation of windings should not have traces of mechanical or electric faults;
– bolted joints should be tightened and should not have slackenings.
After execution of all maintenance operations:
– install covers of access hatches;
– cover surfaces of electric motor with enamel ПФ–115 or MЛ–12.
In case of sending electric motor on storage perform its rust–preventive treatment.
6.3.2 Ремонт аппаратов тягового электропривода

6.3.2.1 Repair of the ventilated brake resistors unit VBU 2x600
DURING OPERATION VENTILATED BRAKE UNIT HAS A VERY HIGH TEMPERATURE PRIOR TO PERFORM-
ING ANY MAINTENANCE OPERATIONS PROVIDE SUFFICIENT TIME FOR ITS COOLING.
The accumulation of dust and dirt on the resistors during long time of operation leads to low ventilation
that may cause overheating. Besides, the adhesion of dirt and dust to the insulators leads to poor electrical in-
sulation.
In case of contamination remove the cover, pull out the resistors sections and remove dirt and dust us-
ing wooden spatula or other object.
When blowing up of resistors sections, rubbing of brushes use safety glasses, as when grinding use in
insulating gloves.
Application of grinders or tools with wire brushes is not allowed. Formed when used them metal chips
can get stuck in the resistors and can cause arcing, and as consequence lead to immflamination.
When blowing avoid ingress of rags, scraps of rope or twine and other debris into the VBU, which will
certainly lead to fire.
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Blow up the dust with clean, dry compressed air (with a pressure of not higher than 2 – 2.5 kg/cm²), or
collect using vacuum cleaner, if using of compressed air is not allowed.
Troubleshooting of VBU is given in Table 6.4.
Table 6.4 – Possible faults of the VBU and its troubleshooting
Fault Possible reason Troubleshooting
Excessive sparking under the brushes Low pressing to the brush. Set the correct pressing force to the
brushes, of 3.2 – 3.8 N (ЭТВ-20М3Л);
4,6 – 6,1 N (ДПТВ16,25-02).
Brushes strongly worn out or brand of brushes Replace brushes with new ones
does not match the recommended. (tabl.6.4), rub them and match them
at low speed.
The working surface of the collector is rough, dir- Wash, clean and polish the collector.
ty.
The collector has a wave shaped worn and insu- Turn through the collector, grind it and
lation between the collector plates guts out. chamfer the collector plates.
Winding short circuit in the armature. Replace the armature.
Excessive heating of the collector Brand of brushes does not match the recom- Replace brushes.
mended.
Excessive pressing force to the brush. Set the correct pressing force to the
brush.
Excessive heating of the armature. Electromotor is overloaded Eliminate overload.
Winding short circuit in the armature. Repair armature winding
Excessive heating of coils Short circuit between separate coil turns Replace damaged coil with new one
Unsatisfactory performance of bear-

ings.
Overheating. Excessive amount of grease or lack of it. Adjust grease amount.
Contamination of the bearing assembly, or poor The bearing assembly is to be rinsed
quality of grease to eliminate the cause of contamina-
tion and lay the grease.
Bearings are damaged Replace bearing.s
Rubber vibroinsulators are loosened or broken. Replace damaged vibroinsulators and
tighten bolts fastening fan set with
iorque of 40 – 45 N.m.
High vibration Poor balancing of fan impeller. Perform static balancing of fan impel-
ler, admitted misbalance is of 0.5gr.
Bearings are damaged Replace bearings.
Overheating of resistors elements Loosened attachment of power cables to the re- Tighten bolts.
sistors outputs.
Touching each other elements of two adjacent Eliminate touch.
resistors.
Fabric branch-pipe is broken. Replace new one and tighten with
clamps
Burnout resistors elements Ingress of foreign objects. Avoid ingress of foreign objects.
No gap between the holders and fehral tape of Set the desired gap and to ensure the
0,7 ± 0,2 (see figure.6.6). free movement of tape over holders
Fan set failure Repair fan set.
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Removal VBU from the dump truck.

Unit in assembly weighs about 650 kg. For removal and installation use appropriate tools.
To remove VBU from the truck remove the side covers, unscrew six bolts securing the unit to the right
truck fender, disconnect the power cables. Secure the unit at four points (each of the four corners are provided
with sling holes) and remove it.
Removing and installing the resistors.
Perform removing of the resistors sections in the following order:
– unscrew and remove bolts 1 (Figure 6.8), washers and nuts fastening two side and upper covers lo-
cated above the resistors set. Remove the cover from the framework;
– unscrew and remove the bolts 2, washers and nuts fastening thermal shield and remove it from the
sections of the resistors set;
– unscrew the bolts 7 and remove the buses 6, and if necessary do the power cables 8 of the fan elec-
tromotor from terminals of the resistor R4;
– unscrew and remove bolts 5, washers and nuts fastening the resistors sections;
– remove the resistor section 3 by pulling it upwards (weight of the section can reach 30kg). Remove the
resistor section only by hands, holding it by the side frames.
Figure 6.8 – Resistors set of the VBU:

1 – bolts fastening the covers of the resistor set (top and side); 2 – bolts fastening the thermal shield; 3 – resistor section;
4 – panel (shutters grating); 5 – bolts fastening resistor section; 6 – bus; 7 – bolts fastening the buses; 8 – power cable;
I – the direction of cooling air flow out when the unit operating
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Mounting sections resistor to take place in the following sequence:

– when assembling the section of the resistor provide the size (548 + 2) mm (see Figure 6.5) by select-
ing the required number of spacers 10, setting them evenly between the insulators 9;
– compress holders 1 and 2 according to the cross section B-B;
– the tightening torque for nuts 14 is of 15 – 20 Nm;
– provide the size (586 + 1.4) mm by selecting the required number of washers 15, setting them evenly
on both sides of the resistor;
– lower gently the resistor section, making sure that the lower part of the side frames 5 enters the guid-
ing brackets of the framework and keeping the smallest possible gap between the side frames.
Neighboring sections should be mounted setting the tape protuberances to different directions.
When mounting the resistor section it is important to set it into the VBU with as little as possible air gap
between adjacent sections. The gaps between the sections lead to loss of the air cooling the section and thus
reduce the life of the whole unit of dynamic deceleration. To perform the proper installation, always start the in-
stallation of the resistor section from the fan set side in the direction of the cooling air exit. Prior to installation,
make sure that resistor catalog number is correct and marking on the section side frames coincides;
– install bolts 5 (see Figure 6.8) in a set of flat washers securing sections and tighten nuts with torque of
10 – 12 Nm;
– install thermal shield, having secured it by bolts 2 and nuts with washers (tightening torque is of
10 – 12 Nm);
– install buses 6, connect the electromotor power cables 8, having secured them by bolts and nuts with
washers (tightening torque is of 50 – 60 Nm). Additionally secure the electromotor cables by clamps;
– install the side and top covers. When installing ensure that the covers are mounted at correct places,
and bolts are properly tightened. Loosened bolts may lead to penetration of moisture and dirt into the resistor
unit, and as a consequence to the VBU malfunction.
Removal and installation of the fan.

Perform removing the fan in the following sequence:
– remove covers over the VBU fan set;
– disconnect power cables from the fan motor;
– disconnect the air duct 9 (see Figure 6.3) from the fan having unscrewed the four nuts on the bolts 19
and move it to the side of the resistor unit;
– unscrew the four bolts 10 securing the fan to the frame 2;
– using appropriate lifting ropes or slings fasten the fan over the holes in the eyelets, the weight of the
fan is of 300 kg.
– remove the fan from VBU.
Perform installation the fan in the following sequence:
– when covers of the VBU fan set are removed lower the fan onto it place in the frame 2 for installation;
– align four mounting holes of the fan with thread holes in the insulators 13 having placed pads 12;
– fit bolts fastening the fan having placed the flat and lock washers under the each bolt;
– using four bolts 19 with washers and nuts install air duct 9. Tighten the nuts with torque of 60 – 70 Nm;
– moving the fan in a horizontal plane reach the best alignment of the air duct 9 and the branch-pipe 5;
– tighten the fan with torque of 60 – 70 Nm;
– connect the motor power supply wires. Tighten the nuts with torque of 15 – 20 Nm;
– install earlier removed protective covers VBU, having locked them by bolts.
Disassembling and assembling of the fan.

Disassembling and assembling will be considered on the example of fan 75139-2126004 (motor
ДПТВ-16,25-02), peculiarities of fan 75139-2126004-01 (motor ЭТВ-20M3L) design will be considered sepa-
rately.
Perform disassembling the fan in the following sequence:
– unlock and unscrew the nut 7 (see Figure 6.4), remove the locking washer 8, mark anywhere with
paint the outer side and carefully remove the fan impeller 5. Eject key 6.
It is not allowed to use hammers and other percussion tools when removing the impeller! Removed fan
impeller should be carefully put onto the rubber or wooden surface avoiding shock loads;
– unscrew power supply electric wires from the terminal pads 13;
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– remove the cover in the engine front part having unscrewed four bolts M4 (ДПТВ-16,25-02) and
putting the hand through out the window, pull the wires feeding the motor inside the engine. Unscrew the bolt
and remove bracket 4. Unscrew two bolts and remove the housing of the collector chamber. Unscrew the lock-
ing bolts 16, preliminarily having loosened the locknuts;
– unscrew four nuts on the bolts 1 and pulling out remove the support 11 and adjusting rings 12
(ДПТВ-16,25-02). There are no adjusting rings in the fan with motor ЭТВ-20M3L;
– remove pipes 1, 2, 5, 7 (see figure 6.4a) supplying grease to the bearing units as well as drainage
ones (ЭТВ-20M3L);
– being careful install the fan set vertically (with side of air outlet up) resting it on the rear part of the
electromotor;
– loosen the nut 10 (see Figure 6.4) of the locking screw 9, unscrew the locking screw (motor
ДПТВ 16,25-02) and remove housing 2 from the engine;
– remove the bearing cover (4 bolts M8) and the front cover of the electric motor (6 bolts M12), pull by
hand wires feeding electromotor inside the engine and remove housing 4 (see Figure 6.5a) from the motor
(ЭТВ-20M3L);
– perform disassembling and assembling of the electric motor in accordance with the electromotor Op-
eration Manual.
Perform assembling the fan in the following sequence:
– install the fan housing 2 (see Figure 6.4) onto supports with side of air outlet down;
– remove the cover (4 bolts M4) in the motor front part opposite to the hole for wires output and pull the
wires inside the engine (ДПТВ-16,25-02);
– remove the bearing cover (4 bolts M8) and the front cover of the electric motor (6 M12 screws) and
pull the wires inside the engine (ЭТВ-20M3L);
– screw two eyebolts M12 into the holes on the rear side of the electric motor (from the collector side)
and lifting eyebolts, install it into the housing. The weight of the motor is about 200 kg. Use appropriate eye
bolts and slings;
– turn the electromotor to match the window for wires output the electromotor and the housing outlet
pipe. Pull the wires through the pipe to the terminal pads 13 and fasten them according to the wiring diagrams;
– install the support 11. For the electromotor (ДПТВ-16,25-03) preliminarily install the desired number of
adjusting rings 12 providing the gap of 1 – 1.5 mm. Then, having installed four bolts 1 with spring washers tigh-
ten the nuts with torque of 40 – 45 Nm;
– install locking bolts 16, tighten them with torque of 15 – 22 Nm and lock them using lock-nuts;
– install the bracket 4 (ДПТВ-16,25-02); tighten fastening bolt with torque of 20 – 30 Nm;
– substitute eyebolts M12 to the plugs;
– turn over the fan set by 180°;
– install locking screw 9 and lock it using lock-nut 10 (ДПТВ-16,25-02);
– install the locking dowel 20 (Ø6x26) (ЭТВ-20M3L, see Figure 6.4a) into the hole in the motor with the
+ 0,18
housing, if the motor was never replaced, or drill the hole (Ø6 to a depth of 27 mm) at the point of contact
of the electric motor and the landing bed of the housing (when the engine is new);
– pull the motor feeding wire into the housing outlet pipe and fasten them on the terminal pads; note the
presence of sealing ring at the point of wires output. When manipulating the wires terminal ends be careful to
avoid damage of the insulation and soldering;
– install the cover in engine front part the (ДПТВ-16,25-02) having tightened four bolts with torque of
2 – 2,5 Nm;
– install the front cover of the electric motor to its place having tightened six bolts with torque of
40 – 45 Nm, as well as do the cover of the bearing unit having tightened four bolts with torque of 15 to 20 Nm
(ЭТВ-20M3L);
– install the washer 10 (ЭТВ-20M3L, see Figure 6.4a) on the motor shaft;
– install the fan impeller 5 (see Figure 6.5) on the motor shaft (the part of the fan impeller marked with
paint should be facing outwards), install locking washer 8 and nut 7. Tightening torque is of 350 – 400 Nm.
Make sure that the engine armature gets rotated freely and there no impeller touching.
Grinding the collector.

If necessary (see table 6.4) perform grinding the collector.
The collector working surface should be smooth, polished, purple or reddish. When scuffs, burns, flow-
ing are found so sand the collector working surface.
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For grinding the collector use glass sandpaper with grit of 8 – 10 Standard 6456 and special wooden
tool with a radius of curvature of the inner surface equal to the radius of the collector and the angle of coverage
of at least 30°. Width of sandpaper should be equal to the length of the collector.
Sandpaper is to be inserted between the tool and the collector grinding surface. The rotation of the mo-
tor is provided by constant source of low-voltage (40 – 50) V. After grinding, or brushes lapping collector
chamber is to be blown up with dry compressed air. If, due to the wear surface of copper is equaled the inter-
plate insulation collector should be turned through; insulation should be slotted to a depth of 1 – 1,5 mm, clean
the slots using rigid hair brush and polish. Prior to turning through wrap the armature winding with paper.
6.3.2.2 Repair of running control unit

While in operation of running control unit can appear such failures, as wear or burning of contact pieces,
slackening of fastening of fixed contacts or contact joints.
Replacement of contact pieces and retorque of fastenings can be produced without removal of control
unit from dump truck. For this purpose unscrew screws 10 (see figure 6.6), fastening side 8 and lower 12 cov-
ers and remove them. Disconnect wires from contact bolts 9, roll lock nut and nut of their fastening and remove
contact bolts.
For dismounting control unit from dump truck disconnect wires from terminal block and pull–rod from bar
13, unscrew four bolts of fastening of control unit to grounding of cabin and remove it.
Disassembly of control unit is to be carried out as follows:
– unscrew screws 10 fastening side 8 and lower 12 covers and remove them together with gaskets;
– disconnect wires from contact bolts 9;
– unscrew bolts 23 and remove lath 3 in assembly with cam elements 1;
– unscrew bolts of 2 fastening cam elements to lath and remove them;
– if necessary unscrew lock nut and nut of fastening of contact bolts 9 and remove them;
– disconnect contact bridge 11 from bar of cam element;
– unscrew bolt 7 and remove bar 13 from shaft 21. Take out tab from keyway of shaft;
– unscrew bolts of fastening of covers 15 and 20 and remove them;
– extract drum of control unit from case;
– press bearings 19 from shaft;
– unfasten and unscrew nut and remove from shaft lock washer 14, ring 16, cams 17 and insulating
washers 18.
Assembly and mounting of running control unit should be carried out observing following requirements:
– at assembly of drum locating holes of cams 17 and keyway of shaft place in one plane, and identifica-
tion mark of cams should be directed aside keyway;
– before mounting of cam drum in case of cavity of ball–bearings 20 fill lubricant Литол–24;
– 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.
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7 ELECTROMOTOR-WHEEL
Dump trucks BELAZ-7513 BELAZ-7513A equipped with traction electric drive GE150AС of “General
Electric” Company depending on modification can be equipped with electric motor-wheels with reduction gears
manufactured by “General Electric” Company or with electric motor-wheels with reduction gears made by
“BELAZ” Company.
Technical description, maintenance and repair of electric motor-wheel of traction electric drive GE150AС
manufactured by “General Electric” Company is given in the documentation attached to the drive by manufac-
turer.
Current chapter describes repair of electric motor-wheels with reduction gears made by “BELAZ” Com-
pany.
7.1 General information
Electromotor–wheel 4 (figures 7.1) is fastened to casing of rear axle 3 by bolts 5 and includes traction
motor 2 (figures 7.2), reduction gear 8, rear wheel hub 4, brake gears of service 3 and parking 1 brake sys-
tems and induction sensor of speed limitation.
Figure 7.1 – Rear axle:

1 – connecting hose; 2 – breather; 3 – rear axle housing; 4 – electric motor-wheel; 5 – bolt; 6 – check plug; 7, 8, 11 – clamps;
9 – tape; 10 – hose
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Brake gears are of disk type, they are mounted on the bearing shield of traction electromotor. Reduction
gear of motor wheel is of double-row, differential type with straight teeth pinions; it is mounted in the hub of
rear wheel.
Technical state of reduction gear is defined during the operation:
– by external examination;
– by hearing (operation noisiness);
– by heat level;
– by results of oil spectral analysis.
During external examination viewing oil leakage it‘s possible to discover wear or damage of cups, as
well as precipitation of pores and cracks in body, cover or hub.
Random breakages or parts attachment loosening can be discovered by hearing.
By heat level it is possible to determine the failure of bearings adjustment or oil level change in the re-
duction gear.
By results of oil spectral analysis it is possible to determine wear of tooth wheels, spline joints and
bearings.
7.2 Removal of electromotor-wheels

Removal of electromotor-wheel from the truck is performed in the following way:
– previously having taken measures, excluding spontaneous truck movement getaway;
– with the help of special hydraulic hoister or hoisting crane put up the certain axle side and place the
rest under the rear axle housing;
– unfasten and take off wheels (see section «Running gear»);
– release working fluid pressure in the brake systems hydraulic drive having turned locking needles on
brake valve and disconnect high pressure hoses from cylinders of service and parking brake systems;
– turn the reduction gear hub in order to the plug of drain hole 5 (see figure 7.2) is from bottom, screw off
it and drain the oil;
– disconnect output cables of electromotor from power cables and unfasten them;
– disconnect harness wiring from the sensor of speed limitation;
– disconnect hoses for lubrication of electromotor bearings (if necessary);
– loosen screw of clamp 7 (see figure 7.1) and disconnect connection hose 1 from breather 2 at rear-
axle housing;
– loosen screw of clamp 8 and disconnect cooling air supply hose 10 from traction motor;
– unscrew bolts 7 (see figure 7.2) and remove reduction gear cover 11 and seal ring;
– dismount locking ring 10 and first-raw sun gear 9 from torsion shaft 12, remove the torsion shaft;
– mount appliance (рисунок 7.3) to the loader and, using attached implements of the loader, arrange the
appliance with electromotor-wheel by fastening them to each other;
– unscrew bolts 5 (see figure 7.1) of electromotor-wheel 4 fastening to rear-axle housing 3;
– disconnect electromotor-wheel from rear-axle housing using bolts that are uniformly screwed in
squeeze holes of reduction gear casing. Move electromotor-wheel into repair area. Be careful – electromotor-
wheel weight is 9 tonnes, ready-assembled traction motor weight is 3.6 tonnes;
– fasten traction motor by eyebolts or appliance (figure 7.4) and unscrew bolts 15 (see figure 7.2) of
traction motor 2 fastening to reduction gear 8 casing,
– disconnect traction motor from reduction gear casing using bolts, that are screwed in squeeze holes of
traction motor, and take the motor aside;
– unscrew bolts of torsion shaft flange 13 fastening to traction motor flange 14 and dismount the flange;
– unscrew bolt of traction motor flange 14 fastening and dismount the flange.
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Figure 7.2 – Electromotor-wheel:

1 – parking brake mechanism; 2 – traction motor; 3 – service brake system; 4 – hub of rear wheel; 5 – plug of drain hole; 6 – plug
of filling hole; 7, 15 – bolts; 8 – reduction gear; 9 – solar pinion of first row; 10 – locking ring; 11 – cover; 12 – torsion shaft; 13 – flange of
torsion shaft; 14 – flange of traction motor
Figure 7.3 – Appliance for removal and mounting of electromotor-wheel:

1 – lateral beam; 2 – longitudinal beam; 3 – chain; 4 – rear stanchion; 5 – front stanchion; 6 – hitch; 7 – thrust; 8 – inner beam;
9 – roller
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Figure 7.4 – Appliance for removal and mounting of traction motor:

1 – reduction gear of motor wheel; 2 – finger; 3 – bracket; 4 – fork of loader; 5 – traction motor; 6 – support; 7 – cross-bar
7.3 Disassembly of reduction gear

Perform disassembly of reduction gear in the following way:
– turn off bolts and nuts 42 (figures 7.5), take out ring 43, squeeze cup 44;
– put the body of motor-wheel reduction gear to the vertical position and with hub up;
– turn off drain plug 13, turn off bolts 12 and by means of bolts, screwing into the squeezing holes, take
off driving cap 14 as assembly with first row and solar pinion of second row 23. Appliance intended for removal
and mounting of carrier of first row without removal of electromotor-wheel and tires is shown in figure 7.6;
– remove sealing ring 35 (figure 7.5) from the driving cap;
– unsplint and turn off bolts 21 and remove 2 locking plates 22 (half-washers) of solar pinion of second
row 23;
– turn off bolts 32, and by means of bolts, screwing into the squeezing holes, take off cap of the first row
16 carrier;
– remove sealing ring 31 from the carrier cap;
– extract the carrier as assembly with satellites and bearings;
– press from the carrier 17 bearings 19 with the help of remover (figure 7.7). For removing place block 1
with screw 3 under outer bearing race, put the ring 2 on and lock by screws 4, turning screws 3 by 0,3 – 0,5
turns remove bearing;
– disassembly carrier, having unspinted and turned off fastening bolts 29 (figure 7.5) of locking plates
27of satellites axles and having removed plates. Squeeze out axles 26, extract spacer rings 55, remove satel-
lites 24 and thrust plates 56.
Removal of axles is to be performed with the help of appliance (figure 7.8). Set screw 3 with nut 1 and
mounting nut 5 into the hole of the axle and lock by block 8 from the reverse side. Tighten nut 5 up to stop.
Place barrel 4 onto retaining surface and support flange 2 between nut 1 and barrel 4. Turning nut 1 remove
axle from the body;
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Figure7.5 – Reduction gear of motor-wheel:

1 – reduction gear body; 2 – under cup ring; 3 – hold-down; 4 – spacer ring; 5, 12, 21, 29, 32, 36, 42,45, 52 – bolts; 6 – cup;
7, 19, 25, 38 – bearings; 8 – hub; 9 – crown pinion of second row; 10 – thrust ring; 11 – adjusting bolt; 13 – drain pipe; 14 – drive cap;
15 – crown pinion of first row; 16 – cover of first row carrier; 17 – first row carrier; 18 – check plug; 20 – reduction gear cover; 22, 27,
37 – locking plates; 23 – solar pinion of second row; 24 – satellite of first row; 26 – axle of first row satellite; 28, 31, 35 – sealing rings;
30, 39 – locking rings; 33 – spacer ring; 34 – greaser; 40 – satellite of second row; 41 – axle of second row satellite; 43 – ring; 44 – cup;
46, 51 – filters; 47 – connection hose; 48, 50 – oil catcher; 49 – split-pin; 53 – probe; 55 – spacer ring; 56 – thrust plate
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Figure 7.6 – Appliance (М513018) for removal and mounting of first row carrier
(rigging equipment for forklift):
1, 2 – brackets; 3 – chain; 4 – finger; 5 – support; 6 – bolt; 7 – hold-down; 8 – first row carrier;
Figure 7.7 – Remover for bearing of first row carrier:

1 – block; 2 – ring; 3, 4 – screws; 5 – first row carrier; 6 – bearing
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Figure 7.8 – Appliance for removing of satellites axles:

1 – thrust nut; 2 – support flange; 3 – screw; 4 – barrel; 5 – thrust nut; 6 – first row carrier; 7 – satellite axle; 8 – block
– take out locking rings 30 (figure 7.5) of satellites 24 and squeeze out bearings 25;
– disconnect crown pinion 15 with drive cap 14 and take off pinion;
– unsplint and turn off bolts 11 of thrust ring 10 fastening and take off ring and spacer ring 33;
– take off inner race of outer bearing 7 from the body of reduction gear 1;
– fasten and take off hub 8 from the reduction gear 1;
– unscrew bolts 5 of clamps fastening, remove clamps 3, extract spacer ring 4 and squeeze big glands
2 (figure 7.9) using remover 4, having placed cover 3 on hub of motor-wheel 1;
– squeeze from hub 4 ( figure 7.10) the external ring at first of external bearing 3, then of internal bear-
ing 1, having placed cover 2 on hub of motor-wheel;
– dismount second-row sun gear 9 (see figure 7.5);
Figure 7.9 – Appliance for removing of cup from motor-wheel hub:

1 – motor-wheel hub; 2 – cups; 3 – cover; 4 – remover
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Figure 7.10 – Appliance for removing of outer bearings races:

1 – remover; 2 – cover; 3 – outer bearing race; 4 – hub of motor-wheel
– unlock and turn off bolts 36 of fastening of locking plates of second row satellite axles, take off locking
plates 37 and squeeze satellite axles 41 using appliance (figure 7.8);
– take out satellites 40 (figure 7.5), squeeze from them bearings 38 using appliance (figure 7.11), extract
distance ring and locking ring 39 (figure 7.5);
Figure 7.10 – Appliance for removing of bearings from satellites:

1 – bushing of support; 2 – cup of support; 3 – bearing; 4 – support finger; 5 – press plate; 6 – distance ring; 7, 11 – satellites;
8 – sector; 9 – outer bearing race; 10 – core
– squeeze inner race of the internal bearing 7;

– turn off bolts 45, disconnect from the body and remove under cup ring 2 using appliance (figure 7.12).
Remove the ring 6 after fastening of trunnion 1 on the hub 5 by bolts 2 turning serially nuts 3.
– remove seal ring 54 (see figure 7.5).
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Figure 7.12 – Remover for under cup ring:

1 – trunnion; 2 – bolt; 3 – nut; 4 –stud; 5 – hub of motor-wheel; 6 –under cup ring
7.4 Checking of the technical state of parts of motor-wheel reduction gear

Nominal and maximum dimensions of the main parts of motor-wheel reduction gears are shown at the
table 7.1.
Table 7.1 – Nominal and maximum dimensions of the main parts of motor-wheel reduction gear
Dimensions, mm
Number, part designation and
Material Hardness
checked performances
nominal maximum
75132-2405210-03
Reduction gear body:
Diameter of landing journals for taper − 0,024
roller bearing 710 709,8
− 0,074
Steel 40Л
Hole diameter for satellite axles
+ 0,087
100 100,15
75132-2405264 Steel 20Х2Н4А Tooth face

−0,30
First row satellite 142,277 141,6 Substitute: 58 – 62 HRC
−0,38
Length of common normal 18ХГН2МФБ Core 34 – 46 HRC
75132-2405284-02
Crown pinion of the first row
Tooth size +1, 4
(over rollers ∅15,037±0,002) 804,04 805,9 Spline and tooth faces
+1,2 Steel 38Х2МЮА
≥700HV2
Spline size −1,5

918,26 915,5
(over rollers ∅9±0,002) −1,7
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Continuation of the table 7.1
Dimensions, mm
Material Hardness
checked performances
nominal maximum
75132-2405300
Carrier of the first row
Diameter of the holes for satellite +0,022
axles 100 100,07 Steel 40Л Spline face ≥45HRC
−0,013
Spline size +0,55

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

440 440,12
75132-2405342
+0,063
Carrier cover 440 440,12 Steel 40Л
Diameter of holes for bearing
7519-2405372
Solar pinion of the second row −0,165
81,74 Steel 20Х2Н4А Tooth and spline faces
Length of the common tooth normal −0,245 81,00 58 – 62 HRC
Substitute:
−0,75 18ХГН2МФБ Core 34 – 46 HRC
Spline size (over rollers ∅9±0,002) 207,83 206,00
−0,85
7519-2405434 Steel 20Х2Н4А Tooth and spline faces
−0,19
Satellite of the second row 111,969 111,40 Substitute: 58 – 62 HRC
−0,31
Length of the common normal 18ХГН2МФБ Core 34 – 46 HRC
75191-2405492
Axle of the second row satellite 100 99,93 Steel 40Х Face ≥50HRC
−0,022
Diameter
75132-2405526
Torsion shaft −0,10 Steel
106,42 105,3 387 – 444 НВ
Spline size −0,20 45ХН2МФА
(over rollers ∅6,5±0,002)
7519-2405496-02
Crown pinion of the second row
Tooth size +1, 4
(over rollers ∅18±0,002) 809,984 812,00 Tooth and spline faces
+1,1 Steel 38Х2МЮА
≥700HV2
Spline size −1,5

948,26 945,5
(over rollers ∅9±0,002) −1,7
75132-3104015-10
Motor-wheel hub +0,26
922,2 923,5 Steel 40Л
Spline size +0,09
(over rollers ∅9±0,002)
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Continuation of the table 7.1
Dimensions, mm
Material Hardness
controlled variables
nominal maximum
75132-2405522
Solar pinion of the first row
−0,165 Steel 20Х2Н4А Tooth and spline faces
Length of the common tooth normal 57,312 56,40
−0,285 Substitute: 58 – 62 HRC
18ХГН2МФБ Core 34 – 46 HRC
Spline size +0,180
86 87,2
(over rollers ∅6,5±0,002) +0,073
7520-2405532
Flange of torsion shaft
Spline size +0,18 Spline face and faces
(over rollers ∅6,5±0,002) 86 87,2 Steel 20Х for cup
+0,07
54 – 60 HRC
Wear of surface under the working 0.3 mm of side
edges of cups
75191-3104114-20
Under cup ring
0.5 mm of side Steel 45 Face for cup≥52 HRC
Wear of surface under the working
edges of cups
7.5 Assemblage of motor-wheel

Assemblage of motor-wheel should be carried out in conditions excluding ingress of dust, chips, dirt to
the parts. Prior to assembling check bearings, diametrical surfaces and faces on the body, hub and thrust ring.
Nicks, scratches and other defects on rings, separators and rolling elements of bearings are not admitted.
When find of nicks on faces of parts, conjugated to bearings, clean flush with the main surface.
During assemblage it’s required to use standard or special instrument. Under mounting of parts and
units it’s permitted to use hammers and drifts from nonferrous metal and alloys. Insertion of bearings is
recommended to realize on hydraulic presses with the help of special arbors or with help of mechanical
appliances.
Perform assemblage of reduction gear of motor-wheel in the following way:
– install reduction gear body 1 (figure 7.5), of the motor wheel to the horizontal site by flange for fasten-
ing and snub from rotation;
– fasten by bolts 52 to the reduction gear body two filters 46 and 51, lock bolts by split-pin wire. Prior to
installing disassemble filters and clean filtering elements and magnets;
– fasten and install to the body under cup ring 2 and fasten it with bolts 45, preliminarily having installed
sealing ring 54 greased by lubricant;
– fasten inner bearing race 7 by ring bolts, turned into threaded holes;
– mount inner bearing race onto reduction gear body and press up to stop.
The gap between thrust face of inner bearing race and body should not exceed 0,03 mm. in case of
0
mounting of bearings with heating the heat temperature should not exceed 120 C.
– assemble satellites of the second row (figure 7.13), having mounted into the satellite 1 locking ring 2
and having squeezed bearings 3 up to stop into the ring, previously having placed distance ring 4 between
bearings and having lubricated by oil the conjugated faces of satellite;
– install satellites into the body of the reduction gear 1 (see figure 7.5), squeeze the satellite axles 41,
previously having lubricated by lubricating grease conjugated holes of the body and bearings, mount locking
plates 37 of satellite axles and fasten them to the body by bolts 36, having stopped bolts 3 (figure7.14) by pin
wire 2.
Satellites should be free rotated on the bearings. Slipping of the inner bearing rings on the axles is not
permitted;
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Figure 7.13 –Satellite of the second row as assembly:

1 – satellite; 2 – locking ring; 3 – bearing; 4 – distance ring
Figure 7.14 – Locking of satellite axle of the second row:

1 – satellite axle; 2 – pin-wire; 3 – bolt; 4 – locking plate
– squeeze into the wheel hub 8 (see figures 7.5) the outer race of the inner bearing 7, cup 6, previously
having lubricated by lubricating grease the conjugated faces of hub.
Mount spacer ring 4 and fasten nips 3 by bolts 5 to the hub, mount the crown pinion 9 and squeeze the
outer race 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 races and hub. The
cavity between cups should be filled by lubricating grease Литол-24;
– adjusting bolts 11 (24 pcs.) should be free turned by hand into the threaded holes of body 1;
– fasten and mount hub onto the body of reduction gear along the internal hub bearing, at that don’t
damage rubber glands of the hub seal and match tooth rims of the crown pinion of second row and satellites of
second row. Before hub installation lubricate the operational edges of cups by lubricant Литол-24. Rotate hub
forward- back on the bearing to ensure abutment of rollers to the operational board of bearing;
– mount inner race of outer bearing 7 and thrust ring 10. Mount oil catchers 48 and 50 with filters 46 and
51 and join them by hoses and clamps. Snug (not tightening) up bolts 11 (24pieces).
Perform adjusting of hub tapered bearings in the following way:
– check the torque of hub rotation through the second row. It should not exceed 500 N.m (on the tech-
nological pinion of the second row not more 135 N.m). Fix the value of that torque;
– rotating hub through the second row, tighten with torque of 20 N.m. serially by 2 diametrically located
eight bolts 11. Repeat bolt tightening in the same way up to setting of torque 20 N.m at all eight bolts. Repeat
bolt tightening in the same way up to setting of torque 40 N.m at all eight bolts.
Check by probe the gap between roller faces and bearing board 4 (figure7.15). If at 70% of rollers the
gap doesn’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
setting of torque 60 N.m. at all 8 bolts.
Check by probe the gap between roller faces and bearing board. If at 70% of rollers the gap doesn’t ex-
ceed 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 setting of torque
80 N.m. at all 8 bolts.
Check by probe the gap between roller faces and bearing board. If at 70% of rollers the gap doesn’t ex-
ceed 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 setting of torque
100 N.m. at all 8 bolts.
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Figure 7.15 –Checking up of clearances:

1 – reduction gear body; 2 – adjusting bolt; 3 – thrust cup; 4 – bearing;
А – placement of probe; B – gap
Check by probe the gap between roller faces and bearing board 4. If at 70% of rollers the gap doesn’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 perform disassembly of parts;
– check up hub rotation torque through the second row. It can be increased in comparison with earlier
measured torque (not more 500 N.m) not more than by 400 N.m (on technological pinion of the second row in
comparison with earlier measured torque (not more135 N.m) not more than by 108 N.m;
– in four equivocated places against bolts measure gap B: B1, B2, B3, B4 with accuracy of +0,02 mm;
– grind spacing rings 33 (24pieces) (see figure 7.5) to size С=(((B1+B2+B3+B4):4)+0,2) with accuracy
of +0,015;
– turn off eight adjusting bolts 11;
– turn adjusting bolts 11 (24 pieces) putting onto each one spacing washer from ground pack in order to
spacing washers are in gap B (see figure 7.15);
– tighten adjusting bolts serially with torque of 400 – 440 N.m;
– cotter bolts in pairs by pin wire.
Perform assemblage of the first reduction gear row of electromotor-wheel in the following way:
– mount into the satellite of first row 24 (figure 7.5) locking ring 30;
– squeeze bearing 25 into the satellite up to stop into the locking ring, previously having lubricated by oil
the conjugated satellite faces;
– install another locking ring 30 into the satellite;
– put satellites 24, spacer ring 55 and thrust plates 56 into the carrier 17 of the first row, squeeze axles
26, previously having lubricated by grease the conjugated faces of body and bearings, mount and fix by bolts
the locking plates 4 (figure 7.16), stop bolts 3 by pin -wire 2;
Figure7.16 – Stopping of the satellite axle of the first row:

1 – satellite axle; 2 – pin-wire; 3 – bolt; 4 – locking plate
– built up bearings 19 onto the carrier 17 (see figure 7.5), here apply force only to the inner bearing rac-
es (at application of force to the outer races of bearings the surfaces and rolling element become damaged);
– mount into the drive cap 14 the crown pinion of the first row 15, the carrier of first row with satellites,
having matched tooth rims of the first row crown pinion and of first row satellites, the cap of first row carrier 16
with sealing ring 31, previously having lubricated the ring by lubricating grease, and tightening by bolts 32 as-
semble the first row of reduction gear;
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– mount the crown pinion of second row 23, fasten

two locking plates 2 (half-washers) (figure 7.17) by bolts 3
to the carrier of first row and stop bolts by pin wire 1;
Figure 7.17 – Stopping of the solar pinion of the second row:

1 – pin-wire; 2 – locking plates; 3 – bolt
– fasten the first row to the hub 8 (see figure 7.5) by bolts 12, having mounted sealing ring 35, previously
having lubricated the ring by lubricating grease (be careful during inserting of solar pinion of the second row 23
into the satellites of the second row 40);
– turn into the hub threaded holes the drain pipes 13. Put the drain pipes on joint sealant
«Унигерм 9».
For mechanization of operations on assembly-disassembly of motor wheel reduction gear and on ad-
justment of second row tapered bearings the stand (figure7.18) is intended.
The stand consists of the following main parts: frame 2 with actuator 1, support footing 3 attached to up-
per part of frame and electrical equipment.
There are dowels 7, placed on support footing. They are intended for mounting and fixation of motor-
wheel reduction gear. Actuator 1 is intended for crank through torsion shaft 6 and pinion 4 of reduction gear
second row during tapered bearings adjustment.
Actuator consists of reduction gear and electromotor. Spline clutch for mounting of spare torsion shafts
is fixed on output reduction gear end.
For gap adjustment in tapered bearings place reduction gear 5 onto support footing 3, fix unit against
turning by dowels 7, mount spare torsion shaft 6, having engaged with actuator clutch.
Mount pinion 4, having engaged it with with satellites of second row. Turning the hub through satellites,
tune gap at the tapered bearings, as mentioned above.
Figure 7.18 – Stand for assembly-disassembly of motor wheel reduction gear and for adjustment
of second row tapered bearings:
1 – actuator; 2 – frame; 3 – support footing; 4 – pinion of actuator; 5 – reduction gear of motor-wheel; 6 – torsion shaft; 7 – dowel
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Perform assemblage of electromotor-wheel in the following way:

– fasten the reduction gear of motor-wheel by appliance and place it onto the support (figures 7.3);
– mount into body 1 the cup 44 (see figure 7.5), previously having lubricated by lubricating grease the
conjugated body face, install safety ring 43, turn bolts 42;
– put flange 14 (see figure 7.2) onto the shaft of traction motor (grease spline surfaces);
– Install plates and tighten bolt fastening the flange Mcr 260 – 320 N.m. having locked it by sealant
«Унигерм 9»;
– fasten by bolts to the flange 14 of traction motor the flange of torsion shaft 13 (tighten with torque of
270 – 315 N.m);
– fill up lubricant Литол-24 and lubricate the operation edges of cup 44 (see figure 7.5);
– fasten the traction motor by appliance and place (see figure 7.4) it into reduction gear body, having
tightened by bolts 15 (see figure 7.2). Tighten with torque of 800 – 1000 N.m. Before installation lubricate the
landing face of electromotor by lubricant Литол-24;
– mount on to torsion shaft 12 the inner locking ring;
– mount torsion shaft into the spline cavity of flange 13 up to stop;
– mount onto torsion shaft the crown pinion 9 of the first row and outer locking ring 10;
– mount cap 11 with sealing ring, previously having lubricated the ring by lubricating grease, and fasten
it by bolts 7;
– mount into the cap 4 (figure 7.19) the thrust 2 up to stop in to the spherical thrust 6 of torsion shaft 7.
Measure gap between faces of cap and thrust. Collect the package of adjusting washers 1 in width for amount
of clearance plus (1 – 2) mm and mount it between cap 4 faces and thrust 2 faces. Fix the thrust in cap
by bolts;
– mounting of brake mechanisms of rear wheels is described in the part “Brake systems”;
– fasten electromotor-wheel 4 (see figure 7.1) by loader and bring it to the rear axle housing 3. Match
the holes by turn of motor-wheel and fasten the motor-wheel to the rear axle housing, having tightened bolts 5
with torque of 1200 – 1300 N.m;
– join to the harness wiring to the gauge of speed limitation and to thermal sensors, fasten cables of
traction electromotors at joint panel in the rear axle housing, fasten hoses for lubrication of bearings traction
electromotor. Join hoses of high pressure to the cylinders of brake system. Mount and fix by clamps 8 the elas-
tic branch-pipe 10 for supply of cooling air to the traction motor;
– connect and fasten using clamp 7 connection hose 1 to the breather 2 on the rear axle housing. Avoid
sag of the connection hose leading to creation of oil jams which shut air flow. Tension of hose can be ensured
by means of cut in proper point;
– after mounting of wheels and removal of support from under the housing refill reduction gear with oil
SAE-85W/140 API:GL5 up to check plug 6 (46 l).
Figure 7.19 – Torsion shaft clearance adjustment:

1 – adjusting washer; 2 – thrust; 3 – locking ring; 4 – cap; 5 – solar pinion of first row; 6 – spherical thrust; 7 – torsion shaft;
А – gap
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7.6 Running-in of the motor-wheel reduction gear

Running – in of the motor wheel reduction gear is carried out with the aim of the quality control of as-
semblage and break-in of its main units and parts .The manufacturer uses for running-in stand, shown in
figure 7.20.
Perform running-in of reduction gear of motor- wheel in the following way:
– install reduction gear 1 as assembly to the running-in stand;
– pour the industrial oil И-20А ГОСТ20799-88 to the reduction gear till the level of check plug;
– perform running-in in 2 modes under the table 7.2.
Table 7.3 – Running-in modes
Running mode 1 2
-1
Rotation speed of electric engine shaft, min 800 + 70 1500 + 70
Running time, not less, min 25 20
During the running-in keep track of appearance of unwanted sounds and knocks. After the running-in
check the reduction gear heating on the external surface of cap at the zone of location of check and filler plugs.
The heat temperature shouldn’t exceed 70 С.
0
If the temperature is augmented; there are leakages, unwanted sounds and knocks at the reduction gear
of motor-wheel it is necessary to eliminate causes of such faults and repeat running-in. Noise level shouldn’t
exceed 95 dB at the distance (1000 + 100) mm at the general noise level not more 85 dB;
– after the running-in drain the oil out of reduction gear.
Figure 7.20 – Stand for running-in of motor-wheel reduction gear

1 – reduction gear; 2 – traction motor; 3 – support; 4 – housing; 5 – hose; 6 – tacho-generator
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8 RUNNING GEAR
8.1 Suspension
8.1.1 General data
The front suspension is dependent and consists of two pneumohydraulic cylinders 2 (figure 8.1.1),
eyelet 17 with hinged lever of front axle and transversal rod 1.
Figure 8.1.1 – Front suspension

1 – rod; 2 – suspension cylinder; 3 – sealing ring; 4, 19 – covers; 5, 28 – greasers; 6, 13, 14, 16, 18, 24, 31, 34 – bolts; 7 – rod
gland; 8, 20 – hinged bearings; 9 – locking ring; 10, 22 – fingers; 11 – bushing; 12, 15 – disks; 17 – eyelet with basing; 21 – central hinge
gland; 23 – disk; 25 – upper bracket; 26 – self-locking nut; 27 – high pressure hose; 29 – shroud; 30 – lower bracket; 32 – sensor housing;
33 – split-pin wire; 35 – locking plate
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The suspension cylinder is fastened to upper 25 and to lower 30 brackets nuts 26. Upper and lower
brackets are fastened by bolts 24 and 31 to bracket of fender attachment and to steering knuckles.
Transversal rod 1 is hingedly connected to cross bar of frame and beam of front axle by means of taper
fingers 10. Eyelet 17 of the central hinge is fixed to lever of front axle with help of bolts 16, and is also hingedly
fixed to bracket of frame by finger 22.
The rear suspension is dependent and consists of two pneumohydraulic cylinders 2 and 3 (figure
8.1.2), eyelet 8 with central hinge, lever of rear axle and suspension transversal rod 4.
Suspension cylinders are fastened to brackets on frame and rear axle housing by nuts 26.
The transversal rod 4 is fastened hingedly by fingers 18 to brackets on frame and rear axle housing.
The eyelet 8 of central hinge is installed on bushings 16 and fixed to central lever with the help of bolts
14 and nuts 15 and it is also hingedly fixed to bracket of frame by finger 10.
Figure 8.1.2 – Rear suspension:

1 – mud shield; 2, 3 – suspension cylinders; 4 – rod of suspension; 5, 15 – nuts; 6, 12, 14, 21, 30 – bolts; 7, 20 – hinged bearings;
8 – eyelet with basing; 9 – cover; 10, 18 – fingers; 11 – locking plate; 13 – greaser; 16 – bushing; 17, 24 – glands; 19 – locking ring;
22 – plate; 23 – bushing; 25 – sealing ring; 26 – self-locking nut; 27 – disk; 28, 29 – protective boots; 31 – split-pin wire
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The suspension cylinder represents piston– type air spring in combination with hydraulic shock absor-
ber. Working element in cylinder is engineering gaseous nitrogen. In suspension cylinder damping fluid
ЛУКОЙЛ – АЖ, (substitutes МГП– 12 or ГРЖ– 12) is applied as working fluid.
The design of front suspension cylinder is shown in figure 8.1.3, as the design of rear suspension cy-
linder is shown in figure 8.1.4
Front and rear suspension cylinders are analogous in design and differ only in sizes of parts, configura-
tion of chase on rod of absorber and amount of filled oil and gas pressure level. The shiftable joint: rod – tube
of the main cylinder is sealed by fluoroplastic cup; there is single set of parts in the front cylinder as there are
two sets in the rear ones. The cup is installed with an interference fit, which can be adjusted by a set of shims
and is maintained spring. Tightness of the cup when assembling should be of 2,0 – 2,3 mm (internal diameter
at the edge of the cup is of 247,7 – 248,0 mm for front suspension cylinders and of 277,7 – 278,0 mm for rear
suspension cylinders).
There are spherical supports with size of Ø150mm and shank size of Ø60mm installed in front suspension
cylinders with rod size of Ø250mm; there are spherical supports with size of Ø180mm and shank size of Ø80 mm
installed in rear suspension cylinders with rod size of Ø280mm.
More detailed description suspension cylinders design is given in the Operation Manual
75131– 3902015 OM.
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 servicea-
bility by defining size Н (see figures 8.1.3 or 8.1.4). This size is defined by special (characteristic) ruler on
which two scales are marked: charge and working.
Points on scales indicate level of gas pressure in cylinder (MPa) of given size at correct charging of cy-
linders. 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 Н install unloaded dump truck on equal horizontal platform. Sus-
pension cylinder is considered normally charged if the end of housing 12 is placed against zone of admissible
scatter of size of cylinder. At measuring of size Н ruler is interposed under protective boot 10 against stop into
ring 15 so that it is not displaced upwards from its seat.
Whereas sizes of all suspension cylinders are interconnected among themselves, change of size of one
(out– of– order) cylinder calls resizing in other cylinders. Out– of– order cylinder, as rule, is the one with the
least size.
Measure in addition gas pressure in out– of– order cylinder by means of work tool (see Operation Ma-
nual) and, if it is below normal (on working scale of characteristic ruler) on more than 0,3 МPа for front and
0,2 МPа for rear cylinders, it is necessary to perform preventive recharge.
Rapid decrease of cylinder height testifies the emersion of significant escapes of working fluid through
joints, and recharge of cylinder with gas on dump truck without elimination of failure is ineffective.
Remove out– of– order cylinder from dump truck, disassemble it observing safety precautions and elimi-
nate failure.
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Figure 8.1.3 – Hydropneumatic cylinder of the front suspension:

1 – pin; 2, 5, 21, 37 – bolts; 3, 13 – safety valve; 4 – bottom cover; 6, 7, 17, 20, 24, 51 – rings; 8 – plug; 9 – threaded bushing;
10 – protective boot; 11 – rod guide with journal box; 12 – casing; 14 – rod; 15 – ring; 16 – seal; 18 – rod; 19 – main cylinder tube;
22 – filler valve; 23 – top cover; 25 – ball joint support; 26, 40 – covers; 27, 49 – adjusting shims; 28 – flange; 29 – guiding journal box of
the piston; 30 – shock absorber rebound valve body; 31 – tab washer; 32 – dump valve plug; 33 – ball; 34 – body compression valve; 35 –
step-bearing insert; 36 – steering lock; 38 – sensor cover; 39 – sensor valve; 41 – filler valve body; 42, 46 – sealing gaskets; 43 – protec-
tive ring; 44 – tape; 45 – valve body; 48 – spring; 50 – thrust ring; 52 – distance ring; 53 – rod cup; 54 – cup ring;
Н – dimension, P1, P2, P3 – cavities
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Figure 8.1.4 – Pneumohydraulic cylinder of rear suspension:

1 – dowel; 2, 5, 21, 37 – bolts; 3, 13 – safety valves; 4 – lower cover; 6, 7, 17, 20, 24, 51 – rings; 8 – plug; 9 – thread bushing;
10 – protective boot; 11 – guiding of rod with axle– box; 12 – housing; 14 – rod; 15 – ring; 16 – sealant; 18 – rod; 19 – tube of main cylind-
er; 22 – priming valve; 23 – upper cover; 25 – spherical support; 26, 40 – covers; 27, 49 – adjusting shims; 28 – flange; 29 – guiding axle–
box of the piston; 30 – body of shock absorber rebound valve; 31 – locking washer; 32 – plug of compression valve; 33 – ball; 34 – seat of
compression valve; 35 – insert of toe step; 36 – turn limiter; 38 – sensor housing; 39 – sensor valve; 41 – body of priming valve;
42, 46 – sealing gaskets; 43 – safety ring; 44 – tape; 45 – body of valve; 47 – thrust ring; 48 – spring; 50 – pressing ring; 52 – spacing ring;
53 – cup of rod; 54 – ring of cup;
Н – size; P1, P2, P3 – cavities
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8.1.2 Suspension cylinders troubleshooting

Suspension cylinders troubleshooting is specified in table 8.1.1.
Table 8.1.1 – Suspension cylinders troubleshooting
Trouble and its symptom Possible reason Remedy
Pressure in all cylinders does not corres- Incorrect charging Adjust charging:
pond 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 cy- Adjust charging of cylinder according to Operation manual
ruler pressure differs from required level linder
most of all
One or several cylinders constantly do not Untight priming valve Check condition of copper gasket under valve. If it is solid or
hold sizes "H" (there are no leakage of oil) damaged on planes replace it and charge cylinder with gas
After charging cylinder abruptly runs down Cup is worn out Remove and disassemble cylinder observing safety precau-
and oil escapes through pressure– relief tions, test condition of cup. Replace worn out and damaged
valve or safety ring parts
On release strokes knocks in cylinder are Fluoroplastic washers Remove and disassemble the cylinder. Replace washers on
heard on piston rod are worn piston of rod
out
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 removing the cylinder from dump truck and in case of its disassembling it is necessary to re-
lease gas from the inner cavity, for which screw connection pipe (included to spare parts kit) so that gas leav-
ing the cylinder. For the complete removal of gas from the suspension cylinder priming valve should be opened
at least three times at intervals of 3 – 5 minutes. After complete removal of the gas open the priming valve us-
ing connection pipe and leave connection pipe in such a position till disassembling of the cylinder is finished.
If gas is not bleeding via priming valve discharge the cylinder having unscrewed priming valve (or valve
sensor) to one – one and a half turnover and no more;
– 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 thread bush-
ing) 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
0
than on 30 ;
– refill cylinders with working fluid from closed volumes after it is settled and cleaned;
– 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;
When receiving gas in bulbs check last for water absence. For that turn bulb over and wait at least for an
hour, the open a tap and release water residue.
ATTENTION: IT IS FORBIDDEN TO PERFORM CHARGING OF SUSPENSION CYLINDERS WITH OXYGEN! IT
CAN CAUSE EXPLOSION!
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– install bulb with gas to the prescribed place equipped with devices for fixing of bulb. At change of bulb
– fix it;
– unscrew valves and connecting nuts only with corresponding wrenches, trying not to hit them;
– gas to suspension cylinders is to be supplied smoothly through reducer;
– observe common safety precautions on working place.
8.1.4 Removal of suspension cylinders from dump truck

Before removal of front and rear suspension cylinders from dump truck release gas through priming
valve of cylinder observing rules specified in subsection 8.1.3. Apply parking brake and install thrust blocks
under front and rear wheels.
Removal of front suspension cylinder is to be carried out in the following sequence:
– turn front wheels in extreme position for convenient dismantling;
– unscrew bolts 31 (see figure 8.1.1) of lower bracket 30 of suspension cylinder fastening to steering
knuckle;
– hang out frame of dump truck, having installed jack in its front part, up to exit of lower bracket of sus-
pension cylinder with tube 27 of lubrication supply from pivot or steering knuckle;
– install special jambs under spars of frame instead of jacks;
– install gripper of device for removal and mounting of suspension cylinders (М513017, figure 8.1.5)
onto the forklift and lock it using bolts 5 and pins 6;
– bring the device to the cylinder, install jaws 9 and 13 on tube of main cylinder under butt of upper cov-
er of suspension cylinder having adjusted their position using handles 1, 2, 11. Press securely jaws by means
of handle 12 to tube of cylinder and secure the cylinder in the device by means of safety chain 8;
– unscrew bolts 24 (figure 8.1.1) fastening upper bracket 25 to bracket fastening the fender;
– remove cylinder (weight of front suspension cylinder is of 324 kg);
– unscrew nuts 26 on spherical supports of upper and lower brackets fastening and remove brackets 25
and 30 from suspension cylinders;
– install suspension cylinders in special container in vertical position.
Figure 8.1.5 – Device (М513017) for removal and mounting of suspension cylinder
(rigging equipment for forklift):
1, 2, 11, 12 – handles; 3, 4 – brackets; 4 – support; 5 – clamping bolt; 6 – pin; 8 – safety chain; 9, 13 – jaws; 10 – insert
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Removal of rear suspension cylinder is to be carried out in the following sequence:

– unscrew nut 26 (see figure 8.1.2) of lower spherical support of suspension cylinder fastening to brack-
et of rear axle;
– hang out frame of dump truck, having installed jack in its rear part, up to exit of tail of spherical support
of cylinder from bore of lower bracket of suspension cylinder;
– install special jambs under spars of frame instead of jacks;
– install gripper of device for removal and mountings of suspension cylinders (see figure 8.1.5), having
installed jaws 11 and 12 at tube of main cylinder under butt of upper cover of suspension cylinder 6 and press
jaws safely by means of nut 9 with handle 10 to tube of cylinder;
– unscrew nut 26 (see figure 8.1.2) of upper spherical support of suspension cylinder fastening;
– remove cylinder(weight of rear suspension cylinder is of 470 kg);
– install suspension cylinder in special container in vertical position.
Front and rear suspension cylinders removed from dump truck with the
help of special device can be carried on section of disassembly and assembly
of cylinders with the help of fastening device (figure 8.1.6).
For transportation it is necessary to screw nut of device 3 on thread tail
of spherical support of suspension cylinder.
Figure 8.1.6 – Device for transportation of suspension cylinders:

1, 2 – rings; 3 – nut; 4 – suspension cylinder
8.1.5 Disassembly of suspension cylinders

Suspension cylinders are to be disassembled on special tilting bench (М555023, Figure 8.1.7), which is
designed for convenience and mechanization of disassembly/assembly operations.
Before placing the suspension cylinder on the bench for disassembly, remove seal 16 off the cylinder
(see Figure 8.1.3) and protective boot 10 and ring 15, remove from the cylinder surface lubricant substances,
working liquid and dirt.
Disassemble the cylinder as follows:
– using tilting bench by means of circular motion of drive lever 4 (see Figure 8.1.7) lower right 10 and left
11 grippers located on the boom 7 in the lower position;
– fasten grippers 10, 11 on the boom 7 in the position where the center of mass of the suspension cy-
linder coincides with the axis of the boom rotation by means of locking fingers 3;
– spread the grippers, rotating clamps 9 levers for the required distance from each other for a smooth
installation of the suspension cylinder between them;
– place the suspension cylinder using hoisting mechanisms and slinging device onto the tilting bench;
– secure the suspension cylinder between the grippers 10, 11 (over the tube of main cylinder), rotating
clamps 9 levers;
– by means of circular motion of drive lever 4 move suspension cylinder 8 in space to the position con-
venient for repair;
– lock the drive lever 4 with the stopper 12, moving the stopper latch to the nearest hole of the disc 13;
More detailed information about the bench (design, operation, maintenance service, etc.) look in the
Operation Manual for the bench.
Cylinders of front and rear suspensions are equal in design. Disassembly of suspension cylind-
ers will be described according to front suspension cylinder. Differences in assembling will be pointed
separately.
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Figure 8.1.7 – Tilting bench for suspension cylinders assembling/disassembling:

1 – base; 2 – stanchion; 3 – locking fingers; 4 – the drive lever; 5 – worm type reducer; 6 – bearing supports; 7 – boom; 8 – sus-
pension cylinder; 9 – the clamps lever; 10 – right gripper; 11 – left gripper; 12 – stopper of the drive lever; 13 – disk
Disassembly of the cylinder is to be performed as follows:

– by means of special sleeve (goes with spare parts kit) open priming valve 22 (figure 8.1.3) in order to
be convinced that there is no gas in cylinder, by lifting rod with sealing taper of safety valve 13 release gas
from housing 12;
– unscrew bolts 2 and remove covers 26 of spherical supports;
– remove spherical supports 25 and liners 35 from upper 23 and lower 4 covers;
– unscrew bolts 5 and 37, remove upper cover 23 with rod 14 of absorber, incline cylinder and drain oil;
– from upper cover 23 turn out priming valve 22, sensor valve 39 and having unscrewed bolts 21 of
flange 28 remove rod 14 of absorber;
– unscrew plugs 8 on housing 12 and drain oil from cavity P3;
– turn cylinder so that its lower cover is up, unscrew bolts 5 and remove lower cover 4;
– install and fix suspension cylinder in horizontal position and pull out rod 18 through upper part of cy-
linder;
– turn out from case of compression valves 34 plugs 32, unlock cases of compression valves, turn out
cases and take out from them balls 33, remove basic washer 31, case 30 of rebound valve of absorber. There
are no compression valves cases in the rear suspension cylinders, as plugs of compression valves are
screwed in into rod septum directly;
– turn out thread bushing 9 of tube of main cylinder 19 and remove ring cup 54 by means of remover
(figure 8.1.8);
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– extract package of parts of sealing: cup 53 with spacing ring 52, pressing ring 50, adjusting gaskets
49, spring 48 and guiding of rod 11 with axle-box.
There are two packages of sealing parts in the cylinders of rear suspension.
Figure 8.1.8 – Remover of the cup ring of suspension cylinder:

1 – screw; 2 – upper crossbar; 3 – nut; 4 – washer; 5 – draw bar; 6 – lower crossbar; 7 – cup; 8 – tube of main cylinder
8.1.6 Disassembly of central hinges of front and rear suspension

While in operation fingers and hinged bearings of central hinge expose to wear. Repair is carried out by
replacement of worn out and damaged parts.
Before disassembly of central hinge of suspension, brake the dump truck with parking brake and then
install thrust blocks under front and rear wheels.
Disassembly of central hinge of front suspension is to be performed as follows:
– install jambs under spars of frame in front part of bumper;
– release gas from cylinders of front suspension through priming valve, observing rules specified in sub-
section 8.1.3;
– install jamb under central bar of beam of front axle in its front part for exclusion of falling out of bar af-
ter squeezing of finger;
– unscrew bolts 14 (see figure 8.1.1) of disk 15 fastening and remove disk;
– unscrew bolts 34 of lock plate fastening 35 and remove plate;
– install device as it is shown in figure 8.1.9 (on side of four tapped holes at butt of finger 2, preliminary
having unscrewed one series of bolts of eyelet 1 fastening to bar of front axle), and, having supplied pressure
in actuator 5 with the help of manual pump НСР–400МА or hydraulic station, squeeze finger 2.
IT IS FORBIDDEN TO STAND OPPOSITE TO FINGER THAT IS BEING SQUEEZED.
– disconnect device from lever;
– lower lever of front axle downwards (in order to provide convenient disassembly) on jamb;
– unscrew bolts 16 (see figure 8.1.1) and remove eyelet 17 from truck;
– unsplint and turn out bolts 18 from both sides of eyelet;
– remove covers 19 with glands 21;
– squeeze out hinged bearing 20 from eyelet 17.
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Figure 8.1.9 – Device for squeezing of central hinge finger of front suspension:
1 – eyelet; 2 – finger; 3 – insert; 4 – bracket; 5 – hydraulic cylinder; 6 – thrust block; 7 – frame girder
Disassembly of central hinge of rear suspension is to be performed as follows:

– install thrust blocks under wheels of front axle and rear axle of dump truck;
– release gas from cylinders of rear suspension through priming valve, observing rules specified in sub-
section 8.1.3;
– remove mud shield 1 (see figure 8.1.2) from central hinge;
– unsplint and turn out locking bolts 30 of nut 5 and unscrew nut;
– unscrew bolts 12 of locking plate 11 fastening and remove plate;
– install jamb in region of flange under lever in order to exclude falling of lever after release of finger;
– install device (preliminary having unscrewed one series of bolts of eyelet 7 fastening to lever of rear
axle) as it is shown in figure 8.1.10 (on part of thread М110х3), and supplying pressure in hydraulic cylinder 3
squeeze finger 9 with the help of manual pump НСР–400МА or hydraulic station.
IT IS FORBIDDEN TO STAND OPPOSITE TO FINGER THAT IS BEING SQUEEZED.
– disconnect device from lever;
– lower lever of rear axle downwards (in order to provide convenient disassembly) on jamb;
– unscrew nuts 15 (see figure 8.1.2) and remove bolts 14 and eyelet 8 from dump truck;
– turn out bolts 6 from both sides of eyelet;
– remove covers 9 with glands 17;
– squeeze hinged bearing 7 out eyelet 8;
– squeeze glands 17 from covers 9.
Figure 8.1.10 – Device for squeezing of central hinge finger of rear suspension:
1 – girder of frame; 2 – thrust block; 3 – hydraulic cylinder; 4 – bracket; 5 – bolt; 6 – nut; 7 – eyelet; 8 – finger; 9 – insert
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8.1.7 Removal and disassembly of transversal rods of front and rear suspension
While in operation fingers, hinged bearings and matching bores for bearings of transversal rod are ex-
posed to wear out. Repair is carried out by replacement of worn out and damaged parts.
Before removal of transversal rod of suspension, brake the dump truck with parking brake and then in-
stall thrust blocks under front and rear wheels.
Removal and disassembly of transversal rod of front suspension is to be performed as follows:
– unscrew bolts 6 (see figure 8.1.1) fastening rod 1 to cone finger 10 on one side of rod;
– remove cover 4;
– remove rod 1 together with bearing 8 from cone finger 10 with the help of remover;
– perform analogous operations on other side of rod;
– extract glands 7 of rod;
– remove locking rings 9;
– press off hinged bearings 8 from rod with the help of arbor;
– if necessary unscrew bolts 13, extract disks 13, press off fingers 10 and bushings 11.
Removal and disassembly of transversal rod of rear suspension is to be performed as follows:
– unscrew bolts 12 and 21 (see figure 8.1.2) and remove clamping plates 22;
– extract distance bushing 23;
– extract finger 18, applying force from the side of taper bushing 23;
– extract liberated end of transversal rod from bracket;
– remove sealing rings 25 from bushings;
– perform analogous operations on other side of rod;
– extract glands 24 of rod;
– remove locking rings 19;
– press off hinged bearings 20 from rod with the help of arbor.
8.1.8 Check– up of technical condition of suspension parts

After disassembly check up technical condition of working surfaces of suspension parts by external ex-
amination and sampling of their critical parameters. Besides, tube of main cylinder, rod, cup, guiding of rod and
piston should not have corrosion, burrs and other mechanical damages on their working surfaces.
Most frequent imperfections of cups are shown in figure 8.1.11.
After disassembly of suspension cylinders all general mechanical rubber work– pieces and cups are
subject to obligatory replacement.
Rated and maximum permissible dimensions of suspension parts are specified in table 8.1.2
Figure 8.1.11 – Most frequent imperfections of sealing cups of rod:

1 – sealing crimps are uniformly worn out; 2 – local wear of crimps or ribbing as result of operation on polluted oil or at insufficient
purity of sealing surfaces; 3 – emergency collapse of cups because of excessive deformation of sealing rings (high tightness)
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Table 8.1.2 – Rated and maximum permissible dimensions of major suspension parts
Dimensions, mm
Number, part designation and con-
Material Hardness index
trolled parameters
rated permissible
7519 – 2907036
Tube of main cylinder: +0,13 +0,21
Inner diameter 280 280 241 – 285 НВ
Steel 45 ТВЧ h ≥1,5 mm
There should not be НRС 45 – 55
Outer diameter 330-0,14
(coverage Хтв.30) places with wear of
chromic coverage
7519 – 2907126-02
75131 – 2907127
Steel 45 167 – 217 НВ
Upper and lower covers: There should not
Diameter of sphere
154,1-0,1 be faults
75131 – 2907056
Rod: Steel 45
Outer diameter −0,100
250 249,7 – 249,8 ТВЧ h 1,5 – 3,0 mm
− 0,172 Strip НRС 50 – 60
Outer diameter on rolled up bronze on ДПРНТ3,0
−0,11
piston 280 279,6 – 279,7 НД Бр.ОФ
− 0,24 6,5– 0,15
7519 – 2907076 Strip
Guiding of rod with axle box: +0,115 ДПРНТ3,0
250 +0,29
250 НД Бр.ОФ
Inner diameter on bronze
6,5– 0,15
7513 – 2907327 241 – 285 НВ
Rod: Steel 45 ТВЧ h 1 – 5 mm
Condition of surface on diameter 25 There should not be burrs and faults НRC50
7519 – 2907500 Surface should be 241 – 285 НВ
Spherical support: +0,08 without burrs
150 Steel 40ХH ТВЧ h 2 – 7 mm
Diameter of sphere Ra 0.32 НRC50
7519 – 2907427 There should not be places with wear of Ribbon of

Cup step plastic stratum brand «С»
2,05х130
7519 – 2907428 241 – 285 НВ
Cover: +0,08 There should not Nitrogenize
150 Steel 40Х
h0,3 mm
Condition of spherical surface be burrs and faults
Ra 0.63 400 НV2
549Б – 2907178
Body of contraction valve of shock–
+0,2 7 Steel 35 229 – 285 НВ
absorber:
8
Diameter of inner hole
549Б – 2907186
Plug of compression valve: ТВЧ h 2 – 5 mm
Steel 35
Condition of butt from the side of di- There should not be chips and cracks 40 – 60 НRC
ameter 10
549А – 2907330 There should not be faults of working surfac-
Plunger of pump es (on diameters 16, 20 and 30 mm). Back– Steel 45
pressure valve should be hermetic
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Continuation of table 8.1.2
Dimensions, mm
trolled parameters
rated permissible
75131 – 2917036
Tube of main cylinder: +0,13 +0,21
Inner diameter 315 315
241 – 285 НВ
Steel 45 ТВЧ h 1,5 – 3 mm
Outer diameter -0,062 There should not 45 – 55 НRC
(coverage Хтв.30) 365 be places with
-0,151
wear of chromic
coverage
75131 – 2917126
75131 – 2917127
184,1-0,072 Steel 45 156 – 217 НВ
Upper and lower covers: There should not
Diameter of sphere be faults
75131 – 2917056
Rod:
−0,110 ТВЧ h 1,5 – 3,0 mm
Outer diameter 280 279,7 – 279,8 Сталь 45
− 0,162 НRC50
Outer diameter on rolled up bronze on -0,110
piston 307 -0,191 306,8 – 307
75131 – 2917076
Guiding of rod with axle box: +0,13 +0,185 УПА (Т) 6/30
280 280
Inner diameter on bronze
7545 – 2907184
Seat of compression valve: +0,22 7 Steel 40Х 32 – 37 НRC
8
Diameter of inner hole
7545 – 2907186
Plug of compression valve: ТВЧ h 2 – 4 mm
Steel 35
Condition of face from side of Absence of nips and cracks 42 – 49 НRC
diameter 14
75131 – 2917327
241 – 285 НВ
Rod:
Steel 45 ТВЧ h1 mm
Condition of surface over There should not be chips and cracks НRC50
diameter 25
75131 – 2917427 There should not be places with wear of Ribbon of
Cup step plastic stratum brand KX
2,05х130
75131 – 2917432 There should not be 241 – 285 НВ
+0,046
Cover: 180 burrs and faults Nitrogenize
Steel 40Х
Ra 0.63 h 0,3 – 0.7 mm
Diameter of sphere
400 НV2
75306 – 2907500 There should not be
241 – 285 НВ
Spherical support: +0,063 burrs and faults
180 Steel 40ХH ТВЧ h 2 – 7 mm
Diameter of sphere НRC50
Ra 0.32
75570 – 2909016
Normalization
Rod of suspension: +0,063
+0,012 160 Steel 35 ТВЧ h3 mm
Inner diameter under bearing 160 НRC42
-0,028
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Dimensions, mm
trolled parameters
rated permissible
75570 – 2909078
Finger: Carbonize
Diameter under bearing -0,012 Steel h 1,6 – 2,0 mm
90 90–0,063 20ХН3А 58 – 64 НRC
-0,034
There should not Cores НRC32
Conic surface (1:10) be faults
75570 – 2909118
Bushing:
Outer diameter (up to cutting) −0,085 There should not
132
− 0,148 be faults Steel 45 241 – 285 НВ
Conic surface (1:10) There should not

be faults
75131 – 2909188
Tall bushing
(length of bushing 84–0,54): +0,125 There should not
148 be faults 241 – 285 НВ
Outer diameter + 0,100
+0,087 +0,14 Steel 45 ТВЧ h 2 – 5 mm

Inner diameter
118 118 НRC50
There should not
be working– out of ТВЧ h 2 – 5 mm
Butt of barrel (on diameter 135– 1) more than 0,5 mm НRC50
7519 – 2919187
Low bushing:
Outer diameter +0,125 There should not
150 be faults 241 – 285 НВ
+ 0,100 Steel 45
Inner diameter +0,16 +0,25 ТВЧ h 2 – 5 mm
134 134
НRC50
75131 – 2909230
Normalization
Eyelet with grounding: −0,014 Steel 35 ТВЧ h 1,5 – 5,0 mm
215 215 – 215,02
Inner diameter − 0,060 35 – 50 НRC
75132 – 2919230
Normalization
Eyelet with grounding: −0,014 215 – 215,02 Steel 35 ТВЧ h 1,5 – 5,0 mm
215 НRC40
Inner diameter − 0,060
75131 – 2919016:
Normalization
Rod of suspension: +0,030 +0,072 Steel 35 ТВЧ h3 mm
200 200
Inner diameter under bearing (length of − 0,016 НRC42
rod on shafts is 1050 mm)
75131 – 2909426
Finger (length of finger 320 mm):
−0,145
First outer diameter 134 134 241 – 285 НВ
− 0,245 − 0, 4
Second outer diameter −0,036 −0,120 Steel 40Х ТВЧ h 2 – 4 mm

120 120
− 0,090 − 0,207 47 – 57 НRC
Third outer diameter Хтв.12 (on three di-
−0,120 118 ameters)
118 − 0,35
− 0,207
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Dimensions, mm
trolled parameters
rated permissible
7521 – 2919078
Finger of rod: Carbonize
Outer diameter −0,043
130 129,85 – 129,9 Steel h 1,4 – 1,8 mm
− 0,083 20ХН3А 59 – 63 НRC
Core НRC32
Conic surface (1:3) There should not
be faults
7513 – 2919187
Low barrel:
+0,125 There should not
Outer diameter 150 241 – 285 НВ
+ 0,100 be faults
Steel 45
+0,16 ТВЧ h 2 – 5 mm
Inner diameter
134 +0,25 НRC50
134
7513 – 2919186
Tall barrel:
Outer diameter +0,125 There should not
241 – 285 НВ
150 be faults
+ 0,100
Inner diameter +0,087 +0,14 Steel 45 ТВЧ h 2 – 5 mm
118 118 НRC50
There should not

Butt of barrel (on diameter 135– 1) be working– out of ТВЧ h 2 – 5 mm
more than 0,5 mm НRC50
75131 – 2919426
Finger (length of finger 450 mm):
−0,145
First outer diameter 134 134 Carbonize
− 0,245 − 0, 4
h 1,6 – 2 mm
Steel
Second outer diameter −0,036 −0,120 57 – 64 НRC
120 120 20XH3A
− 0,090 − 0,207 Core HRC28
Third outer diameter
−0,120 118
118 − 0,35
− 0,207
8.1.9 Assembly of suspension cylinders

Assembly of suspension cylinders should be performed in conditions providing protection of unit from hit
of dust, abrasive corpuscles, water and mud. The site for assemblage of cylinders should not be located near-
by place where operations causing pollution, such as welding and machining are performed. It is necessary to
avoid the streams of air used for cleaning the parts nearby the assemblage area as the stream of air can trans-
fer pollutant over some meters.
On parts there should not be agnails and rust, and on working surfaces and facets there should not be
nicks, scratches and other faults.
Before assembly all ports and remote places of parts should be cleared of fillings and dirt, blown with com-
pressed air. After that parts should be washed out in diesel fuel or white spirit and dried up.
The parts are supposed to be assembled directly after cleaning as even short time storage in environ-
ment conditions can cause corrosion and dust ingress.
At assembly, transportation, mounting and disassembly, and also at other operations with suspension
cylinders it is forbidden to transmit force to housing 12 (see figure 8.1.3) in order to prevent damage in view of
its thinner of walls.
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Assembly of suspension cylinders is performed with observance of following rules:

– at assembly all thread and rubbed surfaces of parts should be greased with working fluid;
– rubber sealing rings of round cross– section, fluoroplastic cups, fluoroplastic protective washers
should be washed out in working fluid before mounting in cylinder;
– at mounting rubber sealing rings make sure that rings are not twisted in grooves and are not under-
cuted.
Assembly of suspension cylinders will be described in example of cylinder of front suspension.
Differences in assembly of rear suspension will be pointed separately.
Assembly of upper cover is to be performed as follows:
– install in groove of upper cover 23 (see figure 8.1.3) rod 14;
In order not to mix rods of absorbers at repair of cylinders identification mark is plotted on their lower
butt on factory – manufacturer. At lower butt of rod of absorber of front suspension cylinders digit "15", and
rear – digit "25" is stamped.
Probably during operation of cylinder digits of identification mark will be “chocked" so that it is impossible
to define them. Than it is possible to distinguish rods only on configuration of chases of variable section (figure
8.1.12);
Figure 8.1.12 – Rod of absorber of suspension cylinder:

1 – rod of front suspension cylinder; 2 – rod of rear suspension cylinder
– put on rod flanges 28 (figure 8.1.3) and fix it by bolts 21 with washers (tightening torques of threaded
connections of suspension cylinders are specified in table 8.1.4);
– install sealing ring 20 in groove of upper cover (two rings for upper cover of rear suspension cylinder).
Assembly of lower cover is to be performed as follows:
– in ring bore of lower cover 4 (see figure 8.1.3) install two rings 6;
Assembly of rod of front suspension is to be performed as follows:
– install case of shock absorber rebound valve 30 into bore of rod 18 baffle;
– install locking washer 31;
– screw cases of compression valves 34 into thread bores of rod baffle;
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– install ball 33 in inner chamber of each shock– absorber compression valve and stamp it;
– turn plugs of compression valves 32, preliminary having installed sealing gasket under butt of plug
heads;
– unbend edges of locking washer 31 on edges of compression valve body 34 (it is recommended to
perform locking after the cylinder is refilled with working fluid);
– install two washers 17 and rod axle-shaft in external groove of rod piston.
Assembly of rod of rear suspension is to be performed as follows:
– install case 30 of shock absorber rebound valve into bore of rod 18 (figure 8.1.4) baffle so that axis of
bore in the valve case matches to axis of bore in the rod baffle;
– install locking washer 31;
– install the seats 34 of rebound valves into the bore of the rod 18 baffle;
– install ball 33 in inner chamber of each seat and stamp it;
– turn plugs of compression valves 32;
– unbend edges of locking washer 31 on edges of compression valve body (it is recommended to per-
form locking after the cylinder is refilled with working fluid);
– install ring 17 and two washers guides of axle-shaft 29 in external groove of rod piston.
Assembly of main cylinder of front suspension cylinder is to be performed in the following sequence:
– fix in stand (see figure 8.1.7) tube 1 (figure 8.1.13) of main cylinder;
– insert into tube of main cylinder guiding 2 of rod with axle box and package of sealing parts: pressing
ring 5 with spring 4, adjusting gaskets 3 (the greatest amount – 4 pieces), spacing ring 8 with cup of rod 7, ring
of cup 10;
Install two thrust rings 9, two sets of sealing parts into the rear suspension cylinders (figure 8.1.14, view b);
– screw in thread bushing 6.
Tightness of cup is adjusted through amount of adjusting gaskets 3. In case of incorrect size delete or
add adjusting gasket.
Measurements of tightness are to be performed at completely compressed package of sealing. Ring of
cup 10 through adjusting gaskets 3 and thrust ring 9 should be pressed to guiding of rod 2.
Measurement of tightness are to be performed by means of measuring device with measuring force from
+3 0
7 up to 9 N, eliminating strain and fault of working crimps at the ambient temperature in the room of (20 ) С.
Sizes of cups of cylinders front and rear suspension at installed tightness in limits from 2,0 up to 2,3 mm
after tightening of thread bushing are shown in table 8.1.3.
Table 8.1.3 – Sizes of cups of suspension cylinders after tightening of thread bushing
Place of Recommended size, Recommended Torque of thread bush-

Name
measuring mm tightness, mm ing, N.m
Cup of rod of the front
247,7 — 248,0
cylinder
Inner diameter 2,0 — 2,3 9000 — 10000
Cup of rod of the rear
277,7 — 278,0
cylinder
THE INDICATED TIGHTNESS OF THE CUP WAS SELECTED EXPERIMENTALLY FOR THE GIVEN MATERI-
AL. WITH EXCESSIVE TIGHTNESS THE CYLINDER GETS HEATED QUICKLY AND THE CUP GETS “BURNT”. WITH
INSUFFICIENT TIGHTNESS THE CYLINDER WILL HAVE LEAKAGES SOON.
Sampling of tightness of cups (inner diameter) is to be performed by measuring tool eliminating strain
and fault of working crimps of cups. For sampling tightness of cups it is recommended to use special caliper
which jaws have big length and width as contrasted to usual calipers (figure 8.1.14).
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.
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Figure 8.1.13 – Scheme of tightness adjustment for cup of rod:

а) – for front suspension cylinder; b) – for rear suspension cylinder:
1 – tube of main cylinder; 2 – guiding rod with axle box in assembly; 3 – adjusting gasket; 4 – spring; 5 – pressing ring; 6 – thread
bushing; 7 – cup of rod; 8 – spacing ring; 9 – thrust ring; 10 – ring of cup; 11 – sealing ring
Figure 8.1.14 – Caliper for sampling tightness of cup of suspension cylinder
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Special device (figure 8.1.15) is designed for mechanization of process of tightness adjustment of cup of
cylinder sealing set. Device consists of adjustment stand, hydraulic equipment and electrical equipment.
The adjustment stand consists of bed 3, hydraulic cylinder 2 and pressing mechanism 1. Hydraulic
equipment consists of pump 4, hydraulic distributor 5 and hydraulic reservoir 6.
For adjusting tightness install set of sealing into the guide of pressing mechanism 1, set upper rod 7 into
working position and then press the set of sealing. Measure inner diameter of the cup and change number of
adjusting gaskets at misfit of size.
Figure 8.1.15 – Device for adjusting tightness of cup:

1 – pressing mechanism; 2 – hydraulic cylinder; 3 – bed; 4 – pump; 5 – hydraulic distributor; 6 – hydraulic reservoir; 7 – upper plate
After adjusting cup tightness (obtaining required size of inner diameter):

– unscrew thread bushing 6 (see figure 8.1.13);
– remove ring of cup 10;
– remove distance ring 8 and set the butts of rod 7 cup into initial state to avoid working surface cuts;
– install distance ring 8 and sealing ring 11 onto cup ring;
– after installation of the seals set into the main cylinder tube screw in the threaded bushing 6 (prelimi-
nary having greased thread with lubricant Lithol-24) not turning approx 1,5 revolutions till compression of set of
sealing parts (against stop);
– install rod 18 (see figure 8.1.3) in assembly with valves into the tube of main cylinder 19 so that butt of
piston was on distance of 25 mm (for the value of upper cover flange) from butt of the tube of main cylinder of
front suspension;
– tighten thread bushing 9 with torque (see table 8.1.4);
The further assembly of suspension cylinders is to be performed as follows:
– put ring 15 in assembly with rod 18 on tube of main cylinder 19;
– install sealing ring 7, oil-removing tape 44 and safety ring 43 into housing 12; hold the tape 44 prior to
installing in working fluid at least 3 minutes;
– put housing 12 on tube of main cylinder 19 and rod 18;
– install semi-assembled lower cover 4 into rod 18 and fix it with bolts 5 with washers;
– set cylinder vertically, unscrew plugs 32 of compression valves and fill working fluid in cavities of cy-
linder up to level of plugs of shock absorber rebound valves, allowing air to bleed via valves bores.
– tighten plugs of compression valves and lock them by locking washer 31;
– install semi-assembled upper cover 23 into the tube of main cylinder, mount turn limiter 36 and hous-
ing 38 onto the cover and fix them with bolts 5 and 37 with washers. After installation squeeze the cylinder
completely till rod piston thrusts to upper cover;
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– refill cylinder with working liquid through bores for filling valves or sensor valve up to level of bores;
– expand the cylinder (gas supply into the main cavity is admitted) for at least 80 mm of completely
squeezed up to piston thrust to the upper cover and setting the cylinder vertically refill working fluid into the
cavity up to level of the lower boss thread as refill main space of rear suspension cylinders with working fluid
3
up to the level of (1847±18) cm ;
– screw plugs 8 and safety valve 13 into bores of the housing bosses having installed sealing gaskets;
– screw filling valve 22 and sensor valve 39, having installed sealing gaskets;
– screw safety valves 3 into upper 23 and lower 4 covers;
– press dowels 1 into the spherical supports 25 keeping the dowel size of 14 mm max for the front sus-
pension cylinders and of 15 mm max for the rear suspension cylinders;
– install inserts 35 and spherical supports 25 into the upper and lower covers and grease friction surfac-
es of inserts, covers and supports with lubricant Lithol-24;
– install adjusting gaskets 27 onto the of upper and lower covers;
– install sealing rings 24 into the covers 26, grease spherical surfaces of covers with lubricant Lithol-24;
– fix with bolts 2 covers 26 to upper 24 and to lower 4 covers.
After tightening the bolts 2 the spherical supports 25 should be rotated in all the directions not limited by
covers 26 with torque of 50 – 100 N.m. for front suspension cylinders and with torque of 120 – 150 N.m. for
rear suspension cylinders and be adjusted by gaskets 27.
Tightening torque of threaded connections at assembly of suspension cylinders should match to values
specified in table 8.1.4.
Table 8.1.4 – Tightening torque of threaded connections at assembly of suspension cylinders
Name of part Designation Tightening torque, N.m
Thread bushing (М300х4) 7519– 2907087 9000 — 10000

Thread bushing (М330х4) 75131– 2907087 9000 — 10000
Priming valve (М16х1,5) 540– 2917360– 01 110 — 140
Bolts of flange of absorber rod fastening (М10) 201495 25 — 32
Bolts fastening upper and lower covers and covers
of spherical supports
(М14х1,5) 340348 110 — 140
(М16х1,5) 340446 160 —200
Plug of compression valve of absorber (М20х1,5) 549Б– 2907186 100 — 140
Case of compression valve of absorber (М32х2) 549Б– 2907178 100 — 140
Bolts fastening pump washer (М10) 201495 22 — 32
Locking screws (М12) 341590 16 — 22
Charging cylinder with gas is to be performed as follows:

– connect reducer of device to bulb with nitrogen through adapter connector 2 (figure 8.1.16);
– screw adapter connector 17 of devices on priming valve of suspension cylinder;
– open valve on bulb with nitrogen. Check gas pressure in bulb on manometer 3;
– tightening regulating screw 12 of reducer create gas pressure in cylinder prior to beginning of release;
– close valve on bulb and release gas from ports and hose of device by sleeve 8;
– turn needle 15 prior to beginning of priming valve opening. Beginning of priming valve opening is de-
fined on moment of aberration of arrow on manometer 10. Perform wrenching of needle cautiously in order not
to damage valve spring;
– open valve on bulb and by screw 12 of reducer release cylinder up to such size that pressure on ma-
nometer 10 coincides with level of pressure indicated on characteristic ruler (see Operation Manual) or it
agrees with table 8.1.5;
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Figure 8.1.16 – Device for charging suspension cylinders:

1, 9, 11, 18 – sealing gaskets; 2, 6, 17 – adapter connectors; 3, 5 – manometers; 4 – reducer; 7 – valve; 8 – sleeve for release of
gas; 10 – manometer for monitoring gas pressure in suspension cylinder; 12 – regulating screw of reducer; 13 – hose; 14 – nut;
15 – needle; 16 – sealing ring
Table 8.1.5 – Gas pressure in cavity of completely released cylinder
Suspension cylinder Cylinder designation Gas pressure, МPа
Front 75131–2907020-11 2,12+0,016

rear 75131–2917020-10, 75131–2917021-10 0,63+0,016
– turn out needle 15 (see figure 8.1.16), close valve on bulb, disconnect device from priming valve, test
impermeability of valve and place of its mounting, close valve cover;
– remove suspension cylinder from device for assembly;
– install protective boot 10 and put sealant 16 (see figure 8.1.3).
IN ORDER TO AVOID GAS LEAKS THROUGH MOBILE ROD SEAL STORAGE AND TRANSPORTATION OF
CHARGED SUSPENSION CYLINDERS IS TO BE PERFORMED IN VERTICAL POSITION, ABERRATION FROM VER-
0
TICAL POSITION SHOULD NOT EXCEED 30 .
8.1.10 Mounting of suspension cylinders on dump truck

Mounting of suspension cylinders on dump truck is to be performed in the following sequence:
– release gas from the suspension cylinders (when cylinders are charged with gas) with the help of
sleeve (chapter 8.1.3) and compress them down to the size according to the characteristic ruler;
– deliver suspension cylinders from section of assembly to place of their mounting to dump truck by
means of special device (see figure 8.1.6);
– install suspension cylinder in gripper of device (see figure 8.1.5) and lock them safely;
– before mounting of suspension cylinders tails of spherical supports and torquering threaded connec-
tions are to be greased with lubricant Литол – 24.
Mounting of front suspension cylinders:
– install disks 23 on lower and upper spherical supports (see figure 8.1.1), on lower – lower bracket 30
of suspension cylinder, on upper – bracket of suspension cylinder 25 and fix them by nuts 26 with torque of
2700 – 3150 N.m,
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– install and fix tubes of lubricant supply 27 of spherical supports in tails of spherical supports;
– install suspension cylinder, fasten by bolts 24 and 31 with washers by torque of 920 – 1020 N.m upper
bracket 25 of suspension cylinder to fender bracket, and lower bracket 30 of suspension cylinder to steering
knuckle;
– fix boots 29 on upper and lower spherical supports.
Mounting of rear suspension cylinders:
– install disks 27 on lower and upper spherical supports (see figure 8.1.2);
– install suspension cylinder by means of device by upper spherical support in bore of bracket of frame-
linstall tail of lower spherical support in bore of bracket of rear axle and fix by means of nuts 26 with torque of
2700 – 3150 N.m;
– screw greasers 13 in tails of upper and lower spherical supports;
– fix boots 28 and 29 on upper and lower spherical supports.
AFTER MOUNTING SUSPENSION CYLINDERS ON ALL DUMP TRUCKS SPHERICAL SUPPORTS ARE TO BE
GREASED WITH LUBRICANT ЛИТОЛ–24 THROUGH GREASERS TILL EMERSION OF LUBRICATION FROM SAFE-
TY VALVES.
After mounting the cylinders to dump truck charge them with gas using performance ruler (look dump
truck Operation Manual).
8.1.11 Assembly of central hinges of front and rear suspension

Grease threaded joints with lubricant Литол – 24 before tightening.
Assembly of central hinge of front suspension is to be performed as follows:
– press glands 21 in covers 19 (see figure 8.1.1);
– install cover 19 with gland in eyelet with grounding 17 and fix it by bolts 18 with torque of
270 – 300 N.m.;
– press hinged bearing 20 against stop in cover. Before mounting hinged bearing is to be greased with
lubricant Литол – 24. Outer ring of hinged bearing is to be installed on sealant "УГ– 9";
0 0
The jointing plane of outer ring of hinged bearing should be under an angle 90 + 5 to shaft, thus identi-
fication mark at butts of both semi– rings should be on one hand of bearing, and semi– ring should be of one
0
serial number. Inner ring of bearing after mounting should be turned on angle of not less than 15 by hand
without jams or under force (20 + 5) Н affixed on distance (200 + 50) mm from butt of inner ring;
– install cover 19 with gland 21 in eyelet with grounding 17 and fix it with bolts 18 with torque of
270 – 300 N.m.;
– lock bolts 18 from both sides of eyelet with split–pin wire 33;
– fix eyelet 17 in assembly with bearing to central lever by bolts 16 with torque of 920 – 1020 N.m;
– install central lever with eyelet 17 inside bracket of frame and, having combined bores in bearing and
bracket, press finger 22 against stop;
– install and fix locking plate 35 by bolts 34 with washers with torque of 450– 560 N.m. Spacing in junc-
tions of lock plate is not permitted, it can be eliminated by turning movement of finger 22;
– install disk 15 and fix finger by bolts 14 with torque of 1100 – 1250 N.m with washers. Axial clearance in
joint butt of finger 22, bearing and butt of barrel is not permitted.
Assembly of central hinge of rear suspension is to be performed as follows:
– press glands 17 in covers 9 (see figure 8.1.2);
– press bushing 16 into eyelet 8 up to thrust to the eyelet face;
– install cover 9 with gland in eyelet with grounding 8 and fix it with bolts 6 with washers with torque of
245 – 300 N.m. Before assembly external surfaces of bolts and bores mated to it are to be greased with five –
seven drops of sealant "Анатерм – 8К";
– press hinged bearing 7 against stop in cover. Before mounting hinged bearing is to be greased with
blend of 90 % of lubricant Литол– 24 and 10 % of copper powder ПМС– 2. Outer ring of hinged bearing is to
be installed on sealant "УГ– 9";
The jointing plane of outer ring of hinged bearing should be installed over axis I, 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;
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– install cover 9 with gland 17 in eyelet with grounding 8 and fix it with bolts 6 with washers with torque
of 245 – 300 N.m. Before assembly external surfaces of bolts and bores mated to it are to be greased with five
– seven drops of sealant "Анатерм– 8К";
– fix eyelet 8 in assembly with bearing to central lever bolted joint, nut 15 torque is of 1200 – 1400 N.m;
– install central lever with the eyelet 8 inside bracket of frame and, having combined bores in bearing
and bracket, press finger 10 against stop;
– install and fix lock plate 11 with bolts 12 with washers with torque of 450 – 560 N.m. Before assembly
external surfaces of bolts and bores mated to it are to be greased with five – seven drops of sealant
"Анатерм– 8К".
Spacing in junctions of lock plate is not permitted. It can be eliminated by turning movement of finger 10;
– place and tighten with torque of 1800 – 2000 N.m. split nut 5, no axial gap from both sides of inner ring
0
is allowed. After torquering nut is to be tightened on angle of 60 (one edge). Torqueing should be performed
by wrench with booster of torque that is sufficient for tightening or other equipment, observing safety precau-
tions.
INSUFFICIENT TORQUEING OF NUT RESULTS IN DAMAGE TO LOCKING WEDGE DEVICE, UNSCREWING
OF NUT AND IN ACCIDENT.
– lock nut 5 from unscrewing by two bolts 30 with torque of 96 – 118 N.m. Splint them in turn by split-pin
wire 31.
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ– 24 TILL EMERSION OF LUBRICATION FROM UNDER GLANDS.
8.1.12 Assembly and mounting of transversal rods of front and rear suspension
Grease threaded joints with lubricant Литол – 24 before tightening.
Assembly and mounting of transversal rod of front suspension is to be performed as follows:
– install locking ring 9 in head of rod 1 (see figure 8.1.1) and press hinged bearing 8 against stop in lock-
ing ring.
0 0
At mounting of hinged bearings 8 jointing plane of outer ring should be installed under angle 90 + 5 to
direct–axis of rod 1, 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.
0
The inner ring of bearing after mounting should be turned in outer ring on angle of 7 by hand without
jams or under load of no more than (20 ± 5) Н, affixed on distance of (100 ± 10) mm from butt of inner ring;
– install second locking ring 9, having fixed hinged bearing 8 in head of rod;
– grease spherical surfaces of bearing with lubricant Литол – 24;
– press glands 7 in head of rod on one from each side of bearing;
– carry out above mentioned operations on second head of rod;
– install fingers 10 in bores of inner ring of hinged bearings 8, and fingers from both sides of rod should
0
be unrolled on angle 180 relative to each other;
– install sealing rings 3 onto covers 4;
– install covers 4 on butts of hinged bearings and tighten them by bolts 6 with washers with torque of
161 – 199 N.m.;
– install bushings 11 and disks 12 in bores of brackets of frame and front axle;
– install transversal rod 1 with fingers 10 in bores of brackets of frame and front axle and tighten bolts 13
with torque of 1100 – 1250 N.m.
Assembly and mounting of transversal rod of rear suspension is to be performed as follows:
– install locking ring 19 in head of rod 4 (see figure 8.1.2) and press hinged bearing 20 against stop in
locking ring.
Before mounting spherical surfaces of bearing are to be greased with blend of 90 % of lubricant
Литол – 24 and 10 % of copper dust ПМС – 2. Set surfaces for bearing in rod are to be greased by sealant
"УГ– 9".
The jointing plane of outer ring of hinged bearing should be installed perpendicularly to axis of rod, 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.
0
Inner ring of bearing after mounting should be turned in outer ring on angle of not less than 7 from force
(20 + 5) Н, affixed on distance (100 + 50) mm from butt of inner ring perpendicularly to lever.
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– install second locking ring 19, having fixed hinged bearing in head of rod;
– press glands 24 in head of rod on one from each side of bearing and install sealing rings 25;
– 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 18;
– install clamping plate 22 (from the side opposite to installation of bushing 23) and tighten by bolts 12
with washers with torque of 450 – 560 N.m. Before assembly external surfaces of bolts and bores mated to it
are to be greased with five – seven drops of sealant "Анатерм – 8К";
– install spacing bushing 23, clamping plate 22 and tighten by bolts 12 and 21 with washers with torque
of 450 – 560 N.m. Before assembly external surfaces of bolts and bores mated to it are to be greased with five
– seven drops of sealant "Анатерм – 8К";
AFTER ASSEMBLY ON ALL DUMP TRUCKS GREASE CENTRAL HINGE THROUGH GREASER WITH LUBRI-
CANT ЛИТОЛ – 24 TILL EMERSION OF LUBRICANT FROM UNDER GLANDS.
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8.2 Front axle

8.2.1 General information
Front axle – steered, not driving. It consists of beam 7 (See Figure 8.2.1), right 5 and left 12 steering
knuckles, connected with the beam by means of cylindrical pivots 17, which are fastened in the beam end-tips
motionless by means of locking bolts 16.
Steering knuckle is rotated over the pivot in five bushings 18, mounted into upper (two bushings) and
lower (three bushings) eyelets of steering knuckle. Bushings are lubricated through greasers 19 and are
sealed in the upper eyelet of steering knuckle by cups 23.
Front axle beam is welded, box-shaped cross-section with cast nozzles welded on the ends. The front
suspension lever is welded on beam with brackets of turn cylinders which hingedly connected with the frame
cross-bar.
Thrust bearing 15 is installed between lower eyelet of steering knuckle and face of beam end-tip. The gap
between upper eyelet of steering knuckle and face of beam end-tip is adjusted by means of compensators 24.
Steering lever of steering trapezoid is fastened to the lower eyelet of steering knuckle by means of studs
24 (figure 8.2.2) and expanding taper bushings 25 and nuts 23.
The hub of the front wheel 11 with the fastened by bolts 15 brake disk 27 rotates on the steering knuckle
journal 26 on two taper roller bearings 13 and 14. Sealing of bearings is ensured by gland 10 and cup 16.
The brake case 29 is fastened to the steering knuckle 26 by bolts 36. Bolts are set in bushings 35 and
locked by screws 33. To adjust the gap between faces of linings shafts of brake case 29 and brake disk 27 ad-
justing washers 34 are used.
In the left wheel of front axle the drive gear of the speedometer sensor 5 is installed, in the right, on cus-
tomers’ order, odometer 30 can be installed.
The front axle is connected to the frame by means of the central hinge, transversal rod and suspension
cylinders.
Greasers 9 and 38 (two for each bearing) are intended for lubrication of hubs bearings during operation.
Some operations on repair of front axle, such as replacement of pivots and bushings, replacement of
bearings of hubs, pull-rod and levers of steering trapezoid, are to be performed directly on dump truck without
removal of front axle. Removal of front axle is needed only in cases if there is necessity of restoring bores in
brackets of turn cylinders or repair of beam itself. In case of necessity in replacement of beam front axle is re-
moved from dump truck and disassembled apart.
8.2.2 Removal of front axle

Front axle in assembly with hubs and brakes, pull-rod of steering trapezoid and turn cylinders are re-
moved 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 high pressure hoses of steering from turn cylinders and brake gears of front axle, lubrica-
tion lines of centralized automatic lubricating system. Before disconnection of hoses release pressure of work-
ing fluid in hydraulic drive of brake systems;
– place special carriage-hoist under front axle and jack beam of front axle against stop in lower shelf of
front axle beam;
– disconnect lower brackets of suspension cylinders from steering knuckles and transversal rod of sus-
pension from beam of front axle (look chapter “Suspension”);
– lead out brackets of suspension cylinder up to exit of flanges from propoints of landing nests of steer-
ing knuckles by smooth omitting of shaft on carriage-hoist;
– disassemble central hinge of front suspension and squeeze finger of central hinge out (look chapter
“Suspension”);
– make sure of reliable position of shaft on carriage-hoist and roll out front axle from under dump truck
and deliver front axle for repair (weight of front axle is approx. 8100 kg).
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8.2.3 Disassembly of front axle

Before disassembly of front axle clean it thoroughly from dirt and wash.
Disconnect and remove steering trapezoid link and turn cylinders from front axle (look chapter
“Steering”).
Disassembly of front axle is to be performed as follows:
– install front axle on special stand for disassembly and fix it;
– disconnect pipelines of braking system, necessary for removal of brake cases 29 (see figure 8.2.2);
– unscrew bolts 44, extract tightening plates 33. Unscrew by two-three turnovers lower bolt 36 fasten-
ing brake case 29 to the steering knuckle 26, unscrew completely the upper bolt 36, extract bushing 35 and
holding case of brake (weight of case is about of 100 kg), lower it against stop downwards, rotating it over
lower bolt;
– unscrew lower bolt 36, extract bushing 35 and by means of hoist appliance remove brake case;
Figure 8.2.1 – Front axle:

1 – knee-piece; 2, 3, 11 – high pressure hoses; 4, 6, 8 – pipes; 5 – right steering knuckle; 7 – beam of the front axle with lever;
9 – nipple; 10 – tee; 12 – left steering knuckle; 13 – safety valve; 14 – spacing bushing; 15 – thrust bearing; 16 – pivot stopper; 17 – pivot;
18 – pivot bushing; 19 – greaser; 20 – bolt; 21 – cramp; 22 – insert; 23 – cup; 24 – compensators
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Figure 8.2.2 – Steering knuckle with hub, brake and steering gears:
1, 24 – studs; 2, 7, 15, 32, 36, 44 – bolts; 3 – adjusting bushing; 4 – cover; 5 – drive gear of speedometer sensor; 6 – sealing
gasket; 8 – pressing ring; 9, 38 – greasers; 10 – gland; 13 – wheel hub; 12 – wheel; 13, 14 – bearings; 16 – cup; 17 – internal cover of the
front hub; 18 – speedometer wire harness; 19 – cable input; 20 – plug; 21 – pivot bushing; 22 – steering lever; 23 – nut; 25 – expansion
bushing; 26 – steering knuckle; 27 – brake disk; 28 – volume limiter; 29 – brake case; 30 – odometer; 31 – split-pin wire; 33 – tightening
plate; 34 – washer; 35 – bushing; 37 – lining; 39 – pipe; 40 – knee-piece; 41 – ring; 42 – flange; 43 – speed sensor
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– in the same sequence remove brake case located from the other side of steering knuckle;
– unscrew bolts 2 and remove external cover 4 of hub of front wheel;
– unscrew bolts 7 and remove drive gear of speedometer sensor 5, gaskets 6, having disconnected wir-
ing harness of speedometer 18 (only for left wheel);
– unlock and unscrew bolts 32 and remove pressing ring 8;
– remove hub 11 in assembly with brake disk 27, outer bearing 13, outer race of inner bearing 14 from
steering knuckle with help of appliance shown in figure 8.2.3;
Figure 8.2.3 – Appliance for removal and mounting of front hub:

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
– unscrew nuts 23 (see figure 8.2.2) fastening steering levers 22 of steering trapezoid to steering
knuckles;
– extract expanding bushings 25 and remove steering levers from studs 24;
– moor steering knuckle 26 with the help of load-lifting device and hang it out;
– turn two ring bolts M16 in opposite tapped holes of pivot 17 (see figure 8.2.1) and moor pivot;
– turn out locking member 16 of pivot;
– squeeze out pivot 17 (weight of pivot is of 135 kg) by means of special device (figure 8.2.4).
– remove steering knuckle, extract thrust bearing 15 (see figure 8.2.1), spacing bushing 14 and
compensators 24. Deliver steering knuckle to workshop for repair. Weight of steering knuckle is of 2200 kg.
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Figure 8.2.4 – Appliance for squeezing of pivot :

1 – power cylinder; 2 – insert; 3 – nut; 4 – bushing; 5 – steering knuckle;
6 – pivot; 7 – beam of front axle; 8 – bracket
– unscrew bolts 15 (figure 8.2.2) and disconnect brake disk 27 from the hub 11;
– extract cup 16 out of the hub;
– extract outer races of bearings 13 and 14 out of the hub.
To squeeze out outer race of outer bearing 13 use appliance shown in figure 8.2.5; for squeezing of out-
er race of inner bearing 14 (see figure 8.2.2) use appliance shown in figure 8.2.6.
Figure 8.2.5 – Appliance for squeezing of outer race of outer bearing:

1 – nut; 2 – screw; 3 – washer; 4 – beam; 5 – cover; 6 – stud; 7 – outer race of bearing; 8 – hub
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Figure 8.2.6 – Appliance for squeezing of outer race of inner bearing

1 – hub; 2 – outer race of bearing; 3 – remover; 4 – washer; 5, 7 – nuts; 6 – screw; 8 – insert; 9 – beam; 10 – stud; 11 – adapter
connector
– squeeze out inner race of inner bearing 14 (see figure 8.2.2) and internal cover 17 of steering knuckle
journal. Use appliance shown in figure 8.2.7.
Figure 8.2.7 – Appliance (М513001) for squeezing of inner race of inner bearing 2007164М:
1 – screw; 2 – cover; 3, 6 – studs; 4 – steering knuckle; 5 – inner race of bearing; 7 – wrench;8 – washer; 9 – beam; 10 – bracket
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8.2.4 Check-up of technical condition of front axle parts
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 are specified in table 8.2.1
Besides, mounting of steering knuckles with cracks is not permitted. Pivots of steering knuckles are dis-
carded also at presence of cracks, faults and wear of cylindrical 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 for bearings.
Table 8.2.1 – Rated and maximum permissible sizes of major parts of front axle

Dimensions, mm
trolled parameters
rated permissible
75131 – 3001005 +0,115

Steel
Beam of front axle with lever 210 210,24
08Г2ДНФЛ, 156 – 229 НВ
Diameter of hole under pivot 40 Л
75131 – 3001012 −0,056

280 279,84
75131 – 3001013 −0,088 Steel 45 241 – 285 НВ
Steering knuckle
−0,018
Diameter of journal for bearings 320 319,88
−0,054
7513 – 3001016-10 There should not

75131 – 3001017 be places with Bimetal band
Bushing of pivot +0,03 wear of plastic 2.56 KX
2,56
Thickness of bushing stratum up to metal
75131 – 3001018
241 – 285 НВ
Pivot −0,050 Steel 45 ТВЧ h 2 – 4 mm
Outer diameter 210 209,80 НRC47
−0,165
7513 – 3103015 −0,045

420 420,00
Hub of front wheel −0,108
Diameter of holes under bearings Steel 40Л 156 – 229 НВ
−0,045
480 480,00
−0,108
7519 – 3103089-20, 7519 – 3103089-21

7519 – 3103089-22 Steel 40Л
410 156 – 229 НВ
Pinch ring −0,97
408,60 Steel 40
Outer diameter under sealant
7513 – 3103070-11
Inner cover of front hub ТВЧ h 1,5 – 4 mm
480-0,155 479,75 Steel 35
НRC40
Outer diameter under sealant
When repairing the front axle beam, use the following electrodes for manual arc welding:
– УОНИ 13/45 Э42А;
– FOX EV 47 – BÖHLER (Austria);
– JET - LH 70 – LINCOLN (USA);
– OVERCORD – OERLICON (USA);
– OK Rapid 23.50 – ESAB (Sweden);
– UTP 611 – UTP (Germany);
– KOBE - 6010 – KOBE (Japan).
It’s permissible to use semiautomatic welding in protective gas medium (СО2, mixture СО2 + argon) by
welding wire of 1,2 mm size, 08Г2С grade or analogs.
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8.2.5 Assembly and mounting of front axle

The parts of front axle delivered for assembly, should be cleaned of dirt, washed out and blown through
by compressed air.
Assembly of front axle is to be executed on special stand. At wear out or mechanical damage of metal-
plastic stratum of pivot bushings extract them from eyelets of steering knuckle and install new.
During dump truck operation when replacing pivot bushings perform reset of pivot from the left side to
the right one and vice versa aiming to increase serviceability of the pivot.
Assembly of front axle.

For simplification of assembly of front wheel hub units and steering knuckle install half-assembled unit in
vertical position on special jamb.
Assembly of front axle is to be performed as follows:
– press internal cover 17 (see figure 8.2.2) of front wheel hub on the steering knuckle 26 journal till it
thrusts to butt of steering knuckle (the probe of 0,05 mm should not pass between butt of steering knuckle and
butt of cover);
– press inner race of bearing 14 on journal of steering knuckle till it thrusts to face of inner cover 17.
For simplification of assembly heat cover 17 and inner race of bearing in oil to temperature 120 С. After
0
cooling up to ambient temperature make sure that race of bearing is completely set on place;
– fill carefully lubricant Литол-24 in space between rollers of bearing 14, put lubricant in cavity of cover 17;
– press outer races of bearings 13 and 14 in hub 11 against stop to butt.
For simplification of assembly, before mounting of outer races of bearings in hub, put them in dry ice.
After press fitting and heat of races up to ambient temperature make sure, that they are completely set
on place (the probe of 0,1 mm should not pass between butt of hub and race of bearing);
– press cup 16 in boring of hub. Press the cup to set hole using special mandrel evenly pressing it over
the whole face surface;
– install brake disk 27 onto the front wheel hub and fasten it by bolts 15 with washers with torque of
650 – 800 N.m.;
– with the help of load-lifting device install hub 11 in assembly with brake disk 27 on journal of steering
knuckle 26. Before mounting fill lubricant Литол-24 in cavity of limiter 28 and inner cavity of cup 16 (between
duster and working edge for 2/3 of the whole volume);
– install inner race of external bearing 13 on journal of steering knuckle 26 up to stop to the outer race,
carefully having filled lubricant Литол-24 in space between rollers of bearing;
– install gland 10 into boring hub, preliminary having impregnated it with oil МС-20;
– install pressing ring 8, preliminary having filled in cavity of ring lubricant Литол-24 and fix ring with
bolts 32 without tightening them;
– perform adjusting of roller taper bearings.
Adjusting of taper bearings is to be performed as follows:
– by turning hub (at three revolutions min) tighten six bolts 32 with torque of 100 – 140 N.m.
0
– unscrew bolts by 22 – 28 ;
– tighten adjusting bushings 3 with torque of 100 – 140 N.m;
– tighten twelve bolts 32 with torque of 100 – 140 N.m and lock by split-pin wire 31;
Perform the further assembling of front axle as follows:
– install and fasten by bolts 7 drive of speedometer sensor 5 (only for left wheel) to the pressing ring 8,
having installed gaskets 6 onto bolts 7 between speedometer drive and pressing ring 18, having connected
wiring harness of speedometer 18;
– install external cover 4 onto front hub 11 and fasten it by bolts 2;
– install external cover with odometer 30 and fasten it by bolts 2 (on customers’ demand for right wheel
only);
– install bushings 35 into the holes of steering knuckle 26;
– install two brake cases 29 onto steering knuckle 26 and fasten them on the lower bolt 36 not tightening
the bolt up to stop for two-three turnovers;
– turn smoothly the brake case, held on the lower bolt, to horizontal position and install brake pads 37;
– fasten brake case to the steering knuckle by bolts 36 with torque of 2000 – 2400 N.m., having pro-
vided using adjusting washers 34 the gap of 1,5 mm between ends of shafts of the brake case 29 pads and
brake disk 27.
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Each adjusting washer, joint of brake casing and steering knuckle, surfaces are to be coated with mix-
ture that contains 80 – 85% of sealant according to specification 6.10-00204234-004-95 and 15 – 20% of ab-
rasive 14А 10Н, 14А 8Н according to state standard 28818-90. The mixture is preliminarily mixed up to uni-
form mixing of abrasive in sealant. Substitutes for abrasive: 25А 10Н state standard 28818-90; 63С 10Н state
standard 26327-84. Stop the bolts 36 against unscrewing tightening plates 33 with bolts 44 and washers;
– install with the help of hoisting gear steering knuckle 26 in assembly with hub 11 and brake gear verti-
cally with shaft of bore under pivot and install it on jamb 3 (see figure 8.2.3);
– install bushing 21 and bushings 18 (see figure 8.2.1) into eyelets of steering knuckle 26 (see figure
8.2.2) and press cups 23 into the upper eyelet of the steering knuckle;
Prior to assembling clean thoroughly the pivot bushing, pivot of dust, dirt and lubricant and dry using soft
paper or fabric napkins.
Before mounting internal surfaces of pivot bushings, surface of pivot and eyelets of steering knuckle,
working crimps of cups are to be greased with thin stratum of lubrication Литол-24. Before assembly fill lubri-
cant Литол-24 in inner chamber of cup 23 (between working crimps) on two – third of its volume;
– lead steering knuckle to beam of front axle 7 and combine bores of steering knuckle with bore of
beam;
– screw two ring bolts into opposite threaded holes of pivot 17 and the pivot into the hole of steering
knuckle upper eyelet;
– install thrust bearing 15 with spacing bushing 14 between steering knuckle lower eyelet and beam face.
Prior to pivot squeezing in adjust the gap between steering knuckle lower eyelet and beam face using compensa-
tors 24. The probe with thickness of 0,8 mm should not pass;
– install arbor on pivot and press pivot till matching of pivot bores and beam bores for stopper 16 of pivot.
– screw stopper 16 up to stop into the aligned holes of pivot and beam;
– install the steering lever 22 (see figure 8.2.2) on the studs 24 and secure it with nuts 23 with torque of
800 – 1000 N.m. to steering knuckle 26, having installed expansion bushings 25 on studs under the nuts.
Before assembly cover the surface G with mixture of by volume: 80% – 85% of sealant
TУ 6.10-00204234-004 and 15% – 20% of grinding material 14A 10H, 14A-8H ГOСT 28818, previously having
stirred the mixture up to even spread of grinding material in the sealant;
– in the same sequence install the other steering knuckle on the beam of front axle.
0
Steering knuckles with hubs, brakes and steering mechanisms should be rotated around pivots for 42
min in any direction without contact with the beam;
– connect and secure the pipelines of brake and lubrication systems;
– install and secure steering trapezoid link and turn cylinders to steering levers of steering knuckles and
to brackets of the front axle beam (see chapter "Steering");
– after assembly spew pivots bushings with lubricant Litol-24 through the greasers 19 (see figure 8.2.1).
The amount of grease is of 0,2 – 0,3 kg to each eyelet of steering knuckle.
After assembly cover the surface F (see figure 8.2.2) with mixture of by volume: 80% – 85% of sealant
TУ 6.10-00204234-004 and 15% – 20% of grinding material 14A 10H, 14A-8H ГOСT 28818, previously having
stirred the mixture up to even spread of grinding material in the sealant.
Mounting of front axle on dump truck.

Mounting of front axle on dump truck is to be performed as follows:
– moor front axle with the help of fastening device and deliver from section of assembly to place of its
mounting on dump truck;
– install front axle on carriage-hoist and, having made sure of its reliable fixing, drive it under dump truck
installed on jambs;
– install front axle beam directing lever eyelet inside frame bracket perform assembling of the suspen-
sion central hinge.
Connect transversal rod of front suspension to the front axle beam.
By smooth lifting of front axle on carriage-hoist inject brackets of suspension cylinder up to input of
flanges into grooves of landing nests of steering knuckles and fasten by bolts;
Assembly procedure for central hinge, mounting of transversal rod and connection of suspension cylind-
ers look in chapter “Suspension”.
– roll out special carriage-hoist from under front axle;
– charge front suspension cylinders with gas;
– connect high pressure hoses of steering to turn cylinders, hoses of brakes and lubrication lines of au-
tomatic lubricating system;
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– install wheels on hubs of front wheels (see «Wheels and tires» section). After tightening of nuts inflate
tires with air up to required pressure.
After mounting front axle on dump truck adjust toe-in of front wheels without removing dump truck from
jambs (look chapter “Steering”). After adjusting of toe-in remove dump truck from jambs, remove thrust blocks
from under rear wheels.
8.3 Wheels and tires

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

1 – valve; 2 – hold-down of wheel fastening; 3 – stud;
4 – nut of wheel fastening; 5 – key rim ring; 6 – sealing ring;
7 – bead ring; 8 – tire; 9 – rim; 10 – landing ring
8.3.1 Removal of wheels from hubs

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

PRESSURE IN TIRE!
It is necessary to observe the specified requirements at performing any works connected with necessity
of unfastening or removal of wheels.
At operation of dump truck in locking part of wheel rim there can be cracks. If there is air in tire at releas-
ing 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 hold-downs 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 on-
ly and release hold-downs 1. Having made sure that hold-downs are released, unscrew nuts completely and re-
move hold-downs. At completely unscrewed nuts there can be blowout of hold-downs, therefore it is forbidden to
stand opposite hold-downs of rear wheels that are being removed.
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Figure 8.3.2 – Mounting of rear wheels:

1 – tire; 2 – rim; 3, 4 – valves; 5 – nut of wheel fastening; 6 – stud; 7 – hold-down of wheel fastening; 8 – landing ring; 9 – key rim
ring; 10 – spacing ring; 11 – sealing ring; 12 – extension lead
Figure 8.3.3 – Work tool for wrench support at unscrewing and screwing nuts of rear wheels fastening:
1 – wrench; 2 – holder; 3 – pin; 4 – washer; 5, 6 – bolts; 7 – disk; 8 – beam
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When fastening rear wheels there are three hold-downs installed from both sides which have additional
threaded hole M24x2. To simplify dismantling of hold-downs when replacing rear wheels use bolt 34758
(M24x2), which is specially attached to the spare parts kit.
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.
Wheeled manipulator 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.
8.3.2 Disassembly and assembly of wheels

Dismantling and assembly of tires is to be carried out only on tire assembly stand providing smooth and
uniform application of loading on wheel parts, with application of work tools and devices.
“BELAZ” – Management Company of Holding “BELAZ–HOLDING” produces and ships on the custom-
ers’ order the tires assembly stand "ЭСМ5А" (figure 8.3.4). Operations of assembly and dismantling of tires on
tire assembly stand are to be performed guided by certificate on stand.
IT IS INADMISSIBLE TO BEAT OUT RIMS FROM TIRES WITH THE HELP OF SLEDGE HAMMER IN ORDER
TO PREVENT DEFORMATION OF WHEEL PARTS, AND EMERGENCE OF NICKS AND CRACKS.
DISMANTLING OF TIRE FROM RIM IS CARRIED OUT ON TIRE ASSEMBLY STAND AT ABSENCE OF AN AIR
PRESSURE IN TIRE.
Dismantling of tires is to be carried out in the following sequence:
– turning handle 11 (figure 8.3.4) install brackets 9 on corresponding standard size of tire;
– install wheel on support platforms of brackets 9;
– install upper cross-piece 7 on bearing part 6 and lock it;
– switch on electromotor of pumping plant 10 having pushed the button 21;
– move down the rod of power cylinder 1 having pushed the button 25; press on landing ring and press
out tire till release of locking and sealing rings;
– remove locking and sealing rings;
– lift rod of power cylinder 1 in upper position having pushed the button 23;
– install thrust blocks of cross-piece 7 on diameter wheel rims and lock them;
– hauling down rod of power cylinder 1 having pushed the button 25 squeeze wheel rim from tire;
– lift rod of power cylinder in upper position having pushed the button 23;
– lift mobile plate 4 by cylinder 16 in upper position having pushed the button 22; the button operates in
the jerking mode;
– install four shoes 1 (figure 8.3.5) of the corresponded size onto the rim face;
– install sectors 2 of the corresponded size into the shoes slots so that the shoe butt point is in the mid-
dle of the sector;
– pull down mobile plate 4 (figure 8.3.4) having pushed the button 24 in lower position, thus tire hangs
on shoes;
– install thrust blocks of upper cross-piece 7 on diameter of upper bead ring;
– pull down rod of power cylinder having pushed the button 25 and squeeze landing ring from tire;
– switch off electromotor of pumping plant having pushed the button 26;
– unlock and remove upper cross-piece 7;
– remove landing and upper bead rings;
– remove tire and lower bead ring;
– remove wheel rim from stand.
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 assembling, but
also subsequent dismantling as tire adheres more strongly to unpainted surfaces of tire beads than to the co-
lored surfaces.
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Figure 8.3.4 – Tire assembly stand 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 – up-
per cross-piece; 8 – jamb; 9 – bracket; 10 – pumping plant; 11 – handle; 12, 13, 14, 15 – pipe ducts; 16 – cylinder of mobile plate lifting;
17 – lower cross-piece18 – стол; 19 – control console; 20 – voltage indicator; 21 – pump actuation button; 22, 24 – buttons controlling the
lifting cylinder; 23, 25 – buttons controlling the power cylinder; 26 – Stop button"
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Figure 8.3.5 – Installation of shoes:

1 – shoe; 2 – sector
Before assembling test condition of tire by external ex-

amination. 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 reason of complicated or
impossible air release from tire because of blockage of valve
canal.
Check carefully condition of rim elements, paying spe-
cial attention on absence of cracks on flute for locking ring
and sealing rings, on fluting planes of clamps of bead groun-
ding and landing ring, on welded connections of locking 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, pres-
ence 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 locking ring, indents, agnails, etc.).
It is forbidden to use rims with bad condition of locking flute and locking rings with above mentioned de-
fects 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 impermeability of joints. Re-use of sealing ring is not permitted. It is
forbidden to use bore fore valve for rim strapping.
For protection of slide valves from clogging and damage the valve should comprise cap.
IT IS FORBIDDEN TO:
– use sealing rings with defects;
– use bore for valve for rim strapping;
– carry out technological operations connected with heating of rim and its parts (welding, cut-
ting, etc.) when wheel is in assembly with tire.
Assembling of tires is carried out in the following sequence:
– power on the stand;
– switch on electromotor of pumping plant 10 (figure 8.3.4) having pushed the button 21;
– lift rod of power cylinder 1 in upper position having pushed the button 23; the button operates in the
jerking mode;
– unlock and remove from support 6 of upper cross-piece 7;
– turning handle 11 install brackets 9 on corresponding standard size of tire;
– install wheel rim on support platforms of brackets;
– put on lower bead ring on wheel rim;
– put on tire on wheel rim;
– install upper bead ring;
– install landing, sealing and locking rings;
– install on support 6 of upper cross-piece 7 and lock it;
– install thrust blocks of cross-piece on diameter of landing ring and lock them;
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– switch on electromotor of pumping plant 10 having pushed the button 21;

– move down the rod of power cylinder 1 having pushed the button 25. The button operates in the jerk-
ing mode; Press landing ring into tire bead before releasing chases for sealing and locking ring;
– install sealing and locking rings in corresponding chases of rim. Grease new sealing ring with solution
of silicone oil or suds;
The tire inflation by air is performed in the following order:
– tire inflation with air is to be performed on tire assembly stand with screw-down mechanism fixed on
rod of power cylinder, providing safety of work.
– preliminary pump up tire up to pressure of 0,08 – 0,10 МPа and test correctness of assembly of tire
with rim;
– pump up tire with air up to recommended pressure and keep for in 10 – 15 minutes for providing
dense fit of tire bead to shelf of rim;
– lower tire pressure to recommended working pressure level and test impermeability, having filled studs
in flute of bead flanged edge. Impermeability of joints “valve – rim” and “slide valve chamber – slide valve” is
also checked by suds;
– lower air pressure in tire up to 0,08 – 0,1 МPа;
– unfasten and remove upper cross-piece together with wheel from stand;
– disconnect cross-piece from wheel and install it on stand.
Impermeability of second bead is checked analogously, but wheel is stacked by locking ring downwards.
Also test impermeability of joint of valve with extension lead by soap emulsion.
Final estimation of impermeability of wheel in assembly with tire is made by manometer on pressure de-
crease for 24 h. Pressure decrease is not permitted.
Lead-up of tire pressure up to normal level follows only after mounting wheel on hub. There should not
be people near to pumped tire. At mounting of extension leads it is necessary to test release of air from tire by
pressing slide valve of extension lead.
Transportation and storage of tires is to be performed in verticality. Assembled tires should be stored at
an air pressure in them of 0,08 – 0,10 МPа.
8.3.3 Mounting of wheels on hubs

For mounting of wheels fastening device or wheeled manipulator are to be used.
Wheel on front hub is to be installed in the following sequence:
– turn hub chase downwards and install wheel on hub having combined arrester of rim with chase of hub;
– install upper and lower, and then left and right hold-downs and tighten nuts;
– install all other hold–downs and tighten nuts. Tighten nuts oppositely for providing wheel wobble on side
member of tire case of no more than 10 mm;
– tighten nuts with torque of 1150 – 1300 N.m;
– pump up tire with air up to the required pressure. Screw cap on valve.
Rear wheels are to be installed on hub in the following sequence:
– put on hub installed by chase downwards internal wheel with extension lead of valve and spacing ring.
For alignment of internal wheel with tire on hub it is necessary to apply special work tool (figure 8.3.6). For
providing concentric position of wheel in regard to hub it is recommended to fix it with lining chocks installed
under tire;
– 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 hold-downs and tighten nuts of wheel fastening gradually in 3 – 4 takings crosswise (serially op-
positely). 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 fur-
ther 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.
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On dump trucks valves such as БС and extension leads УГ17 of increased flow area are installed.
When replacing the wheels tighten nuts after the first trip, then perform tightening in two-three rides up
to stabilization of torque on all the nuts.
Figure 8.3.6 – Work tool for alignment of internal wheel with tire on hub:
1, 4 – bolts; 2 – plate; 3 – chock; 5 – nut
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9 STEERING
Steering system of dump truck is of hydrovolumetric type, with internal hydraulic feedback. It includes
hydraulic steering mechanism, connected by cardan shaft with steering shaft column, the stream amplifier, col-
lector, two turn hydraulic cylinders, axial-piston pump of the variable productivity, filters, three pneumohydraulic
accumulators, oil tank and oil-ducts.
Repair of pneumohydraulic accumulators is shown in section "Braking systems".
9.2 Possible failures of steering

For definition of possible reasons of failures of steering and methods of their elimination it is necessary
to be guided by table 9.1.
Table 9.1 – Basic failures of steering, reasons and methods of their elimination
Failure and its external

Probable reason Method of elimination
development
The slow response of Steered axle is overloaded Reduce axle load

steering on steering cy-
Out-of-order safety valve in hydraulic system of
linder of steering wheel, Replace safety valve
hoisting mechanism
weak amplification or
loss of amplification Pump of steering is defective Replace pump
Slow offset of dump Replace pull-rod and to test convergence of front
Pull-rod of steering trapezoid is damaged
truck on road to one side wheels
Presence of air in hydraulic system because of low
level of oil in tank, cavitations of pump, air inflow Find and remove failure
through sealing
Piston of hydraulic cylinder is slackened Repair hydraulic cylinder
Yawing of dump truck at
in-line motion Breakage of springs of neutral position in steering
Replace springs of steering gear
gear
Curving rod of hydraulic cylinder or fault of nozzle Replace out-of-order parts
Wear of parts of steering gear Replace steering gear
At slow twirl of steering Wear of piston seals of hydraulic cylinder Replace sealing
wheel steered wheels
are not pivoted Wear of parts of steering gear Replace steering gear
Presence of air in hydraulic system owing to low lev-

Remove failures, add oil in hydraulic reservoir up
el of oil, cavitation of pump, escape of oil through
to level
Unstable steering sealing, etc.
Fastening of piston of hydraulic cylinder is slack-
Fix piston
ened
Wear of slots of drive axis of steering gear or propel-
Replace worn-out parts
The steering wheel is ler shaft
freely twirled without re-
Low level of oil in tank Add oil
sponse of front wheels
Fault of hoses Replace hoses
Excessively augmented
free travel of front Wear of sealing of hydraulic cylinders Replace sealing of hydraulic cylinders
wheels
Jamming of steering
Hit of corpuscles of dirt in spool-and-bushing Disassemble steering gear and to wash out parts
gear
The vibration or sponta-
neous twirl of steering Irregular connection of pipe ducts of steering Test correctness of connection of pipe ducts
wheel
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Failure and its external

Probable reason Method of elimination
development
Steerable wheels are pi-
Pipe ducts abnormally connected to ports of hydrau-
voted aside, opposite to Correct connection of pipe ducts
lic cylinders
twirl of steering wheel
Inconsistent or non- Hit of air in hydraulic system Remove leakage of system
uniform operation of
steering Insufficient level of working fluid in hydraulic tank Restore fluid level
Disassemble slow or hard steering unit and re-

Slow or hard steering Jam of spool-valve of flow amplifier
move jam of spool-valve
Heavy twirl of steering Polluted throttle bore in spool-valve of hydraulic dis-
Disassemble unit and clean throttle bore
wheel tributor of sampling of direction of flow amplifier
Polluted throttle bore in spool-valve of flow amplifier Disassemble unit and clean throttle bore
Free rotation of steering Leakage of shock-proof or inlet valves of flow am-
Clean shock-proof and inlet valves
wheel (without jam) plifier
Excessively low pressure of wear of shock-proof
Adjust shock-proof valve
valve
Accumulation of air inside pump Pit air from pump
Breakage of power shaft of pump Replace shaft
Absence of pressure of
oil on exit of pump Significant escapes of working fluid in hydraulic sys-
Remove leakage
tem
Absence of oil on input of pump Restore oil level in tank
Valve of cut-off of pump is misadjusted Adjust valve
Low pressure of oil on
exit of pump Wear of pistons or cylinder block of pumping unit of
Replace worn-out parts or pump
pump
Excessively high pres-
sure of oil on outlet of Valve of cut-off of pump is misadjusted Adjust valve
pump
Pipe ducts and hoses are not fixed Fix pipe ducts by clinches with rubber gaskets
Operation of hydraulic
system is accompanied Insufficient level of working fluid in hydraulic tank Restore oil level
by heightened noise Hit of air in hydraulic system Remove leakage of system
level
Cold enough working fluid or its very tall viscosity Fill working fluid of required viscosity or preheat it
Hit of air in suction hydroline Restore impermeability of suction hydroline

The working fluid foams
Insufficient level of working fluid in hydraulic tank Restore fluid level
Pump works at pressure exceeding acceptable value Adjust valve of cut-off on required pressure
Insufficient level of working fluid in hydraulic tank Restore fluid level
Excessive heating of
hydraulic system Hit of air in suction hydroline Restore impermeability of suction hydroline
Abnormally adjusted or out-of-order safety valve in
Adjust or replace safety valve
hydraulic system of hoisting mechanism
Leak on shaft of pump Fault of sealing Replace cuff
Many of the resulted failures can be eliminated directly on dump truck, without removing knot. However
if after carrying out of corresponding resetting failure isn't eliminated, it is necessary to remove faulty units of
steering from dump truck for repair.
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9.3 Removal of units of steering from dump truck

Before removal of hydraulic device hydraulic unit, proximal to it surfaces, and also pipe ducts and arma-
ture should be cleared of dirt and friable color.
IT IS NOT SUPPOSED TO DISMANTLE AND ASSORT THE ELEMENTS OF HYDRAULIC SYSTEMS WHICH
ARE UNDER THE PRESSURE OF WORKING LIQUID. PRESSURE REMOVAL IN HYDRODRIVE GEAR IS PERFOR-
MESD BY UNSCREWING OF LOCKING NEEDLES IN THE BRAKE VALVE.
After dismounting in order to prevent hit of dirt in bores, waste of tubes and hoses should be enclosed
by plugs or sealed, for example by plastic packages.
9.3.1 Removal of steering column

Remove steering column from dump truck in following sequence:
– unscrew screws and remove plastic shields (figure 9.1) and housings 3 and 4;
– remove cover of steering wheel;
– unscrew nut fastening the steering wheel and remove wheel 1 from shaft of steering column 5;
– remove switches of turn indicators, light of headlights, window wiper and window washer;
– disconnect propeller shaft 6 of steering on part of shaft of steering column;
– unscrew bolts fastening steering column to lower panel of gears and fast-head wall of cabin;
– remove steering column 5 with bracket;
Figure 9.1 – Mechanical drive of batcher:

1 – steering wheel; 2 – cover of upper housing; 3 – upper housing; 4 – housing; 5 – steering column; 6 – propeller shaft;
7 – batcher; 8, 12 – bolts; 9 – cover of bearing; 10 – key; 11 – shaft; 13 – flange with bearing; 14 – handle of steering column tilt;
15 – handle of steering column height reset; 16 – cover with logo
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9.3.2 Removal of steering gear

Steering gear is to be removed in following sequence:
– disconnect propeller shaft 6 (figure 9.1) from shaft 11;
– disconnect hoses of high pressure from steering gear, preliminarily having marked them;
– unscrew bolts 8 fastening batcher to bracket of cabin floor and remove batcher from dump truck to-
gether with flange 13 and cover of bearing 9.
9.3.3 Removal of flow amplifier

The flow amplifier is to be removed in following sequence:
– disconnect, damp and mark each hydraulic line;
– supporting flow amplifier turn out fastening bolts and remove it.
9.3.4 Removal of collector

Collector is to be removed from dump truck in following sequence:
– disconnect, damp and mark each hydraulic line;
– supporting collector turn out fastening bolts and remove it.
9.3.5 Removal of filter

The filter is to be removed from dump truck in following sequence:
– disconnect hoses of high pressure from filter;
– unscrew plug in heel of filter and merge oil;
– unscrew bolts of fastening of filter and remove filter from dump truck.
9.3.6 Removal of hydraulic cylinders of steering cylinder and pull-rod of steering trapezo-
id
The steering cylinder is to be removed from dump truck in following sequence:
– disconnect hoses of high pressure from steering cylinder;
– fasten steering cylinder (102 kg) with help fastening device and hoisting gear;
– unscrew bolts 6 and 10 (figure 9.2) extract spacing bushing 7 and remove clamping plates 9;
– dismantle conic fingers 8 from steering levers 2 or 4, brackets of front axle beam and remove steering
cylinder from dump truck.
Figure 9.2 – Mounting of steering cylinders and steering trapezoid pull-rod:

1, 5 – steering cylinders; 2, 4 – steering levers; 3 – steering trapezoid pull-rod; 6, 10 – bolts; 7 – spacing bushing; 8 – finger; 9 –
clamping plate; В, С – dimensions
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The pull-rod of steering trapezoid is to be removed from dump truck in following sequence:
– fasten pull-rod 3 (175 kg) with help fastening device and hoisting gear;
– unscrew bolts 6 and 10, extract spacing bushing 7 and remove clamping plates 9;
– dismantle conic fingers 8 from steering levers 2 or 4 and remove pull-rod.
For removal of steering levers 2 and 4 fasten them with help fastening device and hoisting gear, un-
screw nuts fastening them to steering knuckles, extract tapered bushings and remove steering levers.
9.4 Disassembly of units of steering

9.4.1 Disassembly of column of steering
Disassembly of column of steering with bracket is to be carried out as follows:
– unsplint and unscrew nut 28 (figure 9.3) on shaft 16;
– unscrew screw from butt of shaft 24 and remove handle 14 (see figure 9.1);
– unscrew nut 14 (see figure 9.3) rod 4;
– extract shaft 16 and separate steering column 15 from bracket 11;
– remove rod 4;
– take out split-pin 22 from finger 23;
– remove finger 23 and stopper 7;
– unscrew screw 17 on shaft 24 and remove lever 18, spring 19 and bushing 20;
– extract shaft 20 of bore in bracket 8;
– remove bushing 1 and stopper 2;
– unscrew nut 8 and remove pusher 12.
Figure 9.3 – Steering column with bracket:

1, 20 – bushings; 2 – stopper; 3 – key; 4 – rod; 5, 10 – bolts; 6, 9, 25, 26 – washers; 7 – stopper; 8, 14, 28 – nuts; 11 – bracket;
12 – pusher; 13 – support; 15 – steering column; 16, 24 – shafts; 17 – screw; 18 – lever; 19 – spring; 22, 27 – split-pins; 23 – finger;
29 – adjusting washers
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The further disassembly of column of steering is to be carried out as follows:

– unscrew nut 3 (figure 9.4) fastening steering wheel 1, if it is screwed onto shaft 6, after steering wheel
is removed;
– unscrew screw 4 and remove it together with kicker bushing 5;
– unscrew screw 14 and remove it with ring 15;
– turn handle 16 clockwise, keeping it in this position remove housing 2 as assembly with shaft 6;
– extract from bore of shaft 13 two springs 10 and washer 1;
– extract locking ring 8 from housing 2 and take out shaft 6 with bearing 9;
– remove locking ring 7 and bearing 9 from shaft 6;
– unscrew screw 4 from shaft 21;
– remove handle 16, spring 17, bushing 18 from shaft 21;
– take shaft 21 out of bushing 19;
– get key 20 from key slot of shaft 21;
– extract locking ring 8 of tube of column 11 and take out bushing 12 with shaft 13 and bearing 9;
– remove from shaft 13 locking ring 7 and bearing 9.
Figure 9.4 – Column of steering:

1 – washer; 2 – housing; 3 – nut; 4, 14 – screws; 5 – kicker bushing; 6, 13 – shafts; 7, 8 – locking rings; 9 – bearing;
10, 17 – springs; 11 – tube of column; 12, 18, 19 – bushings; 15 – ring; 16 – handle; 20 – key; 21 – shaft
9.4.2 Disassembly of propeller shaft of steering

Disassembly of propeller shaft is to be carried out as follows:
– turn out bolts 2 (figure 9.5) fastening of cardan joints and remove cardan joints from shaft of steering
column;
– take out from spline shaft 6 and nozzle of tube 3 of key 10;
– remove wire split-pin 4 from protective clutch 5 and take out spline shaft 6 of tube 3;
– remove protective clutch from spline shaft;
If it is necessary to replace needle bearers execute disassembly of cardan joint, for what remove locking
rings 13 of needle bearers 11 and, tapping slightly in butt of one bearing, squeeze from fork and remove from
remotely spider opposite bearing.
In the same way remove other needle bearers.
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Figure 9.5 – Propeller shaft of steering:

1 – cardan joint; 2 – handrail bolt; 3 – tube; 4 – wire splint; 5 – protective clutch; 6 – spline shaft; 7 – fork; 8 – plug; 9 – safety
valve; 10 – key; 11 – trunnion; 12 – end seal; 13 – locking ring; 14 – needle bearing
9.4.3 Disassembly of batcher

Disassembly of batcher is to be carried out as follows:
– unscrew bolts 3 and special bolt 22 with rolled head (figure 9.6);
– remove cover 4 and sealing ring 21;
– remove rim 5 with spider 6 of feedback hydraulic motor 1 and sealing ring 21;
– extract cardan 8 and remove distributive disk 7 and sealing ring 20;
– turn out thread bushing 19 and extract ball of check valve 17;
– extract from body 18 which is preset in verticality, sleeve 9 as assembly with spool-valve 13, dowel 10,
springs 11 and restrictive ring 12, apply slight force to shank of spool-valve 13. Large force, especially of shock
character, can cause fault of parts of distributive unit;
– remove from spool-valve 13 (or extract from body 18) thrust bearing 16;
– remove from spool-valve 13 restrictive ring 12 and remove from sleeve 9 dowel 10;
– extract from bushing 9 spool-valve 13 and springs 11;
– extract from body 18 sealing 15.
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Figure 9.6 – Batcher:

1 – feedback hydromotor; 2 – distributive unit; 3 – bolt; 4 – cover; 5 – rim; 6 – spider; 7 – distributive disk; 8 – cardan; 9 – sleeve;
10 – dowel; 11 – plate springs; 12 – restrictive ring; 13 – spool-valve; 14 – dust cap; 15 – combined sealing; 16 – thrust bearing;
17 – check valve; 18 – body; 19 – thread bushing; 20, 21 – sealing ring; 22 – special bolt
P – pressure line; T – drain line; L and К – correspondingly cylinder type lines for turn to left and right sides
9.4.4 Disassembly of flow amplifier

9.4.4.1 Disassembly of flow amplifier OSQB 5
Disassembly of flow amplifier is to be carried out as follows:
– unscrew bolts 29 and 30 with locking washers, remove cover 31, sealing rings 32 and 33 (figure 9.7);
– extract from case 9 support of spring 34 and spring 35, support of spring 28 and springs 26, 27;
– unscrew bolts 1 and 2 with locking washers, remove cover 3, sealing rings 4, 5, 6;
– extract from case support of spring 17 and springs 18 and 19;
– take out spring 40;
– take out spool-valve of priority valve 36;
– take out spool-valve of direction 22 and thrust blocks of spring 20 and 25;
– extract spool-valve of amplifier 39. Set aside for consequent disassembly;
– extract shock-proof valves 7 and 23. Set aside for consequent disassembly;
– turn out plug 12, remove sealing ring 11 and extract valve of backpressure 10;
– turn out plug 13, remove layer pad 14 and turn out with help hexahedral key safety valve 15;
– turn out throttle with check valve 38;
– turn out throttles 8 and 37;
– turn out from spool-valve of direction 22 throttles 21 and 24.
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Figure 9.7 – Flow amplifier OSQB 5:

1, 2, 29, 30 – bolts; 3, 31 – covers; 4, 5, 6, 11, 32, 33 – sealing rings; 7, 23 – shock-proof valves; 8, 21, 24, 37 – throttles; 9 – case;
10 – valve of backpressure; 12, 13 – plug; 14 – layer pad; 15 – safety valve; 16 – valve spring of backpressure; 18, 19, 26, 27,
35 – springs; 20, 25 – thrust blocks of spring; 22 – spool-valve of direction; 17, 28, 34 – support of spring; 36 – spool-valve of priority
valve; 38 – throttle with check valve; 39 – spool-valve of amplifier
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Shock-proof valves (figure 9.8) are maintained as sep-

arate units entirely. Sealing rings 1 and 3 can be replaced sep-
arately.
Figure 9.8 – Shock-proof valve:

1, 3 – sealing rings; 2 – part of auxiliary valve
The safety valve 15 (figure 9.7), throttle with check valve 38 and valve of backpressure 10 also are
maintained as separate units entirely.
Disassembly of spool-valve of amplifier 39 is necessary only in event that it is required to replace sealing
ring 2 (figure 9.9), spring 9 or throttle 11, otherwise this unit is subject to substitution entirely:
– take out locking ring 7;
– take out pin 5;
– take out plug 10 and spring 9;
– take out locking ring 6 and pin 4;
– extract internal spool-valve 8;
– turn out butterfly valve of one-sided opera-
tion and extract ring 2;
– turn out throttle 11 of plug 10.
Eliminate opportunity of pollution of unit, install
time plastic plug in ports of flow amplifier.
Figure 9.9 – Spool-valve of amplifier:

1 – throttle valve of single flow operation; 2 – sealing ring;
3 – spool-valve; 4, 5 – pins; 6, 7 – locking rings; 8 – internal spool-
valve; 9 – spring; 10 – plug; 11 – throttle
9.4.4.2 Disassembly of flow amplifier 75131-3416600

Disassembly of flow amplifier is to be carried out as follows:
– unscrew bolts 10 (Figure 9.7a) and disconnect from the cases 5 and 1 respectively left cover 9, right
cover 15 of flow amplifier and left cover 21, right cover 27 of the priority valve. When loosening bolts be
careful as covers are spring loaded;
– extract the distributor 12 spool-valve and the two sets of parts – springs 11 and 14, bushings 13,
springs supports 16; flow amplifier spool-valve 17 in assembly with check valve 18, spring 20 and spring sup-
port 7 out of flow amplifier 5 case and covers 9 and 15;
– extract braking spool-valve 25 and the two sets of parts – springs 22, 23 and guides of springs 24;
priority valve spool-valve 29, spring 28 and spring support 7 out of the priority valve 1 case and covers 21 and
27;
– unscrew check valve 18 out of the flow amplifier 17 spool-valve, do check valve 32 out of the cover 21
and, if necessary, disassemble check valves 18 and 32;
– extract rings 5, 8, 19, 26 and 30 from the grooves of cases 1 and 5.
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Figure 9.7a – Flow amplifier 75131-3416600:

1 – the case of the priority valve; 2 – jet; 3, 8, 19, 26, 30, 31 – rings; 4 – plug; 5 – the case of the flow amplifier; 6, 10 – bolts;
7, 16 – springs supports; 9 – left cover of the flow amplifier; 11, 14, 20, 22, 23, 28 – springs; 12 – distributor spool-valve; 13 – bushing;
15 – right cover of the flow amplifier; 17 – flow amplifier spool-valve; 18 – check valve;21 – left cover of the priority valve; 24 – spring
guide; 25 – spool-valve of braking; 27 – right cover of the priority valve; 29 – priority valve spool-valve; 32 – check valve with throttle;
A, B, A1, B1, P, T, T1, X, Y, X1, Y1 – channels marked on the set of cases
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9.4.5 Disassembly of collector

Perform disassembling of the collector as follows:
– turn out screws 3 with spring washers (figure 9.10);
– remove hydraulic distributor 2 and take out rubber sealing rings 6;
– turn out plug 10 and take out sealing ring 9, bushing 7, spring 5 and valve 4.
Eliminate opportunity of pollution of unit, install temporary plastic plug in ports of collector.
Figure 9.10 – Collector:

1 – case; 2 – electromagnetic hydraulic distributor; 3 – screw; 4 – valve; 5 – spring; 6, 9 – sealing ring; 7 – bushing; 8 – button for
forced pressure release in the pneumatic hydroaccumulators; 10 – plug;
I, II, III – channels connected with pneumatic hydroaccumulators; IV – channel connected with drain line; V – channel connected
with dumping gear control panel; VI – channel connected with brake system; VII – channel connected with flow amplifier
9.4.6 Disassembly of the filter

The filter disassembly is carried out in the following
sequence:
– unscrew plug 1 with ring 2 and drain oil from the
filter (figure 9.11);
– unscrew dirtiness indicator 16 of cover 13.
– unscrew case 6 from cover 13;
– pull out from case 6 filtering element 7, spring 3
and plug 4;
– unscrew bushing 10 of cover 13;
– unscrew valve guide 14 of cover 13, pull out valve
11 and spring 12;
– remove sealing ring 15 with valve guide 14.
Figure 9.11 – Filter:

1 – plug; 2, 5, 9, 15, 17, 18 – sealing rings; 3, 12 – springs;
4 – plug; 6 – filter case; 7 – filtering element; 8 – protective washer;
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10 – bushing; 11 – valve; 13 – filter cover; 14 – valve guide; 16 – dirtiness indicator

9.4.7 Disassembly of hydraulic steering cylinder
Disassembly of steering cylinder is to be carried out as follows:
– drain oil from steering cylinder;
– unscrew bolts 24 (figure 9.12) of front cover 7 fastening to body15;
– pull rod 14 ready-fitted with piston 13 and front cover 7 out of cylinder body 15;
– unscrew nut 10 of piston fastening at the rod and remove the piston from the rod;
– pull two guide rings 11, piston seal 12 out of outer grooves of piston 13 and pull two guard rings 8 and
ring 9 out of inner groves;
– remove front cover 7 from rod 14;
– pull two guide rings 19 and 21, road seal 20, cup 22 and wiper 23 out of cover 7 grooves;
– loosen nuts 18 of end 5 clamping joint and remove the end from rod 14;
– pull stop ring 1 and scrapers 2, press off hinged bearings 3 out of the end eyes and cylinder body;
– pull safety washers 4 out of scrapers.
Figure 9.12 – Steering cylinder:

1 – stop ring; 2 – scraper; 3 – spherical bearing; 4 – safety washer; 5 – end; 6, 24 – bolts; 7 – front cover; 8, 17 – guard rings;
9, 16 – rings; 10 – self-stopped nut; 11, 19, 21 – guide rings; 12 – piston seal; 13 – piston; 14 – rod; 15 – cylinder body; 18 – nut;
20 – rod seal; 22 – cup; 23 – wiper
9.4.8 Disassembly of pull-rod of steering trapezoid

Disassembly of pull-rod of steering trapezoid is to be carried out as follows:
– loosen clamping joints of pull rod, having unscrewed nuts 7 (figure 9.13);
– screw off ends 5 and 9 from tube 8;
– pull stop rings 1 and scrapers 2 out of end eyes, press off hinged bearings 3;
– pull safety washers 4 out of scrapers.
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Figure 9.13 – Pull-rod of steering trapezoid:

1 – stop ring; 2 – scraper; 3 – hinged bearing; 4 – safety washer; 5, 9 – ends; 6 – bolt; 7 – nut; 8 – tube with ends
9.5 Inspection of technical condition of parts

Test level of internal escapes in the batcher. Max admissible level of escapes in bleed holder of the
3
batcher at inlet pressure of 16 MPa is 5 sm /s.
Test level of internal escapes in flow amplifier. Max admissible level of escapes in bleed holder of am-
3
plifier at inlet pressure of 16 MPa is 20 sm /s.
Test level of internal escapes through hydraulic distributor of collector. Max admissible level of escapes
3
in drainage bore of amplifier at inlet pressure of 16 MPa is 2 sm /s.
Nominal and maximum permissible sizes of basic parts of steering gear are shown in table 9.2.
Table 9.2 – Nominal and maximum permissible sizes of basic parts of steering
Number, name of part Sizes, mm
Figure and
and inspected Material Hardness
position Nominal Admissible
parameters
69,88
7513-3429046 -0,030 fault of chromic 241–285 HRC
9.12 – 14 Rod 70 Steel 40Х
-0,076 coverage is not ТВЧ 47–57 HRC
outer diameter
permitted
75137-3429020
+0,1 +0,5
9.12 – 15 Body of cylinder 140 140 Steel 35Х
inner diameter
radial clearance in
9.12 – 3 GШСЛ-70
spherical joint ШХ15 59–65 HRC
9.13 – 3 Hinged bearing
0,5 max
9.6 Assembly of steering system units

Assembly of steering system units is performed on specially equipped places with application of the
special tools, removers, accessories, assembly and test-beds. Places of assembly should not allow penetra-
tion of mud and dust on the assembled parts.
The parts for assembly should be washed carefully in diesel fuel and dried by compressed air. Cleaning
the parts with rag before assembly is not recommended in order to prevent clogging of ports and jamming of
spool-valves. Oil ports should be cleaned and blown through by compressed air. After assembling install tem-
porary plastic plugs into the channels to avoid possibility of dirt ingress.
GENERAL MECHANICAL RUBBER GOODS (SEALING RINGS, GLANDS, LAYER PADS) AT ASSEMBLY ARE
SUBJECT TO OBLIGATORY REPLACEMENT.
9.6.1 Assembly of steering column

Assembly of column of steering with bracket is to be carried out as follows:
– press ball bearing 9 (see figure 9.4) on shaft 6;
– fix bearing 9 by locking ring 7, having installed it in groove of shaft 6;
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– press bearing 9 as assembly with shaft 6 in bore in housing 2;

– install locking ring 8 in groove in housing 2;
– install key 20 in chase on shaft 21;
– start off-center bushing 19 between eyelets on housing 2;
– having combined bores in bushing 19 and eyelets of housing 2 install shaft 21 as assembly with key
so that key has got in key in bushing 19;
– turn off-center bushing 19 with shaft 21 so that as much as possible appearing side of bushing has
come in chase in housing 2;
– put on shaft 21 bushing 18, spring 17 so that direct section of proximal to eyelet of coil of spring rested
against case of housing 2;
– put on spline shank of shaft 21 handle 16, having provided hit of unbend on spring 17 in bore in plate
of handle 16;
– fix handle 16 with screw 4;
– press bearing 9 on shaft 13;
– install locking ring 7 in groove on shaft 13;
– install bearing 9 as assembly with shaft 13 in tube of column 11;
– install bushing 12 and locking ring 8 on part of bearing 9 in bore in tube of column 11;
– install spring 10, flat washer 1 and another spring 10 in axial bore in shaft 13;
– having provided coincidence of slits of shafts 6 and 13 install tube of column 11 as assembly with shaft
13 in housing 2. Thus handle 16 should be revolved clockwise and be kept in such position before full joint of
tube of column 11 and housing 2;
– having combined radial tapped hole in tube of column 11 with chase in housing 2 turn screw 14, hav-
ing installed ring 15;
– install kicker bushing5 onto shaft 6 having provided coincidence of bore in the bushing with another
one in the shaft and lock them by screw 4.
When assembling cover friction surfaces of steering column parts, shafts 6 and 13, shaft 21 and bear-
ings 9 with thin layer of lubricant Lithol-24.
At steering cylinder of handle 16 mutual conveyance of tube of column 11 and housing 2, and also relia-
ble their mutual fixing should be ensured at absence of effect on handle.
Shaft 6 rotation torque after assembling is finished should not exceed 0,8 N.m.
Perform further assembling of steering column with bracket as follows:
– put on stopper 6 (see figure 9.3) stopper 2 and install them between walls of bracket 11, having com-
bined bore in stopper with bore in bracket;
– install in bore finger 23 and lock it with split-pin 22;
– install key 3 in chase on shaft 24;
– place between walls of bracket 11 off-center bushing 1 and flat washer 25;
– having combined bores in them and in addition in stopper 2 install shaft 24 as assembly with key so
that key has got in key in bushing 1, thus stopper 2 should be between bushing 1 and flat washer 25;
– turn off-center bushing 1 with shaft 24 so that bushing is as much as possible appearing at side oppo-
site to stopper 7;
– put on shaft 24 bushing 20 and spring 19 so that direct section of extreme coil of spring touch thrust
block on side wall of bracket;
– put on spline shank of shaft 24 bar 18, having provided hit of unbend on spring 19 in bore in plate of bar;
– fix bar 18 with screw 17;
– install handle 14 (see figure 9.1) from opposite side of shaft 24 (see figure 9.3) and turn from butt of
shaft 24 bolt;
– install shackle of tube of column 11 (see figure 9.4) between walls of bracket 11 (see figure 9.3), hav-
ing placed between walls of bracket and shackle flat washers 29;
– install shaft 18, having combined bores in bracket 11, shackle of tube of column 11 (see figure 9.4)
and washers 29 (see figure 9.3);
– screw on shaft 16 nut 28 with washer 26, having tightened it so that steering cylinder of bracket 11
concerning tube of column from force of arm was ensured and lock nut by split-pin 27;
– install in bores of eyelets of shackle support 13;
– turn shaft 24 with bushing 1 clockwise;
– install rod 4 between stopper 7 and bushing 1 so that longitudinal flat on rod placed on part of bushing
1, and h-pole serrated surfaces of stopper 7 and rod 4 have coincided;
– install thread shank of rod 4 in bore in support 13 and fix its position, having turned nut 14;
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– turn in butt of rod 4 bolt 5, having installed flat washer 6;

– install in bore pusher 12, bracket 11 bolt 10 with nut 8, flat washer 9 and, as much as possible having
approximated pusher to rod 4, turn nut.
When assembling cover friction surfaces of steering column 1 parts, support 13, shafts 16 and 24 with
thin layer of lubricant Lithol-24.
In assembled column steering cylinder of column 15 concerning bracket 11 from force of arm should be
ensured at steering cylinder of handle installed on shaft 20, and also reliable their mutual fixing at absence of
effect on handle. Steering column 15 rotation torque relatively to bracket 11 should be of 19 – 38 N.m.
9.6.2 Assembly of propeller shaft of steering

Assembly of propeller shaft is to be carried out as follows:
– if it is necessary replace needle bearers to install remotely spider 11 (see figure 9.5) in fork of cardan
joint 1, install needle bearers 14 in bore of fork 7 of cardan joints, having provided hit of remotely spider in
crank chamber of needle bearer, preliminary having filled in lubricant № 158М;
– install locking ring 13 on needle bearer from interior of fork 7 of cardan joints;
– install in same way other needle bearers;
– install protective clutch 5 on slit shaft 6 and fix clutch with wire split-pin 4;
– insert slit shaft 6 in slit bore of tube 3 so that key on shaft 6 and tube 3 placed in one plane, prelimi-
nary having greased with lubricant Литол-24 slots of shaft 6;
– put on protective clutch 5 tube 3 and fix clutch with wire split-pin 4;
– install in chases on shaft 6 and tube 3 semicircular keys 10;
– turn handrail bolts of 2 fastening of cardan joints 1 and pull together terminal connections of cardan
joints.
9.6.3 Assembly of batcher

The steering gear batcher is precision device, manufactured on close tolerances, therefore it is neces-
sary to provide full parallax purity at dealing with it. All operations should be performed only on clean work
bench, and for wiping apply soft cleaning cloth not leaving frieze.
Assembly of batcher is to be carried out as follows:
– install sealing 15 (see figure 9.6) in special groove in case 18;
– install plate springs 11 on spool-valve 13. First flat springs are established, and then between them
(moved apart with help of screw-driver) are interposed curved;
– install in sleeve 9 spool-valve greased with hydraulic oil 13 with springs. Contract waste of springs 11
and move springs into chases of bushing;
– install in bushing 9 dowel 10;
– having centered springs install on sleeve 9 restrictive ring 12;
– install on shank of spool-valve 13 thrust bearing 16, thus facet on lower bearing race should be lo-
cated on side opposite to bearing (it conversion to seating of spool-valve);
– grease external surface of sleeve 9 and shank of spool-valve 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 spool-valve 13 downwards;
– insert bead of check valve 17 into bore in case 18 and screw in this bore thread bushing 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 spool-valve 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 21 greased with grease in grooves of wreath 5 of feedback electromotor 1;
– install rim 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 bushing 19;
– turn bolts 3 with seal washers;
– test smoothness of twirl of shaft of steering gear. At non-uniform force, required for twirl to release fas-
tening of bolts, carry out retightening at fixed twirl of shaft of steering gear.
After assembling of steering column 5 (figure 9.1) and the batcher 7 the steering wheel 1 should be ro-
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tated evenly without jamming.

9.6.4 Assembly of flow amplifier
The flow amplifier is precision device, manufactured on close tolerances, therefore it is necessary to
provide full parallax purity at dealing with it. Operations should be performed only on clean work bench, and for
wiping apply soft cleaning cloth not leaving frieze.
9.6.4.1 Assembly of flow amplifier OSQB 5

Assembly of flow amplifier is to be carried out as follows:
– carefully grease each part with clean hydraulic oil before installing it;
аssembly of spool-valve of amplifier:
– turn throttle 11 in plug 10 (see figure 9.9);
– turn butterfly valve of one-sided operation 1 with sealing ring 2 in spool-valve 3;
– insert into spool-valve 3 internal spool-valve 8;
– fix internal spool-valve 8, having installed pin 4 and locking ring 6;
– insert spring 9 and plug 10, having fixed its pin 5 with locking ring 7;
аssembly of flow amplifier:
– screw throttle 8 (see figure 9.7), having tightened with torque 0,5 N.m;
– screw throttle 37, having tightened with torque 1 N.m;
– screw throttle with check valve 38, having tightened with torque 1 N.m;
– screw safety valve 15, install layer pad 14 and turn plug 13 with torque of 2,5 N.m;
– install valve of backpressure 10 with spring 16 and turn plug 12 with sealing ring 11;
– install shock-proof valves 7 and 23;
– screw in spool-valve of direction 22 throttles 21 and 24;
– install spool-valve of direction 22 in case 9;
– install spool-valve of amplifier 39 in case;
– install spool-valve of priority valve 36 in case;
– install spring 40 on spool-valve of amplifier 39;
– install thrust block of spring 20, springs 18 and 19, support of spring 17 on spool-valve of
direction 22;
– grease sealing rings 4, 5 and 6 and install them in cover 3;
– install cover 3 and rings 4, 5, 6 on case 9;
– turn bolts 2 with locking washers and tighten them with torque of 2,5 N.m;
– turn bolt 1 locking washer and tighten it with torque of 8 N.m;
– install thrust block of spring 25, springs 26, 27 and support of spring 28 on spool-valve of direction 22;
– install spring 35 and support of spring 34 on spool-valve of priority valve 36;
– grease sealing rings with 32 and 33 and install them on cover 31;
– install cover 31 and rings 32 and 33 on case 9;
– turn bolts 30 with locking washers and tighten them with torque of 2,5 N.m;
– turn bolt 29 locking washer and tighten it with torque of 8 N.m.
9.6.4.2 Assembly of flow amplifier 75131-3416600

Assembly of flow amplifier is to be carried out as follows:
– thoroughly lubricate every part with clean hydraulic fluid prior to installing it;
– the spool-valves 12, 17, 25 and 29 (see Figure 9.7a) are to be processed over respective openings in
the set of cases, wherein a gap in conjunction of from 0,010 to 0,016 mm is provided. Spool-valves and the set
of cases are marked with the same order number and applied together; when repairing the replacement of
parts of marked kit is not allowed;
– install rings 3, 8, 19, 26 and 30 into grooves of cases 1 and 5;
– screw the check valve 18 into the flow amplifier spool-valve 17, as do check valve 32 into the cover
21, having installed new sealing rings on the valves bodies. If the check valve were dismantled, then when as-
sembling emboss balls to the seats;
– screw jets 2 into the threaded holes in the ends of spool-valve 12 of distributor and in the end of flow
amplifier spool-valve 17;
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– install the braking spool-valve 25 and spool-valve of priority 29 into the case of the priority valve 1. In-
stall into hole of case from both sides of the braking valve 25 a kit of parts – spring guides 24, springs 22 and
23, as do in the hole of the case for spool-valve 29 from the side of the right cover 27 the spring 28 and the
spring support 7. Install covers 21, 27 and secure them to the priority valve 1 case by bolts 10;
– install distributor spool-valve 12 and the flow amplifier spool-valve 17 into the case of the flow amplifier
5. Install into hole of case from both sides of the distributor spool-valve 12 a kit of parts – bushings 13, springs
11 and 14, springs supports 16, as do in the hole of the case for spool-valve 17 from the side of the left cover 9
the spring 20 and the spring support 7. Install covers 9 and 15 and secure them to the case of the flow amplifi-
er 5 by bolts 10.
Test for outer impermeability supplying pressure of the working fluid (20±1,5) MPa. Supply working fluid
to port P and do sequentially to ports X and Y. Port T thus should be connected to the tank, as the other ones
are to be plugged. Working fluid is oil И-20A, the temperature of the working fluid when testing should be of
0
30 – 50 C.
9.6.5 Assembly of collector

Assembly of collector is to be carried out as follows:
– carefully grease each part with clean hydraulic oil before installing it;
– insert into case 1 valve 4, spring 5 and bushing 7 (see figure 9.10) and screw in plug 10 having in-
stalled sealing ring 9;
– install sealing rings 6 into ring shape grooves of hydraulic distributor 2;
– install hydraulic distributor 2 and clamp it by screws 3 with spring washers.
The hydraulic distributor 2 should provide the pass for the working fluid from over-valve space of the
check valve 4 into channel IV at the voltage supply U 24V to the electromagnet and close the pass when deac-
tivating the electromagnet.
The internal leakage of the working fluid from the over-valve space of the check valve into channel IV at
pressure (16+1) MPa should not exceed of 0,05 l/min. The internal leakage of the working fluid from the over-
valve space into under-valve space at pressure (16+1) MPa should not exceed of 0,01 l/min.
Check outer impermeability at earlier mentioned testing.
9.6.6 Assembly of the filter

Assemble the filter in the following sequence:
– install in valve guide 14 (figure 9.11) the spring 12, valve 11 and sealing ring 15;
– screw the guide 14 in assembly in the cover 13. The valve 11 should move in the guide 14 against the
stop without jamming;
– install on the bushing 10 the sealing ring 5. Screw the bushing 10 in the filter cover 13;
– install in the filtering element 7 the plug 4 with the sealing ring 5;
– install in the case 6 the spring 3 and subassembly filtering element;
– install the protective washer 8 and the sealing ring 9 in the ring groove of the cover 13;
– screw the case 6 in the cover 13;
– screw plug 1 into case 6 with sealing ring 2;
– screw the impurity indicator 16 with sealing rings 17 and 18 in the cover 13 of the filter;
Test the filter in assembly on the external impermeability within at least 30 s, with pressure (25+1) MPa,
so upon that the discharge outlet must be blanked off, and the working fluid must be supplied in the intake. The
leaks are not allowed.
9.6.7 Assembly of hydraulic steering cylinder

Sealing rubber rings before mounting keep in oil for not less than 48 hours.
When assembling steering cylinders: heat wiper 23 (see figure 9.12), guide ring 19, rod seal 20 and pis-
ton seal 12 to 80 – 100 С temperature within 3 – 5 minutes before mounting. The heating should be carried out
0
in boiling water (with its subsequent removal from part surface) or in working fluid warmed up to 80 – 100 С.
0
Warps, torsion, mechanical damages and cuts are not allowed during mounting of seals, rings and cups.
Assembly of steering cylinder is to be carried out as follows:
– mount guard ring 17 and seal ring 16 into outer groove of front cover 7, and mount wiper 23, cup 22,
rod seal 20 and two guide rings 19 and 21 into inner grooves. At the same time, pay attention to orientation of
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leading edges of wiper 23, cup 22 and seal 20.

Locks of guide rings 19 and 21 must be located opposite each other during mounting;
– mount front cover 7 to rod 14;
– mount seal ring 9 and two guard rings 8 into inner groove of piston 13;
– mount piston 13 to rod 14 and fasten it by nut 10. Tighten the nut by torque 2400 – 3000 N·m;
– screw end 5 onto rod 14, secure clamping joint by bolts 6 and nuts 18 with washers;
– mount piston seal 12 and two guide rings 11 (ring locks must be located at opposite sides of the pis-
ton) into outer grooves of piston 13;
– mount rod 14 with front cover 7 and piston 13 into cylinder body 15;
– fasten front cover 7 to cylinder body 15 by bolts 24 with washers;
– mount safety washers 4 into grooves of scrapers 2;
– mount scrapers 2 and stop rings 1 into eyes of end 5 and body 15 from one side;
– press spherical bearings 3 in the eyes and mount scrapers 2 and stop rings 1 from the other side of
the eyes.
Lubricate spherical surfaces of bearings by lubricant Литол-24 before mounting. When mounting the
0 0
bearings, the bearing cup parting plane must be located at the angle of 90 +5 degrees to cylinder axis. At the
same time, marking on ends of both semirings must be from the same side. Lubricated inner ring of bearing
must be rotated by torque not more than 150 N·m.
Strength test is to be carried out at static pressure 16 – 18 MPA in cylinder head end and rod end.
Check rod seal leakage of working fluid during performance check. At the same time, formation of oil
film at the rod surface is permitted without drop fall. The rod must move freely, without jamming. Working fluid
О
temperature is 35 – 50 С.
9.6.8 Assembly of pull-rod of steering trapezoid

For assembly of pull-rod of steering trapezoid first of all perform assembly of nozzles of pull-rod.
Assembly of end-tips of pull-rod of steering trapezoid is to be carried out as follows:
– mount safety washers 4 into grooves of scrapers 2 (see figure 9.13);
– mount scrapers 2 and stop rings 1 into eyes of ends 5 and 9 from the same side;
– press spherical bearings 3 into the eyes. Lubricate spherical surfaces of bearings by lubricant Литол-
24 before mounting.
0 0
When mounting the bearings, the bearing cup parting plane must be located at the angle of 90 +5 de-
grees to link pin. At the same time, marking on ends of both semirings must be from the same side. Lubricated
inner rings must be rotated in outer rings by torque not more than 180 N·m;
– mount scrapers 2 and lock washers 4 into eyes of ends 5 and 9.
Assembly of steering link is to be carried out as follows:
– screw tie-rod ends 5 and 9 in threaded ends of tube 8 according to thread hand (left or right) for equal
number of revolutions;
– screw nuts 7 with washers on bolts 6 of steering link clamping joints.
Tighten the nuts of tie-rod end clamping joints by torque 110 – 140 N·m only after mounting and toe-in
adjustment (see section “Steering” in operating manual).
9.7 Mounting of units of steering on dump truck

9.7.1 Mounting of column of steering with propeller shaft
Column of steering on dump truck is installed in following sequence:
– connect column of steering 5 (see figure 9.1) by bolts and nuts to lower panel of gears;
– fix front of bracket 11 (figure 9.3) of steering column to fast-head wall of cabin bolts;
– install semicircular key in chase on shaft of steering column and install propeller shaft 6 on shaft of
steering column 5;
– tighten handrail bolt of terminal joint of cardan joint;
– install steering wheel 1 on shaft of steering column and tighten nut of fastening of steering wheel;
– install cover 16 of steering wheel;
– install switches of turn indicators, light of headlights, window wiper and window washer;
– install plastic housings 3, 4 and cover 2 of upper housing and fix with screws.
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9.7.2 Mounting of batcher

The batcher is installed together with flange.
Steering gear is installed on dump truck in following sequence:
– install batcher 7 (see figure 9.1) together with flange 13 in bracket under floor of cabin;
– turn bolts 8 fastening batcher 7;
– connect hoses of high pressure to batcher;
– install key onto the groove on the shaft 11 connect propeller shaft 6 to shaft of batcher;
– fasten bolt 12 of terminal joint of cardan hinge.
9.7.3 Mounting of flow amplifier

The flow amplifier is installed on dump truck in following sequence:
– install flow amplifier on bracket of frame and turn bolts of fastening;
– connect hoses of high pressure to flow amplifier.
9.7.4 Mounting of collector

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

The filter is installed on dump truck in following sequence:
– install filter on dump truck and to turn bolts of fastening of filter;
– connect hoses of high pressure to filter.
9.7.6 Mounting of hydraulic steering cylinder and pull-rod of steering trapezoid

Hydraulic cylinders of steering cylinder are installed on dump truck in following sequence:
– moor steering cylinder 1 (see figure 9.2) with help of fastening device and hoisting gear;
– mount cylinder directing rear cover of the cylinder body to the bracket of front axle beam and set end-
tip to turn lever of steering trapezoid, having mated hole for fingers;
– install fingers 8;
– install distance bushings 7;
– install clamping plates 9 and fasten them by bolts 10 and 6 with torque of 490 – 600 N.m.; tighten bolts
from distance bushings 7 side after bolts are fastened from opposite side;
– mount the other cylinder analogously;
– connect hoses of high pressure to of steering cylinder thus rod end of left steering cylinder head end
left – with rod end of right cylinder should be connected to head end of right cylinder.
Pull-rod of steering trapezoid is installed on dump truck in following sequence:
– moor pull-rod of steering trapezoid with help of fastening device and hoisting gear;
– install pull-rod of steering trapezoid 3 (figure 9.2) in eyelets of turn levers 2 and 4 of steering trapezoid,
having mated hole for fingers;
– install fingers 8;
– install distance bushings 7;
– install clamping plates and fasten them by bolts 10 and 6 with torque of 490 – 600 N.m.;
– tighten bolts from distance bushings 7 side after bolts are fastened from opposite side;
– screw lubricators in bolts 6 and lubricate spherical hinged bearings of steering cylinders 1 and 5, and
pull-rod 3 through lubricators by lubricant Литол–24 up to its appearance through seals.
After mounting of steering cylinder and pull-rod of steering trapezoid it is necessary to adjust conver-
gence of steered wheels and tighten nuts of terminal joints of pull-rod end-tips with torque of 110 – 140 N.m.
(look chapter “Steering” of Operation Manual).
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10 BRAKE SYSTEMS
The dump truck is equipped with the service, parking, auxiliary and reserve brake systems.
The service brake system with the hydraulic actuator divided into the circuit of the front wheels and that of
the rear ones acts upon all the wheels. It is not intended to slowdown the speed motion and braking in ordinary
mode. The system should only be used in low efficiency of the auxiliary brake system and when critical situation
occur for the emergency stop; for complete stop of a truck moving at low speed and short time parking.
The parking brake has hydraulic drive and acts on the rear axle wheels. It is intended for braking of
dump truck during parking, at loading and unloading, and also in emergency situations at refusal of service
brakes.
Auxiliary brake is of electric type, used during traction motor braking mode.
As the reserve (emergency) brake system the parking brake and the operable circuit of service brake
system are used.
10.1.1 Service brake system

The service brake system comprises the four disk-type brake gears, hydraulic actuator, controls and in-
strumentation for monitoring the system operation.
The service brake system is controlled by the brake valve pedal.
The brake gears of the front wheels are of single-disk dry-friction type hydraulically actuated ones.
The brake case 2 (Figure 10.1) is fastened to the front axle steering knuckle 1 by means of the two bolts
15. The bolts are fitted into the bushings 14 and locked against turning out by means of locking plates 12,
which are locked by bolts 27.
The brake disk 4 is bolted to the front wheel hub. The brake case accommodates the six cylinders (three
cylinders on each side), into which the pistons 6 are inserted. The brake case supports 10 bear the two brake
pads 5 which are pressed against the disk by the pistons during the braking. The piston is sealed by the rubber
cup 17 with the protective ring 16 over the outer diameter and the coupling 3 protects the working surface of
the piston against getting dirty. From the outside, the cylinders are closed with the covers 7. The cylinders are
interconnected by means of the channels for feeding the working fluid under the piston.
Each cylinder is equipped with the device for automatic adjustment of the clearance between the brake
disk and the brake pads. The design of the device is similar, as for the rear wheels cylinders.
The brake gears of the rear wheels are single-disk dry-friction hydraulically actuated ones.
The end shield of each traction motor 13 (Figure 10.2) bears two service brakes through the brackets 22
and 23. The service brake consists of two cheeks 3 and 17 tied together by means of the pins 8 through the
inserts 19 and supports 20. The eight cylinders 11 (four on each side), in which the pistons 29 are mounted,
are fastened to the cheeks. The piston is sealed by the rubber cup 63 with the protective ring 62 over the outer
diameter and the coupling 26 protects the working surface of the piston against getting dirty. The cylinders are
interconnected by means of internal channels in the cheeks 3 and 17 for feeding the working fluid under the
piston. Each cylinder is equipped with the device for automatic adjustment of the clearance between the brake
disk 28 and the brake pads 27.
The brake disk 28 is bolted to the flange 16 mounted on the splines of the shaft of the armature of the
traction motor.
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Figure 10.1 – Brake gear of the front wheel:

1 – steering knuckle; 2 – brake case; 3 – protective coupling; 4 – brake disk; 5 – brake pad; 6 – piston; 7 – cover; 8, 15, 27 – bolts;
9, 11, 19 – rings; 10 – support; 12 – tightening plate; 13, 21 – adjusting washers; 14 – bushing; 16 – protective ring; 17 – cup; 18 – rod;
20 – nut; 22 – friction bushing; 23 – spring barrel; 24 – spring; 25 – pusher; 26 – locking ring;
К – space for working fluid supply; H – size defining the gap between brake pads and disk
10.1.2 Parking Brake System

The brake gear of the parking brake system is of hydraulically actuated disk dry-friction type with two
spring energy accumulators. The brake disk 28 (see Figure 10.2) is common for the parking and service
brakes. The parking brake gear is fastened to the bracket 22. The cheeks 50 and 52 are interconnected by the
pins through the inserts 19 and supports 20. The outer cheek bears the two parking brake cylinders 5 with the
pistons 48 and springs 47.
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Figure 10.2 – Brake gears of the rear wheels and of the parking brake:
1 – hoses of high pressure; 2, 6, 18 – angle pieces; 3, 17, 50, 52 – cheeks; 4, 10, 14, 21, 25, 54 – bolts; 5 – parking brake cylind-
er; 12 – T-connector; 7, 32, 34, 41 – nuts; 8 – stud; 9, 20 – supports; 11 –cylinder of working brake; 13 – the traction motor; 15 – plate;
16 – disk with flange; 19 – insert; 22, 23 – brackets; 24, 36, 38, 59, 63 – sealing rings; 26, 51 – protective couplinges; 27 – brake lining;
28 – brake disk; 29, 48 – pistons; 30 – rod; 31, 49 – cases; 33 – thrust block; 35, 39, 62 – protective washer; 37 – plug; 40 – the locking
bolt; 42 – the indicator; 43 – splint; 44 – nut of unbraking; 45 – washer; 46 – cover; 47, 55, 64 – springs; 53 – adjusting shims; 56 – lock
ring; 57 – stop ring; 58 – adjusting washer; 60 – frictional bush; 61 – cup
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10.2 Possible troubles of brake systems and methods of their removal
Possible troubles of brake systems and methods of their removal are given in Table 10.1.
Table 10.1 – Possible troubles of brake systems and methods of their removal
Trouble and symptom Probable cause Remedy
Insufficient braking efficiency Brake linings are oiled or worn out Replace brake linings
Wheel brake gears do not unbrake The piston of brake gear is jammed Eliminate jamming of the piston
Leakage of pair (sleeve–valve) of brake valve Replace the pair (sleeve -valve)
Low efficiency of parking brake system Big clearance between braking disk and braking To adjust clearance
brake linings of parking brake
Shoes are oiled or worn out To replace braking shoes
To replace knuckle
The knuckle of parking brake valve
Insufficient capacity of pneumatic hy- Low (high) pressure of nitrogen in gas space of Discharge oil from oil space, check-
droaccumulator, drop of pressure when pneumatic hydroaccumulator pressure og nitrogen, bring it to the
braking norm
Drop of pressure in pneumatic hy- Leakage of pair (sleeve–valve) of brake valve Replace the pair (sleeve -valve)
droaccumulator when engin is shut
down
Drop of pressure of nitrogen in pneu- External leakage of priming valve To check with soap solution, to elimi-
matic hydroaccumulator nate leakage
Leakage between gas and oil spaces Replace sealing of piston of pneumat-
ic hydroaccumulator or replace
pneumatic hydroaccumulator
10.3 Repairing of brake systems

Before repairing the brake systems eliminate spontaneous driving of dump truck from place.
Assembly of gears of service brake system is to be performed on the specially equipped places with ap-
plication of the special instrument, accommodations and test-beds. Places of assembling should eliminate hits
of mud and dust on collected parts.
The assembling parts should be washed carefully out in diesel fuel or in the lacquer petroleum and
blown up by compressed air. Oil channels should be cleaned and blown up by compressed air.
When assembling the case of brake it is necessary to use new package of general mechanical rubber
goods (sealing ring, cups).
IT IS NOT ALLOWED TO DISMANTLE AND DISASSEMBLY OF BRAKE SYSTEMS PARTS WHEN THEY ARE
UNDER PRESSURE OF WORKING FLUID. ELIMINATE PRESSURE IN THE HYDRAULIC DRIVE TURNING LOCKING
NEEDLES AT BRAKE VALVE
10.3.1 Repairing of brake gears of front wheels

Disassembling of brake gears of front wheels.
Disassembling of brake gears of front wheels is to be performed in the following sequence:
– release pressure in hydraulic system of brakes (releasing of pressure is to be performed by turning out
lock needles of the brake valve);
– remove front wheel from the hub (the order of removal of wheels look in section « Wheels and tires);
– remove two cases of brake from steering knuckle and brake disk from the hub.
The order of removal of cases of brake and brake disk look in section "Front axle".
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Disassembling of brake case is to be performed in the following sequence:

– remove brake linings 5 from brake case 2 (figure 10.1);
– unscrew bolts 8 fastening cover 7, unscrew the nut 20 and remove cover;
– take sealing ring 9 out of groove of cover;
– take protective coupling 3 out of groove of the piston 6;
– take the piston 6 out of the case of brake 2;
– take protective ring 16, cup 17 and protective coupling 3 out of the case of brake;
– press the pusher 25 and remove the locking ring 26;
– extract pusher 25, spring 24, barrel 23, adjusting washers 21, rod 18 with friction bushing 22 from the
piston 6;
– extract the ring 19 out of the rod 18 and remove friction bushing 22 from the rod;
– perform disassembling of other five cylinders of the case of brake analogously.
Assembling of brake gears of front wheels.

Assembling of the case of brake is to be performed in the following sequence:
– grease the piston 6 and cup 17 with working fluid;
– install cup 17 and protective ring 16 into groove of the case of brake 2;
– install protective coupling 3 into groove of the case of brake;
– install sealing ring 19 and friction bushing 22 onto the rod 18. The force of the friction bushing moving
along the rod should be within the range of 2000 – 3000 N;
– install the rod 18 with a friction bushing 22 in the piston 6;
– install necessary number of adjusting washers 21, barrel 23, spring 24 and pusher 25 onto the rod;
– press the pusher 25 and install locking ring 26 into the groove of the piston 6. The gap between the
face of barrel 23 and pusher 25 (size H) should be of 1 – 2 mm, adjust using washers 21;
– insert the piston 6 into opening of the case 2 of brake, using guiding mandrel;
– install protective coupling 3 into groove of the piston;
– install sealing ring 9 into groove of cover 7;
– install cover 7 and fix to the case of brake 2 with bolts 8. Secure the rod 18 in the cover 7 using nut 20
with a spring washer;
– perform assembling of other five cylinders of the case of brake analogously;
– move all six pistons of brake gear to home position against the stop to covers.
Testing of the case of brake.

Before setting of the case of brake to test it on impermeability.
When testing the case of brake to limit displacement of pistons up to 20 mm with the help of special liner
1 (figure 10.3). Working fluid is supplied under pressure 15 МPа during five minutes into openings 3 and 4 (all
other openings should be plugged).
Escapes of working fluid are not admitted, including in the inner space of protective coupling.
After testing of the brake case to return pistons in home position.
Figure 10.3 – Scheme of brake case testing:

1 – liner; 2 – brake gear; 3, 4 – openings of intake of working fluid
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The further assembling of brake gears of front wheels is to be performed in the following sequence:
– install brake disk onto the hub of front wheel; install the hub of front wheel in assembly with brake disk
on steering knuckle. Install two cases of brake onto steering knuckle, install brake linings.
The order of setting look in section "Front axle";
When brake linings are worn out to replace brake linings of brake gears of left and right wheels simulta-
neously. Brake linings shall be of the same manufacturer.
10.3.2 Repairing of brake gears of rear wheels and parking brake system
Removal and disassembling of brake gears of rear wheels and brake gears of parking brake is recom-
mended to perform with removal of electric motor-wheels.
Fractional disassembling, and in unusual cases full disassembling are possible without removal of elec-
tric motor-wheels in rear axle housing.
Disassembling of brake gears of rear wheels and parking brake system.
Removal of brake gear of rear wheels and brake gear of parking brake in assembly with electric motor-
wheel from dump truck is to be performed in the following sequence:
– release pressure in hydraulic system of brakes (releasing of pressure is to be performed by turning out
of lock needles of the brake valve);
– remove rear wheels from the hub (the order of removal of wheels look in section « Wheels and tires);
– remove motor-wheel from dump truck and to make disassembling of reducer of motor - wheel (the or-
der of removal and disassembling look in section "Electric motor-wheel").
Disassembling of brake gear of rear wheels and brake gear of parking brake is to be performed in the
following sequence:
– remove all high pressure hoses 1 (figure 10.2);
– unlock nuts 7 and to turn them out of studs 8;
– remove external cheeks 3 of service brakes with cylinders 11 of service brakes, brake linings 27, sup-
ports 9, bolts 54, springs 55 from studs 8.
Before removal of external cheek 50 of parking brakes to unlock and to turn nut 44 before disengaging
brake linings 27;
– remove external cheeks 50 of parking brakes with cylinders 5 of parking brakes, brake linings 27, sup-
ports 9, bolts 54, springs 55 from studs 8;
– remove supports 20 and inserts 19 from studs 8;
– turn out studs 8;
– unscrew bolt 14 and to remove plates 15;
– remove brake disk with flange 16 from the shaft of the traction motor (the disk with flange is treated
and balanced jointly and disassembling is not admitted);
– unscrew bolts 10 and to remove internal cheek of parking brake 52 with brake lining 27, thrust blocks
33, nuts 34, supports 9 and adjusting shims 53;
– unscrew bolts 4 and to remove internal cheeks 17 of service brakes with brake cylinders 11, brake lin-
ings 27, supports 9 and brackets 22 and 23.
Disassembling of external and internal cheeks of service brake.
– unlock and to turn out supports 9 and bolts 54 to remove springs 55 and brake linings 27;
– unscrew bolts 25 and to remove cylinders 11 of service brakes, protective couplinges 26, sealing
rings 24.
Disassembling of the cylinder of service brake.
– turn out nut 32 and to take out from the case 31 piston 29 with rod 30, retaining ring 56, stop ring 57,
adjusting washers 58, sealing ring 59, the frictional bush 60, cup 61, spring 64;
– take sealing ring 63 and protective washer 62 out of groove of the case;
Disassembling of the piston of the cylinder of service brake:
– press stop ring 57 and to remove retaining ring 56;
– take stop ring 57, spring 64, cup 61, rod 30 with the frictional bush 60 and sealing ring 59 out of the
piston 29;
– remove frictional bush 60 and sealing ring 59 from rod 30.
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Disassembling of internal cheek of parking brake:

– unlock nuts 34 and to turn out thrust blocks 33 with nuts 34;
– unlock supports 9, bolts 54 and to turn them out, to remove brake linings 27 and springs 55;
Disassembling of external cheek of parking brake:
– unlock supports 9, bolts 54 and to turn them out, to remove brake linings 27 and springs 55;
– unscrew bolts of fastening of cylinders 5 of parking brake;
– remove cylinders 5 of parking brake and protective couplinges 51.
Disassembling of parking brake cylinder:
– turn in nut 44 of disengaging against the stop;
– unlock nut 41 and to turn out the locking bolt 40 with nut 41;
– turn cover 46 in assembly with the piston 48, indicators 42, nut 44, washer 45 and splint 43 out of the
case 49;
– take sealing rings 36, 38 and protective washers 35, 39 out of grooves of the case 49.
TURNING OUT OF NUTS 44 OF DISENGAGING FOR DISASSEMBLING OF COVER OF THE PISTON AND
TAKING OUT SPRING 47 ARE STRICTLY FORBIDDEN WITHOUT THE SPECIAL ACCOMMODATING PROVIDING
RELIABLE FIXING OF THE PISTON 48 OF COVER 46 AND SMOOTH RELEASING OF SPRING 47.
Assembling, adjustment and testing of brake gears of rear wheels and brake gears of parking
brake.
Brake linings are to be from the same manufacturer.
Assembling of brake gear of rear wheels and brake gear of parking brake is to be performed in the fol-
lowing sequence:
Assembling of parking brake cylinder:
– install sealing rings 36, 38 and protective washers 35, 39 into grooves of the case 49 (look figure 10.2)
(protective washers should be on the opposite side of cavity of high pressure);
– turn cover 46 in assembly with the piston 48, indicators 42, nut 44, washer 45 and splint 43 into the
case 49;
Assembling of external cheek of parking brake:
– install parking brake cylinders 5 into openings of external cheek 50 of parking brake;
– install protective coupling 51 into grooves of cheek 50 and of the piston 48 and to fix parking brake cy-
linders 5 with bolts;
– turn supports 9, preliminary having greased the thread surface with graphite lubricant, to install brake
lining 27 on them;
– turn bolts 54 with springs 55 into openings of brake lining 27;
– splint supports 9 and bolts 54 (splitting should not hinder from displacement of bolt 54 in axial direction
on distance not less than 25 mm);
Assembling of internal cheek of parking brake:
– turn supports 9, preliminary having greased the thread surface with graphite lubricant, to install brake
lining 27 on them;
– turn bolts 54 with springs 55 in openings of brake lining 27;
– turn thrusts 33 with nuts up to displacement of brake lining 27;
Assembling of the cylinder piston of service brake:
– put sealing ring 59 and the frictional bush 60 onto rod 30. The force of displacement of the frictional
bush 60 on rod 30 should be in limits 2000 – 3000 N;
– install rod 30 with the frictional bush 60 and sealing ring 59 into the piston 29;
– install necessary amount of adjusting washers 58, cup 61, spring 64, stop ring 57 into the piston;
– press stop ring 57 and to install retaining ring 56. The clearance between butt-end of cup 61 and stop
ring 57 should be 1 – 2 mm.;
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Assembling of the cylinder of service brake:

– install sealing ring 63 and protective washer 62 into groove of the case 31;
– install the assembled piston 29 into opening of the case 31;
– fix rod 30 by nut 32;
– move pistons 29 against the stop to the case 31;
Assembling of external and internal cheeks of service and parking brakes:
– install sealing rings 24 into grooves of the case 31;
– install cylinders 11 of service brake into openings of cheeks 3 and 17 and to fix them with bolts 25;
– install protective coupling 26 into grooves of cheeks and pistons 29;
– turn in supports 9, preliminary having greased the thread surface with graphite lubricant, to install
brake linings 27 on them;
– turn bolts 54 with springs 55 into openings of brake linings 27;
– install brackets 23, 22 and internal cheeks 17 of service brake in assembly on the traction motor 13
and to fix with bolts 4;
– install internal cheek of parking brake onto bracket 22, to install adjusting shims 53 and to fix with bolts
10 (adjusting shims ensure symmetric arrangement of external and internal brake linings 27 concerning disk
with flange 16);
– put disk with flange 16 onto the shaft of the traction motor 13 (to grease spline joint with graphite lubri-
cant);
– install plates 15 and to turn bolt 14, having installed it using sealant Uniherm-9;
– turn studs 8 into internal cheeks 52, 17 of parking and service brakes, having installed studs using
sealant Uniherm-9;
– put inserts 19 and supports 20 on studs 8;
– put external cheeks 3 of service brake in assembly and external cheek 50 of parking brake in assem-
bly on studs 8;
– turn nuts 7 and to stop splint;
– connect all high pressure hoses 1.
Tightening torques of threaded connection during assembly of brake gears of rear wheels and
parking brake shall meet the values indicated in table 10.2.
Adjustment of clearances between brake linings and disk.

Adjustment of clearances between brake linings and disk is to be performed in the following sequence:
– turning thrust blocks 33 to adjust clearance of 1 – 1,5 mm between brake lining 27 and brake disk 28.
After setting necessary clearance to stop thrust blocks 33 with nuts 34;
– turning covers 46 in assembly with the piston 48 to adjust clearance of 1 – 1,5 mm between brake lin-
ing 27 and brake disk 28 by special wrench for openings in cover 46. To turn out nuts 44 of disengaging before
coincidence of nut openings to opening of the screw and to stop by splint 43;
– screw in locking bolts 40 and to stop by nuts 41.
Testing on leakprofness and serviceability of brake gears.

Supply working fluid under pressure (16 ± 2) МPа to cavities of cylinders 11 of service brake (triangle 2)
and cavities of cylinders 5 of parking brake (T-connector 6), thus the clearance between brake linings 27 of
parking brake and brake disk 28 should be 1 – 1,5 mm.
Escapes of working fluid are not admitted.
After release of pressure the clearance between brake linings 27 of service brake and brake disk 28
should be 1 – 2 mm.
The further assembling is to be performed in the following sequence:
– make assembling of reducer of motorized wheel and to install the motorized wheel onto dump truck
(look the order of assembling and setting in section "Electric motor-wheel");
– install rear wheels onto hubs (look the order of setting of wheels in section « Wheels and tires).
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Table 10.2 – Tightening torque of threaded connections at assembling of brake gears
The name of part Number on Figure 10.2 Torque, N.m
Nut lock (М30х2) 34 200 – 250

Support of brake linings (М42х2) 9 200 – 250
Bolt of fastening of brake disk (М30х2) 14 260 – 320
Nut of fastening of external cheeks (М27х2) 7 370 – 450
Stud of fastening of external cheeks (М27х2) 8 370 – 450
Bolts of fastening of internal cheeks (М30х2) 4, 10, 21 550 – 700
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:
– release pressure in hydraulic system of brakes (release of pressure is to be performed by turning out
of locking needles of the brake valve);
– unsplint and turn out nuts 7 (look figure 10.2) of fastening of the lower external cheek 3;
– remove the lower external cheek 3 from studs 8 in assembly with cylinders 11, brake linings 27, sup-
ports 9, bolts 54 and springs 55;
– turn studs 8 out;
– unscrew bolts 4 and to lower internal cheek 17 in assembly with cylinders 11, brake linings 27, sup-
ports 9, bolts 54 and springs 55 downwards in parallel with brake disk;
– 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 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 parking brake on brake disk, thus wheels should stand on ground.
Replacement of brake linings of brake gears of rear wheels and brake gears of parking brake.
Replacement of brake linings is to be performed without removal of reducer of electric motor-wheel, in
axle casing. Brake linings are to be from the same manufacturer.
Replacement of brake linings of brake gears of rear wheels and parking brake is to be performed in the
following sequence:
– release pressure in hydraulic system of brakes (release of pressure is to be performed by turning out
of locking needles of the brake valve);
– unlock nut of disengaging 44 (look figure 10.2) and to turn it against the stop;
– unlock and to turn out supports 9 and bolts 54 on all cheeks of service brake and if necessary on
cheeks of parking brake;
– take brake linings;
– move pistons 29 of cylinders of service brake 11 against the stop to the case 31;
– install new brake linings 27, to turn in supports 9 and bolts 54 and to lock them;
– adjust clearances between brake linings of parking brake and brake disk;
– unscrew nuts 44 of disengaging before coincidence of nut openings to opening of the screw and to
stop them by splint 43.
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10.3.3 Checking of technical conditions of parts of brake systems

After disassembling to check technical conditions of service surfaces of parts by 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 brake systems are given in table 10.3.
Table 10.3 – Nominal and maximum permissible sizes of basic parts of brake systems
Dimensions, mm
Number, name of part
Maximum permiss- Material Hardness
and parameters to be checked Nominal
ible
7513 – 3501072
Disk 32-0,39 28,00 Steel 35 187 – 241 НВ
Thickness
75570 – 3501089
+0,035
Brake case 90 90,050 ВЧ 50 187 – 241 НВ
Internal diameter
7555 – 3501102-10
89,900 241 – 285 НВ
Piston −0,036
90 Steel 45 ТВЧ
External diameter − 0,090 There must not be h 1,5 – 3 mm
damages of chrome 53 – 61 НRC
coating
7555В – 3501190-01
Asbestos code
Brake lining 40-1,0 22,0 composition
Thickness with frame
75132 – 3507232-10
Cylinder case of parking brake
+0,035 90,050
Internal diameter 90
Steel 40Х 241 – 285 HВ
+0,054
Internal diameter 105 105,100
7512 – 3514025 Clearance in coupl-

Bush sleeve ing with spool-valve
+0,027
12 7512–3514026 Steel 40Х 40 – 46 НRCэ
Internal diameter 0,01 – 0,03 mm
no more
75132 – 3507281
Cylinder piston of parking brake
External diameter −0,036 89,900
90 156 – 187 HВ
− 0,071
Steel 45 ТВЧ
External diameter −0,036 104,900 h 1 – 3 mm
105 49 – 59 НRC
− 0,071
There must not be
damages of chrome
coating
7512 – 3514026 Clearance in coupl-
Spool-valve ing with bush sleeve Carbonization
12,00 7512–3514025 Steel 20Х h 0,7 – 0,9 mm
Diameter of corbels 0,01 – 0,03 mm 57 – 63 НRC
no more
7512 – 3514045
+0,043 34 – 40 НRC
Plug 12 12,050 Steel 40Х
Internal diameter
Continuation of Table 10.3
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Dimensions, mm
Number, name of part
Maximum permiss- Material Hardness
and parameters to be checked Nominal
ible
7512 – 3514060-10
−0,016
Rod 12 11,900 Steel 40Х 45 – 50 НRC
− 0,059
External diameter
75450 – 3415016
+0,1
170,1
Case 170 There must not be Steel 45 149 – 207 НВ
Internal diameter damages of surface
75132 – 3577043-20
+0,025 СЧ 20
Cylinder case of service brake 50 50,03
Internal diameter
75132 – 3577044-10 49,9 241 – 285 НВ
−0,025 There must not be ТВЧ
Cylinder piston of service brake 50 Steel 40Х
− 0,087 damages of chrome h 1,0 – 2,5 mm
External diameter coating 49 – 59 НRC
75132 – 3577152
Disk 32-0,16 28,00 Steel 35 145 – 187 НВ
Thickness
75131 – 3577060-01
Lining 40 Asbestos code
−1,0
22,0 composition
Thickness with framework
10.3.4 Repairing of gears of the hydraulic actuator of brake systems
BEFORE REMOVAL AND DISASSEMBLNG OF GEARS OF THE HYDRAULIC ACTUATOR TO RELEASE

PRESSURE IN HYDRAULIC SYSTEM OF BRAKES (RELEASING OF PRESSURE IS TO BE PERFORMED BY TURN-
ING OUT OF LOCK NEEDLES OF THE BRAKE VALVE).
10.3.4.1 The brake valve

At disassembling of the brake valve it is not admitted to disassemble spool-valves and bush sleeve.
Spool-valves and bush sleeves are picked up by pairs with clearance of 0,01 – 0,03 mm.
Removal and disassembling of the brake valve is to be performed in the following sequence:
– disconnect lubricated hoses and electricity cable of the switch of stop light;
– turn out nuts of bolts of fastening of the brake valve to the panel of floor of cabin;
– remove the brake valve;
– unscrew bolts 21 (figure 10.4);
– remove cover of 22 valve case as assembly with treadle 1, roller 2, spring 3, holders 4 and 25, case
23 and pusher 24;
– take balancing element 20 and plate 5 out of the upper case 6;
– turn out plug 19 of the upper case 6;
– take rod 18 out of the upper case 6;
– unscrew bolts 17, to disconnect upper 6 and the lower 11 cases of the brake valve;
– take spool-valve 8 and bush sleeve 7 out of the upper case 6;
– take pusher 10, spring 16 out of the lower case 11;
– turn out plug 13 of the lower case 11;
– take piston 12 and spring 14 out of plug 13;
– take spool-valve 8 and bush sleeve 15 out of the lower case 11.
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Figure 10.4 – Brake valve:

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

Assembling of the brake valve is to be performed in the following sequence:
– install bush sleeve 15 with sealing rings in the lower case 11;
– install spool-valve 8 into bush sleeve 15 (the bush sleeve and spool-valve are selected with clearance
of 0,01 – 0,03 mm and are installed in complete);
– install bush sleeve 7 with sealing rings in the upper case 6;
– install spool-valve 8 into bush sleeve 7;
– install spring 16 and pusher 10 into bush sleeve 15 of lower case 11;
– connect the upper cease to lower case and to screw in bolts 17;
– insert spring 14 and piston12 into plug 13;
– turn fuse 13 with rubber seal into the lower case 11;
– insert rod 18 with rubber seal into fuse 19;
– turn fuse 19 with rubber seal in the upper case 6;
– install plate 5 and balancing element 20 into the upper case;
– connect cover 22 of valve case to the upper case 6 and to screw in bolts 21;
– get dense adjacency of roller 2 to pusher 24 with help of holder 4, conveyance not triggering it.
Before setting of the brake valve on dump truck to turn lock needles 9 against the stop and to test it for
impermeability.
Testing of the brake valve on impermeability.

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

Removal and disassembling of the double protective valve is to be performed in the following sequence:
– disconnect oil hoses from the double protective valve;
– turn out nuts of bolts of the double protective valve fastening to bracket of frame and to remove it;
– turn out plugs 1 (figure 10.5) with sealing rings 6;
– take pushers 2 with springs 11, distance bushes 10, washers 9, beads 4 out of the case 3;
– take out piston 5 with sealing rings 8;
– turn plugs 7 out of the case 3.
Assembling of the double protective valve is to be performed in the following sequence:
– insert piston 5 with sealing rings 8 into the case 3;
– insert beads 4, washers 9, distance bushes 10 into the case 3;
– put springs 11 onto pushers 2 and to insert pushers with springs into openings of plugs 1;
– turn plugs 1 with sealing rings 6, pushers 5 and springs 11 into the case 3 against the stop;
– turn plugs 7 into the case 3.
Testing of the double protective valve.

At pressure in channels II and IV (12 ± 1) МPа escapes into channels I and IV are not admitted. External
escapes are not admitted.
Setting of the double protective valve is to be performed in the following sequence:
– install the double protective valve onto bracket of frame and to fix it with bolts;
– connect channel I to automatic machine of unload of the pump, channels II, IV to pneumatic hydroac-
cumulators, the port III to the control valve of parking brake system.
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Figure 10.5 – The Double protective valve:

1, 7 – fuses; 2 – pusher; 3 – case; 4 – bead; 5 – piston;
6, 8 – sealing rings; 9 – washer; 10 – distance bush; 11 – spring;
I – channel, connected to pressure hydroline; II and IV –
channels, connected to pneumatic hydroaccumulators; III – channel,
connected to the control valve of parking brake
10.3.4.3 Pneumatic hydroaccumulator

Safety precautions during removal, repair and installation of pneumatic hydroaccumulator.
Be careful during disassembly and assembly of pneumatic hydroaccumulator, as the gas in them is un-
der high pressure. Persons engaged in repair and service jobs of pneumatic hydroaccumulator, should be ac-
quainted with safety precautions and regulations of pressurized vessels.
At removal of pneumatic hydroaccumulator and their repair observe the following rules:
– before removal of pneumatic hydroaccumulator from dump truck release gas from gas cavity through
charge valve. For releasing of gas remove cap from charge valve and turn special connecting pipe on the
valve before opening the valve.
Operation on opening and close of charge valve with three minutes interval to be done at least three
times as dissolved nitrogen in oil evaporates quickly, and right after turning out the connecting pipe pressure is
recreated in pneumatic hydroaccumulator;
After releasing of gas open charge valve using the connecting pipe and leave the connecting pipe in
such a position till disassembling of hydroaccumulator is finished;
– when starting disassembly of pneumatic hydroaccumulator make sure that there is no gas pressure in it;
– before connection of reducer to new cylinder check identification mark of compressed gas correspond-
ing to nitrogen. The cylinder should be labeled “Nitrogen” and shall have annular band of brown color.
When receiving gas in cylinders check them prior to using for absence of water. For this keep cylinders
being turned over for at least one hour, then open a tap and drain water residue;
ATTENTION: IT IS FORBIDDEN TO CHARGE PNEUMATIC HYDROACCUMULATOR WITH OXYGEN!
IT IS EXPLOSIVE!
– install cylinder with gas in the special place equipped with fixing devices for cylinder. When changing a
cylinder do not forget to fix it;
– unscrew valves and connecting nuts only with the corresponding wrenches, not hitting on them;
– supply gas to pneumatic hydroaccumulator smoothly through step-down reducer;
– observe common safety precautions regulations at work place.
Removal and disassembling of pneumatic hydroaccumulator.

Before removal of pneumatic hydroaccumulator to release nitrogen through the charge valve of
pneumatic hydroaccumulator, observing rules described above.
Removal of pneumatic hydroaccumulator is to be performed in the following sequence:
– disconnect oil hose;
– turn out the priming valve 12 (figure 10.6);
– turn the ring- bolt into opening of the upper cover;
– fasten pneumatic hydroaccumulator with the help pull accommodating and the hoisting device;
– turn out nuts on clamps of fastening of pneumatic hydroaccumulator and remove pneumatic
hydroaccumulator. The weight of steering pneumatic hydroaccumulator is of 96 kg., as weight of brake system
one is of 66 kg.
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Figure 10.6 – Pneumatic hydroaccumulator:

1 – bolt; 2 – lower cover; 3, 5 – piston seals; 4 – piston;
6 – guiding ring, 7 – housing; 8 – ring; 9 – protective washer; 10 – upper
cover; 11 – sealing gasket; 12 – priming valve;
I – fluid cavity; II – gas cavity;
Disassembling of pneumatic hydroaccumulator is to

be performed in the following sequence:
– turn out bolts 1 fastening the upper 10 and lower 2
covers;
– unscrew covers from housing 7;
– extract rings 8 and washers 9 from grooves of cov-
ers 2 and 10.
– extract piston 4 from housing 7;
– extract guide rings 6 and piston seals 3 and 5 from
piston grooves.
Assembling and testing of pneumatic hydroaccumulator.

When assembling wash mating surfaces of parts, sealing and guiding rings, seals, protective washers in
hydraulic fluid before setting in pneumatic hydroaccumulator.
Assembling of pneumatic hydroaccumulator is to be performed in the following sequence:
– set piston seals 3 and 5 and guiding rings 6 into grooves of piston 4;
When mounting piston seals 3 and 5 keep up that rings are not twisted in grooves and not be undercut.
Sealing rings of piston seals 3, 5 and protective washers 9 prior to installing are to be heated up to tem-
0
perature of 80 – 100 C during 3 – 5 minutes. Heat them in boiling water (then remove water from the part sur-
0
face) or in the working fluid heated up to 80 – 100 C.
The locks of guiding rings 6 should be located at opposite sides;
– install the piston 4 into the inner space of housing 7 and screw in covers 2 and 10 with torque of
500 – 700 N.m.
Pay special attention to the piston position – six holes (diameter of 4 mm) should be located from the
side of gas cavity. Prior to assembling lubricate surfaces of covers 2, 10 and piston 4 with grease Ж;
– lock covers by bolts 1;
– screw in priming valve 12 with gasket 11 into upper cover 10.
Testing of pneumatic hydroaccumulator.

Pressure of the piston breakaway and move from the lower to upper cover or back should not exceed
0,4 MPa.
Test the strength and tightness supplying the hydraulic pressure of (24±0,5) MPa. Working fluid is to be
supplied to the liquid chamber, the piston must be in the uppermost position close to upper cover and the air
from the gas chamber must be completely removed. During the test the pressure increasing should be smooth.
Exposure with a test pressure should be of – 3 minutes, no less.
Test with gas for the outer and inner impermeability supplying nitrogen pressure (5,5±0.5) MPa and
(16 ± 0.5) MPa in a gas cavity and held at each pressure for 3 min, not less. Increase pressure from 5,5 to
16 MPa by supplying pressurized fluid into the fluid cavity. External and internal gas bleeding is not allowed.
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Check functioning in the range of nitrogen pressure variation in the gas cavity from (5,5 ± 0.5) MPa up to
(16 ± 0,5) MPa for at least three cycles. Increase of pressure from 5,5 to 16 MPa should be performed by sup-
plying pressurized fluid into the fluid cavity. In this case, the piston movement should be smooth, without vibra-
tion and knocks.
After testing pour (0,5 + 0,1) L of fluid into the gas space of pneumatic hydroaccumulator via the hole of
priming valve.
Mounting of pneumatic hydroaccumulator:
– fasten pneumatic hydroaccumulator with the help pull accommodating and the hoisting device;
– install pneumatic hydroaccumulator on bracket of frame and to fix with clamps and nuts;
– connect oil hoses and to charge gas cavity of pneumatic hydroaccumulator with nitrogen.
Charging of pneumatic hydroaccumulators with nitrogen.
Inspection of pressure of nitrogen in pneumatic hydroaccumulators and their charging is to be performed
at the lower position of the piston, i.e. at absence of pressure in the fluid-flow chamber. For this purpose to turn
out cover of the priming valve and to connect accommodating for pressure measurement (look chapter “Sus-
pension” of Operation Manual) through adapter connector and to open the valve smoothly. Pressure of nitro-
gen should be 7,5 – 8,0 МPа.
If necessary to refuel pneumatic hydroaccumulator with nitrogen in the following sequence:
– connect reducing reducer 4 (look figure 8.1.17) of accommodating for charge to bulb with nitrogen
through adapter connector 2;
– screw adapter connector 17 of accommodating on the priming valve of pneumatic hydroaccumulator;
– open valve on bulb with nitrogen and, turning adjusting screw of reducer of accommodating for charge
of suspension cylinders to charge the gas chamber with pressure of 7,5 – 8,0 МPа. To check pressure with the
help of manometer on accommodating;
– close valve on bulb with nitrogen and the connecting pipe 8 to release gas from channels and hose of
accommodating;
– disconnect accommodating from the priming valve;
– check impermeability of the priming valve with the help of soap emulsion;
– close the priming valve by cover.
10.3.4.4 The control valve of parking brake system

Disassembling of parking system brake valve.
Perform removal of brake valve as follows:
– disconnect from the brake valve the hy-
draulic system pipelines (having marked them for
further assembling) and electrical equipment wiring.
– unscrew screws fastening the valve to the
panel on the console with controls in the dump
truck cabin (figure 10.7);
– remove the brake valve.
Figure 10.7 – Control valve of the parking brake:

1 – lever; 2 – latch; 3 – protective boot; 4 – body; 5 –
information plate;
S – outlet connected with the pneumatic hydroaccumu-
lator; B, DS – outlets connected with the brake cylinders; T –
outlet connected with draining into the hydraulic tank.
I – unbraked (released) position of the lever; II –
braked (applied) position of the lever
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Perform installation of brake valve as follows:

– place brake valve onto the panel on the console with controls in the dump truck cabin and fasten using
screws;
– connect hydraulic system pipelines to the brake valve in accordance with marking of hoses and out-
puts on the valve;
– connect electrical equipment wiring.
Look the procedure of disassembling, repairing, assembling and testing of the valve in the Manual sup-
plied by manufacturer «Вosch Rexroth».
10.4 Repair of brake gears of rear wheels on dump truck equipped with motor
wheels 5GEB23 manufactured by “General Electric” Company
Brake gears of rear wheels – of two-disk, dry friction type with hydraulic drive.
There are two service brakes mounted on the reduction gear casing of each electric motor wheel 13
(figure 10.8) through brackets 16 and 24. service brake comprises two cheeks 22 and 23, which are tightened
by studs 1 and 9 through inserts 17 and supports 18. Eight cylinders (two on each cheek) comprising pistons
48 are fastened to the cheeks. Piston over outer diameter is sealed by rubber ring 51 with washer 50, whereas
coupling 25 prevents dirt ingress onto piston working surface. Cylinders are connected by inner channels in the
cheeks for supplying of working fluid under the piston.
Brake mechanism of parking brake – is of disk, dry friction type with two spring power accumulators
has hydraulic drive.
Parking brake (manufactured by “KNOTT” Company) is bolted to bracket 8, which is in its turn through
bracket 20 is fastened by nuts 7 to the cheek 22.
Repair of rear brakes and parking brake.
Disassembling of the rear wheels brake gear and brake gear of parking brake:
– release the pressure in the hydraulic system (pressure release is to be performed by unscrewing of
locking needles in brake valve);
– remove the housing 14;
– remove all the high–pressure hoses;
– unlock crown nuts and unscrew them from the studs 1;
– remove from studs the outer cheek in assembly with service brake cylinders, brake pads 29, supports
18, inserts 17, supports 61, bolts 60 with springs 59;
– unscrew bolts 2 and remove the inner cheek in assembly with service brake cylinders, brake pads 29,
supports 61, bolts 60 with springs 59;
– if necessary, unscrew bolts 15 and remove the bracket 16;
– unscrew bolts 33 and remove two brake mechanisms of the parking brake;
– unlock crown nuts 7 on studs 9 and to turn them out from the studs;
– remove the bracket 8 fastening parking brake mechanisms and the bracket 20;
– remove from studs the outer cheek 22 in assembly with service brake cylinders, brake pads, supports,
inserts, supports 61, bolts 60 with springs 59;
– unscrew bolts 11 and remove the inner cheek 23 in assembly with service brake cylinders, brake
pads, supports 61, bolts 60 with springs 59;
– If necessary, remove the bracket 24;
– unscrew bolts 55 and remove the brake disc 19 and the pipe 56;
– unscrew bolts 57 and remove the other brake disc and flange 58.
Disassembly of external and internal cheeks, the service brake cylinders is to be performed analogously
to brake mechanisms of service brake manufactured by "BELAZ" Company, which was described above.
The assembly of brake mechanisms is to be performed in the reverse order.
Tightening torques for bolts 2 and 11 is of 510 – 700 Nm, for bolts 15 and 33 446 – 551 Nm, for bolts 55
and 57 239 – 269 Nm, for studs 1 and 9 370 – 450 Nm, for nuts 7 370 – 450 Nm, for supports 61
200 – 250 Nm.
Before installing lubricate the threaded surface of the support 61 with graphite grease УСсА ГОСТ3333.
Studs 1, 9, plugs 21 and knee–pieces are to be set with the sealant Унигерм 9.
Cotter pin 62 should not prevent axial movement of the bolt 60 by a distance not less than 25 mm.
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Figure 10.8 – Brake gears of the rear wheels and parking brake with the complete electric transmission
manufactured by General Electric Company:
1, 9 – pins; 2, 11, 15, 26, 33, 55, 57, 60 – bolts; 3, 4, 5, 6, 12 – high-pressure hoses; 7, 43 – nuts; 8, 16, 20, 24 – brackets;
10 – cotter pin; 13 – power-wheel; 14 – casing; 17 – insert; 18 – support; 19 – disk; 21 – plug; 22, 23 – cheeks; 25 – protective coupling;
27 – cylinder body; 28, 39, 41, 51, 54 – sealing rings, 29, 37 – brake linings; 30 – adjusting ship; 31 – plug; 32 – body; 34 – cover;
35, 36, 52, 59 – springs; 38, 48 – pistons; 40, 42, 50 – protective washers; 44 – retaining ring; 45 – adjusting washers; 46 – friction bush-
ing; 47 – cage; 49 – rod; 53 – thrust ring; 56 – pipe; 58 – flange; 61 – support; 62, 63 – cotter pin wire
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11 PNEUMATIC SYSTEM
The pneumatic system intended to provide engine pneumatic starter system, pneumatic gears of cabinet
of traction electric drive, radiator shutters by compressed air, to connect the appliance for tires inflation and to
feed the balloon of a pneumocushioning of the driver's seat.
11.2 Possible failures of pneumatic system and troubleshooting

Possible failures of pneumatic system and troubleshooting are given in Tables 11.1 of 11.2.
Table 11.1 – Possible failures of pneumatic system and troubleshooting
Failure and symptom Probable cause Troubleshooting
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 tigh- Tighten gasket or tighten cylinder head

tened 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
Таблица 11.2 – Possible failures of pressure regulator with adsorber and troubleshooting
(figure 11.1)
Failure and symptom Probable cause Troubleshooting

Bleeding of compressed air over seal 6 Body 11 is insufficiently tightened Tighten body with torque of (10 – 15) N.m.
Seal 6 is damaged Replace seal 6
Ingress of moisture into pneumatic system Adsorbent 8 is oiled Replace adsorbent 8
Bleeding of air via atmosphere outlet during Safety valve 2 is clogged Clean body and seat of valve 2. Replace if
refilling of the system necessary
Sealing ring of valve 2 is damaged Replace ring
Regulator doesn’t switch compressor to idl- Channels G, H are clogged Clean channels.
ing mode Piston 14 is jammed by cup Replace cup
Regulator doesn’t switch compressor to the Atmosphere orifice K is clogged Clean the orifice
mode of the system refilling Valve 16 is clogged or damaged 16 Clean or replace valve
Spring 13 is broken Replace spring
Sealing ring on the piston 17 is damaged Replace ring
Piston 14 is jammed by cup Replace cup
Regeneration receiver cannot be empty Check valve 12 is clogged or defective. Clean or replace valve
completely (Рост > 0,05 МPа) Valve 15, sealing ring on piston 17 or cup on Replace defective parts
piston 14
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Figure 11.1 – Schematic of the pressure regulator with adsorber:

1, 3, 9, 13 – springs; 2 – safety valve; 4 – bypass valve;
5 – sleeve; 6 – seal; 7 – polyurethane-foam filter; 8 – zeolite adsorber;
10 – filter gasket; 11 – body; 12 – check valve; 14 – following piston;
15, 16 – ball valves; 17 – piston;
I – outlet from the compressor; II – outlet into the pneumatic
system; III – outlet into the regeneration receiver; IV – outlet into the
atmosphere;
А, В, С, D – chambers; Е – chamber connected with the com-
pressor;
F, G, H – channels; K – channel to the atmosphere
11.3 Repairing of devices of pneumatic system

In case of malfunctions disassembling and troubleshooting of apparatuses are to be performed only by
qualified specialists at workshops, specified for repair of pneumatic system units on vehicles.
BEFORE REMOVAL AND REPAIRING OF DEVICES OF PNEUMATIC SYSTEM REDUCE AN AIR PRESSURE
IN SYSTEM UP TO ATMOSPHERIC. DISCHARGE OF AIR FROM SYSTEM IS MADE THROUGH THE CONDENSATE
DUMP VALVE OF AIR TANK.
Repair of pneumatic system units is to be carried out in conditions which exclude dust, abrasive par-
ticles, oil, water and dirt ingress on the unit. Parts are to be free of burrs and rust, and working surfaces and
input edges are to be free of nicks, scratches and other damages. Prior to assembling all the channels are to
be cleaned of cuts and dirt and blown up with compressed air. After that wash parts by diesel fuel or white-
spirit and dry them.
Prior to assembling pay special attention to condition of rubber sealing rings. When assembling
use a new package of general mechanical rubber goods. Perform mounting of sealing rubber rings
carefully, keep up that rings are not twisted in grooves and are not undercut.
When assembling grease friction surfaces of parts with thin layer of lubricant Litol–24.
11.3.1 Repair of pressure regulator with adsorber

If any troubles with repair of pressure regulator occur apply to the manufacturer of unit, which produces
repair kits with tag-list.
11.3.2 Repair of the check valve

Check valves are installed in the pressure line leading to the receivers of the pneumatic start-up system
from the receiver of the pneumatic system and from the compressed air external source. Check valve provides
the air passage in one direction only - to the receiver of the pneumatic start-up system.
In case of loss of circuit tightness through the check valve it is necessary to disassemble it and to re-
place the intake valve 5 (Figure 11.2).
BEFORE REMOVING AND REPAIRING THE CHECK VALVE PERFORM REDUCING THE AIR PRESSURE IN
THE PNEUMATIC START-UP SYSTEM UP TO THE ATMOSPHERIC ONE. DISCHARGE OF AIR FROM SYSTEM IS TO
BE PERFORMED THROUGH THE RECEIVERS CONDENSATE DRAINING VALVES.
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Disassembly of the check valve.

Perform disassembling of the check in the following order:
– Unscrew the guide of the valve 2 out of the housing 1;
– Extract rod 3 assembled with the intake valve 5 and spring 4 from the body;
– Extract intake valve 5 from the rod 3.
Assembly of the check valve.
Perform assembling of the check in the following order:
– Install the new intake valve 5 onto the rod 3.
– Install rod 3 the assembled with the valve 5 and spring 4 into the body 1;
– Screw in the guide of the valve 2 into the body 1 aligning the hole in the guide and rod 3.
Assembled valve is to be tested for leaks, for what supply the air with pressure of (0.5 + 0.1) MPa. Into
the space I. The pressure drop during one minute is not allowed.
Figure 11.2 – Check valve:

1 – body; 2 – valve guide; 3 – rod; 4 – spring; 5 – intake valve;
I – outlet connected with the receiver of the pneumatic start-up system; II – outlet connected with the receiver of the pneumatic
system or from the compressed air external source
11.3.3 Repairing of safety valve

Safety valves are mounted into the pneumatic start-up system receivers set (single valve for each re-
ceiver) and reduces the pressure in the system.
Before removing and repairing the safety valve perform reducing the air pressure in the pneumatic start-
up systemreceivers.
Disassembling of a safety valve.
Disassembly of a safety valve should be performed in the following sequence:
– to turn out and to remove a nut 7 (figure 11.4);
– to turn a press–on hush 8 out of the case 3;
– to take out a stock 4 with washers 6 and a spring 5;
– to turn seatof a safety valve 1 out of a tapped hole of the case 3;
– to take the valve 2 out of the saddle.
Figure 11.3 – Safety valve:

1 – seat; 2 – valve; 3 – case; 4 – stock; 5 – spring; 6 – washer; 7 – nut; 8 – pressing bushing
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Assembling of a safety valve.

Assembling of a safety valve should be performed in the following sequence:
– place valve 2 in seat of a safety valve 1. The valve 2 and seat of a safety valve 1 grease with a thin
layer of spindle oil АУ OCT 38.01.412 – 86 before assembling;
– turn the case 3 on seat of a safety valve against the stop;
– put sequentially a washer 6, a spring 5, a washer 6 on a stock 4 and install a rod into an internal open-
ing of the case up to contact with a mounting surface of the valve seat 2;
– turn pressing bushing 8 into a threaded hole of the case 3;
– screw in a nut 7, not pressing on a thread of the pressing bushing.
Adjusting and testing of a safety valve.
Each collected safety valve should be adjusted and tested on setting which scheme is given in figure
11.4.
Pressure of opening of safety valve is of 5 (1,5 + 0,15) МPа.; as the shut up pressure is of 1,2-0,1 МPа
Adjusting of the spring tightening is made by turning–in a press–on hush 8 (look figure 11.3) into the case 3.
After adjustment to stop a press–on hush with a nut 7.
Check a safety valve for impermeability. The valve should be leak proved under the presuure of
1.2 MPa. The pressure drop not exceeding 0.05 MPA during five minutes is allowed.
Figure 11.4 – Scheme of testing of a safety valve:

1 – pipeline of input of compressed air; 2, 6 – cocks; 3 – receiver;
4 – manometer; 5 – safety valve
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12 ELECTRICAL EQUIPMENT
12.1 Possible failures of electric equipment
During the long-term operation of dump trucks in electric equipment can appear typical failures such as
disruption of wire covering, wearing-off of electric machine brushes, oxidation of terminals and leads, malad-
justment of electric devices.
To maintain the electric equipment of dump trucks in serviceable condition, the main attention should be
drawn to the condition of electric wiring, devices and units, timely to eliminate the identified faults. Small fail-
ures of electric equipment that not eliminated in time can lead to serious malfunctions in future, the elimination
of which requires more time and expenses.
The repair of electric equipment should be carried out in specially equipped places by skilled techni-
cians, using special devices, tools and benches.
Possible malfunctions of the electrical equipment system are listed in table 12.1.
The truck electric equipment is protected by automatic thermal switches disconnecting circuit in case of
its overload. When any malfunction in the electrical circuit occurs check the condition of the automatic switch-
es. Actuation of the automatic switch (electrical circuit breakage) indicates about short circuit or about circuit
overload. In this case eliminate malfunction and only after that turn on the automatic switch.
Location of automatic thermal switches, their designation and rated meaning are given in the circuits of
the low-voltage electric equipment of the dump trucks, delivered within the complete set of operating docu-
ments.
Starting search of failure in the electrical equipment of the dump truck, keep in mind, that almost all elec-
trical circuits gain feed from one point - "+" the ammeter (voltage meter). This point is a startup of all the cir-
cuits and it would be reasonable to start the search from this particular point.
Table 12.1 – Electrical equipment troubleshooting

The description of failure The possible reason Troubleshooting
At the key inserted into the lock – switch sto- Automatic switch is OFF because of mal- Actuate after troubleshooting
rage batteries are not connected to the elec- function of the power circuit
trical circuit; pilot lamps or instrumentation
devices do not work Breakage of the electrical circuit Check the circuit integrity
Lock-switch or “ground” contactor are de- Check serviceability of switches. Re-
fective place failure devices.
Incorrect connection of electrical wires to Check electrical wires connection
batteries
One of instrumentation devices does not Sensor or indicator failure Replace the failure device
work
Integrity of the circuit breakage Check integrity of the circuit
Voltmeter pointer indicates voltage < 22 V Storage batteries are discharged Charge storage batteries
Voltmeter shows discharging at average en- Built-in automotive relay regulator is faulty Replace automotive relay regulator
gine speed (< 24,5 V) or at powering on the
consumers and increasing engine speed, Open failure or unreliable contact in power Check circuit and eliminate failure
voltage drops even more circuit
Alternator is defective See the alternator Operation Manual
Alternator drive is faulty Check and if necessary perform belt

tensing
Voltmeter pointer deviates too much at Alternator is defective See the alternator Operation Manual
change of engine rotation frequency
Belt is loosened Check and if necessary perform belt
tensing
Voltage on the alternator is more than 28 V, Built-in automotive relay regulator is faulty Replace automotive relay regulator
lamp s are burnt out or abnormal bright their
light
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Continuation of Table 12.1
The description of failure The possible reason Troubleshooting

Alternator or built-in automotive relay regu-
Check charging current
lator is defective
Storage batteries are discharged A short-circuit between plates in the sto-
rage battery Repair or replace storage battery
Plates sulfating
Lowering of an electrolyte level in storage
Gassing Check serviceability of alternator
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 circuit in one of storage batte-
Repair or replace storage battery
ries
12.2 Troubleshooting and repairing of power supply system

The power supply system comprises storage batteries, alternator with built-in relay regulator, voltmeter,
remote “ground” switch, in-cab “ground” switch, wire harnesses connecting the power sources and consumers.
Damaged sections of the wiring are subject to complete or partial replacement and in this case crosscut
of the newly-laid wire must equal to the damaged one or meet minimum allowed requirements.
12.2.1 Troubleshooting and repairing of storage batteries

The storage batteries are determined on dump trucks such as 6СТ-190A. general data and service of
storage batteries look in the Operation Manual.
Before repair of the storage batteries find the reasons of the failure. To check the batteries remove them
from the machine, then clean batteries from dirt, moisture and electrolyte on the battery covers. Inspect visual-
ly condition of the unit, covers, terminals and jumpers. Test the condition of the monoblock, the covers, the
mastics, the plugs and interelement jumpers. After inspection check for performance and charged state.
The serviceability will be read from a voltage value measured by a battery tester in every element off the
unit. The voltage in a fully charged element must be within 1,80 – 1,85V (loaded) and remain stable for 5 – 6
sec (refer to table 12.2). The charging degree of the storage battery depending on the density of electrolyte is
shown in table 12.3.
Тable 12.2 – 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
Table 12.3 – The charging degree of the storage battery depending on the density of electrolyte
Electrolyte density, reduced t 25 0С, g/sm3
Flat battery
Completely charging battery
25 % 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
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The electrolyte density is determined with the help of the areometer in each element of the battery.
The battery discharged more than by 25 % in the winter and more, than by 50 % in the summer is to be
removed from vehicle and sent for boost charge.
Filling-up of battery with electrolyte and its charging are given in the Dump Truck Operation Manual.
During batteries operation following failures can occur.
Plates sulfation.
The sulfate presence in the accumulator can be defined to the following features:
– at the voltage metering by accumulator tester the voltage meter arrow is not retained during 5sec. in
limits 1,8 – 1,85 V and deflects below mark of 1,7 V;
– at the charging the voltage is increase and the gassing begins;
– presence of the white bloom on negative plates (sulfation).
The white bloom is formed on the surface of positive plates at the strong sulfation. In case of the plate
strong sulfation (if there is such opportunity) it is necessary to replace on new, otherwise such accumulator is
unsuitable to the further maintenance and is subject to replacement.
Short circuit inside the accumulator.
Short circuit has following features:
– rapid electrolyte temperature increase and the weak gas emission in the charging process ;
– significant voltage reduction at short–time discharging.
The short circuit removal is possible only at complete disassembly of the storage battery.
Breakage of output pines.
The element with the torn pin is defined with the help of the voltage meter of the discharge tester (at not
to powered loading) serial the control of the storage battery elements. In the element with the torn pin the vol-
tage meter arrow does not deflect.
The repair work which does not require the disassembly of the storage battery.
For elimination of outer damages of the storage battery it is necessary to drain electrolyte and to enclose
holes of sells by plugs.
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 jumpers solder by the electrode. In the place of the jumper connection by
three–square file cut the flute on all width. Under the jumper put the strip of the tin which cleaning cloth turn up
so that they densely joint to the jumper and have formed the tray. The jumper 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 damaged jumper 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 sulfation 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);
– drain electrolyte and fill up with distilled water or the weak solution of sulphuric acid (densities
1,04 – 1,06);
– charge the battery by current 3,5 – 4 amp. If in charging time the electrolyte temperature it will be
raised up to plus 45 С, the charging interrupt and give the storage battery to be cooled up to normal tempera-
0
3
ture. When the electrolyte density will reach 1,15 g/cm , drain it, then again fill up by distilled water or the weak
solution of sulphuric acid and continue charging.
The charging and the electrolyte gang to manufacture until the electrolyte density will cease to raise.
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Figure 12.1 – Discharging circuit of the storage battery
12.2.2 Repair and service of the alternator

On dump trucks the three–phase synchronous alternator with built–in voltage regulator is installed. Al-
ternator is delivered together with the engine.
At repair and service of the alternator it is necessary to use the documentation attached to the engine.
12.3 Repair and service of external and internal illumination system

Repair of illumination and signaling systems comprises replacement of faulty elements. Designation and
location of systems elements are described in the schemes of electrical equipment.
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13 FRAME AND BODY
Frames and bodies used on dump trucks of a welded structure are characterized by tall longevity at op-
eration in the close conditions of maintenance.
For security long and a fault–free operation of the basic bearing components of a structure of a dump
truck it is necessary:
– 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 is made of high–strength low–alloy steel 10ХСНД with the following mechanical properties:
ultimate strength σВ ≥ 500 МPа, a yield stress σТ ≥ 400 МPа, impact strength at a minus 70 С not less
0
аН = 30 N.m/sm . And cast elements made of low-carbon steel with the following mechanical properties: ulti-
2
mate strength σВ ≥ 500 МPа, a yield stress σТ ≥ 310 МPа, impact strength at minus 40 С not less
0
аН = 50 N.m/sm .
2
The body is made of high–strength, antiwear alloyed steel 18ХГНМФР or HARDOX 450 with the follow-
ing mechanical properties: a ultimate strength σВ ≥ 1050 МPа, a yield stress σТ ≥ 950 МPа, impact strength at
a minus 40 С not less аН = 30 N.m/sm .
0 2
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 Э70 of АНП-2 type (international qualification Е7015/AWS A 5.5 Е10015), elec-
trodes Э60 of УОНИ 13/65 type (international qualification Е7015/AWS A 5.1 Е51 3 В20 / ISO 2560) for weld-
ing the face layers of the body weld seams;.
– electrodes such as Э50A of УОНИ 13/65 type (international qualification Е7015/AWS
A 5.1 Е42 3 В 2 2 Н10 / EN 499), for welding the “soft” layers of the body weld seams, for the body counte-
forts, for welding and repairing the frame elements;
Application of these electrodes allows to provide a necessary ultimate strength of a weld seam (a ulti-
mate strength should be not lower σВ = 420 МPа).
Electrodes should be stored in a dry heated location with temperature not below plus 16 С and a rela-
0
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.
13.1 Technical condition inspection of frame and body and defects imperfections
definition
Well-timed detection of frame and body damages and identification of their causes, selection of suita-
ble repair methods and sequential thorough repairing promote the increment of dump truck operability and
service life.
Before inspection of availability index of product of a frame and body it is necessary to wash up a dump
truck water or the ferry under a high pressure, to install on well covered body. It will facilitate visual inspection
and searching of faults. For searching faults use improvised means – a portable flashlight, the putty knife, a
wire brush, a gas burner, etc.
Many cracks are easy for noticing on pure metal, sometimes it is possible to resort and to the help of co-
louring agent. It is possible to take advantage for searching cracks of a method of insignificant heating (up to
300 С) a prospective section with the help of a gas burner. Thus the crack will extend. The given method will
0
allow to define also, whether the prospective imperfection a crack or a small scratch is.
At visual inspection pay special attention to a condition of brackets and their welding places as they are
the most loaded and most responsible sections of structure.
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Check up a condition of weld seams. Cracks usually appear in the places were under an operation of
stretching efforts. The location of such sections is shown in figures 13.1, 13.2.
Cracks, as a rule, are augmented, if the dump truck continues to remain in–process. Therefore, the most
preferable is repair on initial stage of a cracking.
If nevertheless after detection of a crack the dump truck cannot be delivered on repair, it is necessary to
apply a method of «stopping wimbling» which will consist in the following: define finite points of a crack and
drill there bores. It will reduce magnitude of effort by a waste of a crack and temporarily will stop its increase.
Figure 13.1 – Location of the most loaded elements of the dump truck frame (indicated by pointers):
1 – first crossbeam; 2 – second crossbeam; 3 – third crossbeam; 4, 6 – side members; 5 – rear crossbeam
13.2 Preparation of frame and body for repair

ATTENTION: IT’S NECESSARY TO DISCONNECT STORAGE BATTERIES FROM DUMP TRUCK ELECTRIC
EQUIPMENT NETWORK BEFORE WELD STARTING.
Preparation of a frame (body) for repair consists in preparation of a surface to a welding.
For this purpose it is necessary:
– precisely to define an occurrence of cracks. At a development of cracks on parent metal in both ends
bore via holes 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 compressed 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.
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13.3 Frame and body repair

Welding up of the most responsible sections prepared for this operation on a frame and a body is ne-
cessary for executing with preheating and consequent heat treatment (tempering). Before the beginning of a
welding a section preheat a gas burner up to temperature 150 – 200 С, and after a welding preheat up to
0
temperature 600 – 650 С and then slowly chill.

0
Figure 13.2 – Location of the most loaded sections of a body of dump truck (are shown by arrows)
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Preheating and consequent heat treatment prevent undesirable structural transformations into metal,
considerably sink residual stresses at a welding and by that eliminate formation of crazes in a welding weld
and an adjoining zone. With same purpose the welding should be manufactured at above–zero temperature in
conditions of a guard of a place of a welding from deposits and drafts.
When repairing the frame by mounting of reinforcement plates, only longitudinal welding of the plates at
frame girders and cross-members should be carried out, and transverse joints should be left unwelded, as oc-
currence of transverse welds makes the structure less durable. The plate should be closely fitted to reinforced
surface.
13.3.1 Down hand welding

Welding up of the prepared sections to manufacture in some passes. At a welding the first pass it is ne-
cessary to pay special attention to that the radical of a weld well foundered as faulty fusion sinks quality of re-
pair. At a welding of a root pass it is necessary to use electrodes in diameter of 3 – 4 mm.
Welding methods of a root pass:
– in a case, when a spacing no more than 3 mm – foundered completely the radical of a weld (Fig.13.3);
– in a case, when a spacing more than 3 but less 6 mm – a gap of the radical fuse two passes;
– in a case when a spacing more 6 mm – to manufacture a welding on a lining;
– at a welding (welding up) of the cut cracks it is forbidden to include electrodes, a wire, an armature, etc.
Figure 13.3 – Methods of welding of first layer
Methods of driving of an electrode at V–shaped preparing of edges (with lining):

– at a welding of a root pass to shade slide an electrode on width of a spacing of the radical;
– after the second stratum driving of an electrode is made on width of the previous axle;
– the penultimate stratum direct up to a level on 1–2 mm is lower than a surface of parent metal (Figure
13.4).
Axles of last stratum of a weld should have smooth mating as among themselves, and with a surface of
parent metal.
At veed cutting crimps and spacings up to 6 mm a welding of the first and second stratum to manufac-
ture the methods which have been mentioned above.
Figure 13.4
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.
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Graphic representations of the specified welds are shown in Figure 13.5.
Figure 13.5
13.3.2 Welding in vertical position

The welding of joints in a verticality is made from below up. The welding of a root pass is analogous to
item 13.3.1. Thus it is necessary to do steps of a lateral vibrations as small as possible to provide a weld pene-
tration on edges of the previous axle of a weld (figure 13.6).
Figure13.6
13.3.3 Welding in horizontal position

Welding of a root pass to manufacture analogously to item 13.3.1 and figure 13.7.
At a spacing more than 6 mm to cook two "checkpoint", starting to superimpose first the lower axle.
From the second stratum it is preferable to cook a method of a "through passage" weld. The order of suturation
is shown in figure 13.8.
Figure 13.7 Figure 13.8
13.3.4 Welding in overhead position

The graphic representation of execution of the specified welds is reduced in Figure 13.9.
Figure 13.9
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13.4 Welding quality control and defects elimination

Quality of welded joints should be controlled by external examination and weld measurement. Each weld
throughout its full length is subject to external examination.
In welded connections the following visible imperfections are not supposed:
– cracks of all aspects and directions;
– faulty fusion and lack of fusion;
– groups of pores and slag inclusions;
– separate pores and turnings on in diameter more than 1 mm in an amount more than 4 imperfections
on a section of a weld in length of 400 mm at distance between imperfections less than 50 mm;
– not made craters;
– snatching on parent metal;
– undercuts of parent metal depth more than 0,5 mm.
Defects of weld seams render the big agency on toughness of joints. On detection of imperfections of
welds the visual method is informative enough. On its grounding it is possible to manufacture their reparation.
When welding-up the faulty seam with removal of metal from the weld area, use preliminary and post-
welding heating.
Welding defects have a strong effect on welded strength. Visual method is sufficiently informative in
identification of welding defects. The defects can be cleared on the basis of this method.
To reduce a stress concentration, weld seams should be treated polishing machine having deleted thus
irregularities of a surface of an axle of a weld. Rolls and irregularity of the shape of a weld correct on all length
of a weld (look Figure 13.10).
Figure 13.10
At removal of defective places it is necessary to observe defined rules:

– the length of a deleted section should be equated to length of a defective section plus of 10 – 20 mm
from each side, and the width of cutting of sample should be such that the width of a weld after welding up did
not exceed double width of a weld after welding up;
– the shape and sizes prepared under welding up excerpts should ensure an opportunity of a reliable fu-
sion in any place;
– the surface of each sample should have smooth outlines without sharp protuberances, acute deepen-
ings and agnails.
Craters of welds are necessary for making. Burn–through in welds are preliminary necessary for
smoothing out, and then to make.
To reduce a stress concentration by fusion lines with parent metal at polishing machine it is necessary to
remove undercuts depth up to 0,5 mm with a gradient junction to parent metal. At undercuts with depth more than
0,5 mm to manufacture a building–up welding a welding of filar weld on all length of an imperfection and repeat-
edly to treat polishing machine up to a gradient junction to parent metal. An abrasive wheel it is necessary to
have at a square–wave stripping across a weld (look Figure 13.11).
Figure13.11
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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 moldings
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 13.12). Tran-
sition sections are expedient for treating at polishing machine;
Figure13.12
– moldings 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 13.13) is not supposed;
– the molding 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.
Figure13.13
– MOUNTING OF REINFORCEMENT PLATES “ON RIB” IS PROHIBITED (FIGURE 13.14);
Рисунок 13.14
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13.5 Body removal and setting

In most cases repair of a body is executed without its removal from a dump truck.
If for holding repair it is necessary to remove a body to perform these operations in the following se-
quence:
– install under wheel of a front axle and a rear bridge of a dump truck the thrust blocks;
– disconnect mud shields of rear whees;
– disconnect from the connective panel the wires going on a body;
– disconnect ejectors;
– disconnect cylinders of the tumbler from a body, for what it is necessary to turn out bolts 5 with protective
hollow disks (Figure 13.15) to extract distance sleeves 7 and to beat out fingers 6.
After unhooking, cylinders to fix the special loose straps used in transit of dump trucks, with the purpose
of exclusion of a fault of cylinders;
– disconnect a body from a frame for what it is necessary to turn out bolts 8, to remove covers 9 with lock
plates and to beat out fingers 10. Fingers to back out in an external direction from a shaft of a dump truck;
– remove a body. For removal and settings of a body are used special pull accommodating (Figures
13.16) and two additional expansion for maneuvering in transit and setting of a body.
Frame weight is 12860 kg, body weight is 19700 kg.
Figure 13.15 – Body removal and setting scheme

1 – body; 2 – cylinder of the tumbler; 3, 12 – adjusting plates; 4 – contact plate; 5, 8, 14 – bolts; 6, 10, 16 – fingers; 7 – distance sleeve;
9 – cover; 11 – adjusting hollow disks; 13 – absorber, 15 – stone bufler; 17 – ring
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ATTENTION: AT THE BODY REMOVAL AND SETTING IT IS FORBIDDEN TO BE ON THE CHASSIS OR UN-
DER THE CHASSIS OF A DUMP TRUCK, BETWEEN WHEEL AND THE LIFTED BODY!
Setting of a body on a dump truck to manufacture in the following sequence:
– before setting of a body on a dump truck to grease fingers 10 (look Figure 13.15) with lubricant Литол–24;
– fasten a body, as shown in figure 13.16 and to combine bores of brackets of a body with bores of
brackets of a frame;
– install from outer sides fingers 10 (look Figure 13.15). Between bearing parts and bosses of brackets of a
body preliminary establish adjusting hollow disks 11 to remove axial clearances in hinges. Spacing should be no
more than 2 mm. The spacing is defined in a zone of the least distance between surfaces.
After setting fingers to combine their lock plates with splits of clampers and to fix by means of covers 9 and
bolts 8 with locking washers;
– test and if necessary to provide the greatest possible alignment of branch–pipes of outlet pipes with
bores in the lower sheets of body gas–collecting at the expense of oval bores of brackets of strengthening of
branch–pipes;
– enclose between spars of a frame and a body technological linings and sink on them a body;
– fill in cavities of bearings of the upper heads of cylinders of the tumbler lubricant Литол–24 and to in-
stall distance sleeves 7. To combine bores of heads of cylinders with bores of eyelets of brackets, to install fin-
gers 6 upper bearing parts of cylinders;
– install covers 9 with lock plates and to fix bolts 5;
– test and if necessary, with the help of adjusting shims 12 to provide a uniform fit of absorbers 13 to a
seating of spars of a frame. Layer pads of the full shape go into into a package and components of 1/2 and 1/3
lengths and 1/2 width for elimination wedge–shaped spacing. The spacing between the absorber and a frame
should not exceed 1 mm. In separate places the wedge–shaped spacing up to 3 mm is supposed. A minimum
size of contraction of a shock–absorber – 37 mm;
– lift a body and to remove safety linings. To remove pull accommodating and the expansion. To grease
hinges of end support bearings of a body and the upper bearing parts of cylinders of the tumbler;
+1,2
– test presence of a spacing of 0 mm between guiding bodies and contact plates 4. If necessary to ad-
just a spacing by means of adjusting plates 3 (cross–section B–B);
– install stones eliminator, having connected them with brackets by means of fingers and splints;
– install mud shields of rear wheel, having attached them to a body by means of bolts, nuts, flat and re-
taining washer;
– connect with the additional panel the wires going on a body.
Figure 13.16 – Body removal and setting scheme
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14 DUMPING MECHANISM
Dumping mechanism 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. Dump-
ing mechanism is actuated from the cab by electric switch available on the instrumentation panel.
It consists of two three-stage telescoping hydraulic cylinders, hydraulic distributor, control unit, recipro-
cating pump, automat of pump release, double way valve, filter, magnet filters in the suction pump branch-pipe
and in drain collector, oil tank of united hydraulic system with filter and oil pipes joining them. The dumping
mechanism schematic diagram is given in the Operation manual.
The dumpling mechanism is controlled from the cab by means of electric switch located on the instru-
mentation panel.
14.2 Dumping mechanism troubleshooting

Possible causes of dumping mechanism failures and their troubleshooting are given in the table 14.1.
Table 14.1 – Possible causes of dumping mechanism failures and their troubleshooting
Body fails to be lifted Insufficient level of working fluid in the oil tank Restore the level of the working fluid,
eliminate the leakage
Working fluid is not supplied to suction line of Open shutter of oil tank, refill pump body
pump with working fluid
Power supply circuit of hydraulic distributors Eliminate the electric circuit fault
with electromagnetic control of control unit is
damaged
Pilot of hydraulic distributor of body lifting is Wash hydraulic distributor
jammed
Spool valve of hydraulic distributor of body lift- Wash hydraulic distributor
ing is jammed
Pilot of hydraulic distributor of floating position Check spool valve manually, if necessary
is jammed disassemble and wash
Safety valves КП1, КП2 or overflow valves K1 Disassemble valves and check working
are not impermeable surfaces. Test valves impermeability
Failure of end switch of body lifting Eliminate the fault
Body lifts slowly Low capacity of pumping Repair or replace pump
Excessive leakage of working fluid through spool Replace hydraulic distributor
valves of hydraulic distributor (Platform sinks
down spontaneously from neutral position)
Overflow valves of hydraulic cylinders are not Eliminate the fault
impermeable
Safety valves КП1, КП2 or overflow valves K1 Disassemble valves and check working
are not impermeable surfaces. Test valves impermeability
Platform is lifted jerkily Insufficient level of working fluid in the oil tank Restore the level of the working fluid,
eliminate the leakage
Air inflow in intake line of pumps (working fluid Tighten the joint members of hydraulic
in tank froths) lines
Platform sinks down spontaneously Non–hermetic pressure–safety valves of hy- Calk the valves
draulic cylinders
from neutral position
Overflow valves K1 are not impermeable Disassemble valves and check working
surfaces. Test valves impermeability
Pilot of hydraulic distributor of floating position Check spool valve manually, if necessary
is jammed disassemble and wash
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Platform fails to sink down Power supply circuit of sinking hydraulic dis- Eliminate the electric circuit fault
tributor of control unit is damaged
Pilot of hydraulic distributor of body sinking is Wash hydraulic distributor
jammed
Spool valve of hydraulic distributor of body Wash hydraulic distributor
sinking is jammed
Overheating of working fluid (t>80 °C) Working fluid does not correspond to the opera- Replace working fluid for suitable to sea-
tion season (table 14.1, part “Dumping gear” of son of operation
Operation Manual”).
Pressure in the charging line of the pump ex- Automaton of pump release is defective.
ceeds 18 MPa Perform adjusting of hydraulic system
(look “Adjustment of hydraulic system with
automaton of pump release”). If proce-
dure is failed replace pump
Safety valves KП1 or КП2 are not impermeable Replace valve
Lower efficiency of pump (pump is worn out), Repair or replace pump
leaks from drain line of pump exceed Q=20 l/m
Pressure in the pumping line can not Spool valve of regulator is jammed Wash regulator
be adjusted by screw of regulator
Safety valves KП1 or КП2 are defective Replace valve
14.3 Dismounting of the dumping mechanism units from dump truck

In the process of dismounting of the dumping mechanism units it is necessary:
– to ensure safe locking of the body (to check that body rests solidly on the frame or to lock the body in
raised position by steel cables);
– to ensure null pressure in pneumatic hydraulic accumulators;
– to close shutters in the oil tank to prevent waste of working fluid from the hydraulic tank in the process
of units dismounting;
– to mark piping, high–pressure hoses and their junction places on the hydraulic equipment;
– to disconnect piping and high–pressure hoses from hydraulic equipment and to ensure working fluid
collection into special vessels;
– to loosen fastening bolts and to dismount hydraulic equipment from frame brackets using if necessary
hoisting devices;
– in the process of repairs irrelevant objects or dirt should by no means get into piping and hydraulic
equipment.
Dismounting of the dumping mechanism cylinder.
Cylinder of the dumping mechanism is to be removed from the dump truck observing the following se-
quence:
– to place anti–backtracking supports under wheels of the front and axes of the dump truck;
– to disconnect oil piping from lower support of the cylinders;
– to lift body by crane thus body floor being in horizontal position. To place technological stands be-
tween frame and lifted body;
– to place technological clamp 1 (figure 14.1) for fixing cylinder to the frame (is delivered with new dump
truck);
– to loosen bolts 5 and to take pin 9 out;
– to loosen bolts 11 and to remove cover.12;
– to uncotter , to loosen bolts 14 and to remove hold–down cover 13;
– to place gripping hand of the appliance for cylinder removal (M513015 see figure 14.2) on to the forklift
on the cylinder and to secure it tightly with bolts 5 and pins 6;
– bring the device to the cylinder, install jaws 9 and 13 on tube of main cylinder under butt of upper cov-
er of suspension cylinder having adjusted their position using handles 1, 2, 11. Press securely jaws by means
of handle 12 to tube of cylinder and secure the cylinder in the device by means of safety chain 8;
– to remove technological clamp for fixing cylinder to frame and to remove cylinder.
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Figure 14.1 – Dismounting of the dumping mechanism cylinders:

1 – technical clamp; 2, 15 –spherical bearing; 3 – locking ring; 4, 12 – cover; 5, 11, 14 – screw; 6, 17 – lubricator; 7, 16 – gland;
8 – spacer bushing; 9 – pin; 10 – hydraulic cylinder; 13 – hold–down cover
Figure 14.2 – Appliance ( M513015) for removal and mounting of the dumping mechanism cylinders:
1, 2, 11, 12 – handles; 3, 7 – beams; 4 – pedestal; 5 – bolts; 6 – pin; 8 – basket; 9, 13 – jaws; 10 – insert
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14.4 Disassembling of dumping mechanism units

14.4.1 Disassembling the dumping mechanism cylinder
Disassembling of the dumping mechanism cylinder is effected at stand (look part “Running Gear” figure
8.1.7).
Disassembling the dumping mechanism cylinder is to be performed in the following sequence:
– place and secure dumping mechanism cylinder to stand. When disassembling and assembling rotate
the cylinder to a position convenient for maintenance;
– unscrew and remove bolts 25 (figure 14.3) with washers from the outer tube 18;
– extract cylinder cover 28 assy. from the tube 18. Unlock bolts 26, turn them out of the cover 28, re-
move the plate 24, 27, stem 31 and the valve 21.
Remove rings 40 and protective ring 41 from cover grooves;
– unscrew the cylinder head 1 from the rod with piston 15 and extracted from the head grooves rings 44,
48 and protective rings 45, 49;
– unlock and unscrew bolts 23, remove plates 39 and unscrew the threaded bushing 22 out of the
tube 17;
– extract the rod with piston 15 out of the tube 16. Pull cylinder pipe 14 out of the piston; extract guide
rings 19, piston seal 29, ring 42 and safety ring 43 out of the of the piston grooves;
– unlock and unscrew the restrictive nut 3 from the tube 16;
– extract bushing of rod 13 from the tube 16. Extract rings 46, safety ring 47, guide rings 11, rod seal 8,
and wiper 2 from the grooves of rod bushing;
– pull the tube 16 out of the tube 17. Extract guide rings 30 from the grooves of the tube;
– extract the thrust ring 38, the upper guide 36, rod seal 34, the spacer 33 and restrictive ring 32 from
the tube 17. Pull guide rings 35 and wiper 37out of the grooves of upper guide 36;
– extract the tube 17 from the outer tube 18. Remove guide rings 20 from the grooves of tube 17;
– extract the locking ring 4, the upper guide 6, rod seal 9, the spacer 10 and restrictive ring 12 from the
outer tube 18. Extract guide rings 7 and wiper 5 from the grooves of upper guide 6.
Removal of head bearings 23 and cylinder cover 10 is to be performed in the following sequence:
– to remove glands 7, 16 (see figure 14.1) of the cylinder head and cover;
– to remove retainer rings 3;
– to squeeze out spherical bearings 2 and15 using arbor.
14.4.2 Disassembly of hydraulic distributor in the dumping mechanism

Disassembly of hydraulic distributor in the dumping mechanism is to be performed in the following se-
quence:
– to loosen bolts 28 and to remove cover 29 from casing (figure 14.4);
– to loosen bolts 16 and to remove pilot valves 4 and 15;
– to loosen bolts 3 and to remove pilot valve 4 with crossover plate 2;
– to loosen bolts 5 and to remove safety valves 6;
– to loosen bolts 31 and to remove overflow valves 30;
– to loosen bolts 10, to remove covers 9 and plugs 14 out of stack of casings 11.
– to loosen bolts 18 and to disconnect casings 11 unit;
– to loosen bolts 13 and to remove covers 19;
– to turn shanks 21 and 26 out of spool;
– to remove springs 20 and 27; springs 22 and 25 out of thrust casing;
– to remove spool 24 out of casing;
– to disassemble the second section of distribution valve the same way.
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Figure 14.3 – Dumping mechanism cylinder:

1 – cylinder head; 2, 5, 37 – wipers; 3 – restrictive nut; 4 – locking ring; 6, 36 – upper guides; 7, 11, 19, 20, 30, 35 – guide rings;
8,9, 34 – rod seals; 10, 33 – spacer; 12, 32 – restrictive rings; 13 – rod bushing; 14 – inner cylinder pipe; 15 – rod with piston;
16, 17 – tubes; 18 – outer tube; 21 – valve; 22 – threaded bushing; 23, 25, 26 – bolts; 24, 27, 39 – plates; 28 – cylinder cover; 29 – piston
seal; 31 – stem; 38 – thrust ring; 41, 43, 45, 47, 49 – safety rings; 40, 42, 44, 46, 48 – rings
I – cavity communicating with the rod cavity; II – rod cavity; III – piston cavity; IV – cavity communicating with the piston space
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Figure 14.4 – Hydraulic distributor:

1, 8, 12, 17, 23 – O–ring; 2 – crossover plate; 3, 10, 16, 18, 28, 31 – bolts; 4, 15 – pilot valve; 5, 13 – screw; 6 – safety valve;
7 – protective washing; 9, 19, 29 – covers; 11 – casings block; 14 – plug; 20, 22, 27 – spring support; 21, 26 – shank; 25 – spring;
24 – spool–valve, 30 – overflow valve; 32, 35 – pumping casings; 33 – body; 34 – plate
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Disassembly of safety valve in hydraulic distributor of the dumping mechanism.

Disassembly of safety valve in hydraulic distributor of the dumping device is to be performed in the fol-
lowing sequence:
– to unscrew cover 7 (figure 14.5);
– to remove spring 5 and valve 4 out of casing 1.
Figure 14.5 – Safety valve:

1 – casing; 2 – seat; 3 – protective ring; 4 – valve; 5 – spring;
6 – O-rings; 7 – cover
Disassembly of auxiliary valve in hydraulic distributor.

Disassembly of auxiliary valve in hydraulic distributor (dumping mechanism) is to be performed in the
following sequence:
– to loosen bolts 17 (figure 14.6) and to remove spring cover 16;
– to remove in the following sequence piston 15, spring 12, washer 11, adjusting valve 10 out of casing 14;
– to loosen bolts 1 and to remove cover 2;
– to remove plug 3, rod 5 and seat 7 out of casing 14.
Figure 14.6 – Auxiliary valve:

1, 17 – bolts; 2 – cover; 3 – plug; 4 – ring; 5 – rod; 6, 8, 13 – ring; 7 – seat; 9 – safety ring; 10 – adjusting valve; 11 – washer,
12 – spring, 14 – body; 15 – piston; 16 – cover of spring; 18 – seal; 19 – adjusting screw
14.4.3 Disassembly of dumping mechanism control unit

Disassembly of control unit in the dumping mechanism is to be performed in the following sequence:
– loosen screws 18 (figure 14.7) and to disconnect hydraulic distributors 15 and 19;
– unscrew bolts 20 and remove covers 7 and 12;
– remove spring cover 3 and valve spring 6 from the casing 21;
– unscrew adjusting bolt 1 with nut 2 from spring cover 3 and remove spring plug 4;
– using spring plug 4 remove plug sleeve 14 and spool–valve 11 with thrust of spring 9;
– turn over spring plug and remove sleeve 10 from casing 21;
– unscrew plugs 24 from casing 21.
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Figure 14.7 – Control unit:

1 – adjusting bolt; 2 – nut; 3 – spring cover; 4 – spring plug; 5, 8, 13 – sealing rings; 6 – valve spring; 7, 12 – covers; 9 – spring
thrust; 10 – sleeve; 11 – spool-valve; 14 – sleeve plug; 15, 19 – hydraulic distributors with solenoid control; 16 – lock-nut; 17 – emergency
pusher of manual control; 18 – screw; 20 – bolt; 21 – casing; 22 – protective cover; 23 – nipple for manometer connection; 24 – plug;
25 – reduction valve;
X, Y – channels for pressure supply to the spaces of control panel (lifting-lowering); А, В – channels controlling overflow valves in
the mode “floating position”; T, T1, T2 – channels for drainage to the tank; P – channel for working fluid supply from the pump; M – inlet to
the channel for measuring of reduced pressure;
R – manual device of emergency control
14.4.4 Disassembling of pump release automaton

Disassembling of pump release automaton is to be performed in the following sequence:
– unscrew plug 1 (figure 14.8) and remove spring 3, sleeve 5 with spool-valve 6 out of casing 2. Be careful
unscrewing the plug as it is under the force of squeezed spring 3;
– extract spool-valve 6, two rings 26 and ring 27 out of sleeve 5;
– extract ring 28 out of plug 1;
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– unscrew four bolts 17 and remove control unit in assembly from casing 2;
– extract two rings 29 and ring 24 out of casing 2 grooves;
– unscrew two bolts fastening cover 20 and remove it. Be careful unscrewing bolts as cover is under the
force of squeezed spring 18;
– extract plug 19, spring 18, block 16 and ball 15 out of casing 14;
– unscrew two bolts 7 fastening cover 8 and remove it. Be careful unscrewing bolts as cover is under the
force of squeezed spring 10;
– extract plug 9, spring 10, ball 11, sleeve 13 with spool-valve 12 out of casing 14;
– extract spool-valve 12 out of sleeve 13;
– extract rings 23 out of grooves of plugs 9 and 19, and do rings 25 out of grooves of sleeve 13.
Figure 14.8 – Pump release automaton:

1 – plug; 2, 14 – casings; 3, 10, 18 – springs; 4 – plug; 5, 13 – sleeves; 6 – spool-valve; 7, 17, 22 – bolts; 8, 20 – covers;
9, 19 – plugs; 11, 15 – balls; 12 – plunger; 16 – block; 21 – nut; 23, 24, 25, 26, 27, 28, 29 – rings
Р – output connected with collector; Т – output connected with drainage; А – output connected with line “LS” of pressure regulator
of variable productivity pump
14.4.5 Disassembling of double way valve

Disassembling of double way valve is to be performed as follows:
– unscrew cover 7 (figure 14.9) out of casing 4;
– extract thrust 1, sleeve 2 with spool-valve 3 out of cas-
ing;
– extract spool-valve 3 out of sleeve 2;
– extract sealing rings out of grooves of sleeve 2, and do
sealing ring 5 as well as safety ring 6 out of groove of cover 7.
Figure 14.9 – Double way valve:

1 – thrust; 2 – sleeve; 3 – spool-valve; 4 – casing; 5 – sealing ring;
6 – safety ring; 7 – cover
I – output to pump release automaton; II – output to line “LS” of pres-
sure regulator; III – output to control unit
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14.5 Checking up of technical condition of dumping mechanism parts

Design and tolerance limit dimensions of major parts in dumping mechanism are stated in table 14.2.
Table 14.2 – Design and tolerance limit dimensions of major parts in dumping mechanism
Part number, part denomination and Dimensions, mm

Material Hardness
controlled specifications design tolerance
75131–8603010 – Cylinder:
75131-8603130 – cylinder pipe
30 micro micron 12 micro micron 45 steel HRC 47 – 56
thickness of chrome coating
75131-8603134 – cylinder pipe
30 micro micron 12 micro micron 45 steel HRC 47 – 56
75131-8603164 – Cylinder rod
30 micro micron 12 micro micron 40Х steel HRC 47 – 54
75132–8606410 – Control unit:
75132–8606423 – Sleeve Clearance in match-
Cementing
inner diameter +0,015 ing sleeve–spool
10 20Х steel h 0,7 – 0,9 mm
0,01 – 0,02
57 – 63 HRCэ
not more
75132–8606456 – Spool–valve Clearance in match-
Cementing
belt diameter ing spool – sleeve
10,00 20Х steel h 0,7 – 0,9 mm
0,01 – 0,02
57 – 63 HRCэ
not more
75306–8606100–10– Hydraulic dis-
tributor:
*78211–4612015 – Casing Clearance in match-
spool opening +0,027 ing sleeve–spool
25 ВЧ 50 cast iron 150 – 190 НВ
0,005 – 0,020
not more
*78211–4612042 – Spool–valve Clearance in match-
Cementing
belt diameter ing sleeve–spool
25,00 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
* Parts are supplied jointly
14.6 Assembly of dumping mechanism units

Assembly of dumping mechanism units is to be performed at specially conditioned sites using special
purpose tools, extractors, appliances, assembly and trial stands. Assembly sites should prevent dirt and dust
ingression on the parts to be assembled.
Assembly parts should show no evidence of rust, cinder, abrasives and other mechanical fouling. They
are to be thoroughly washed in diesel fuel and blown out by compressed air. It is not recommended to wipe
parts before assembly with scouring cloth to avoid channel clogging up and spool jamming. Oil channels are to
be cleaned up and blown out by compressed air.
WHEN ASSEMBLING A NEW SET OF GENERAL MECHANICAL RUBBER GOODS IS TO BE USED (O–RINGS,
GLANDS, GASKETS).
BEFORE ASSEMBLY ALL O–RINGS ARE TO BE CLEANSED IN THE WORKING FLUID.
Assembling sequence for every unit is considered thus, giving a chance to disassemble this unit respec-
tively for repair purposes. If unit was disassembled partially, assembly sequence can differ.
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In the assembly procedure mating faces of the parts are to be lubricated with oil of A make or with oil
running in the hydraulic system of dumping mechanism.
After repaired assembly has been mounted in the dump truck, functioning of dumping mechanism is to
be supervised, it should satisfy the following requirements:
– raising arrangement system must ensure smooth jerk– and jamming free raising and lowering of body;
– body interlocking in any intermediate position;
– oil leakage at junctions of oil piping and joint planes of the units is not allowed.
14.6.1 Assembling dumping mechanism cylinder

Assembling dumping mechanism cylinder is to be performed in the following sequence:
– install guide rings 7and 35, wipers 5 and 37, respectively into the guides 6 and 36 (Figure 14.3);
– install the outer tube 18 of the cylinder in the tilter;
– installed restrictive ring 12, spacer 10, rod seal 9, the guide 6 assy. and locking ring 4 into the outer
tube;
– install restrictive ring 32, the spacer 33, the rod seal 34, the guide 36 assy., locking ring 38 and two
guide rings 20 into the tube 17;
– install the tube 17 assy. into the inner space of tube 18. It is recommended to perform installation in a
vertical position to center the tube 17 and to avoid damage of seals, be careful. Limit movement of the tube 17
downwards outside of the tube 18 end;
– install guide rings 30 into the grooves of tube 16;
– install the tube 16 assy. into the inner space of tube 17. It is recommended to perform installation in a
vertical position to center the tube 16 and to avoid damage of seals, be careful. Limit movement of the tube 16
downwards outside of the tube 17 end;
– install guide rings 19, piston seal 29, ring 42 and safety ring 43 into the grooves of rod with
piston 15. Install the inner pipe 14 into the internal cavity of the rod. The piston seal 29 prior to installation is to
0
be heated to a temperature of 80 – 100 C for 3 – 5 minutes. Heating is to be performed in boiling water (with
following its removal from the part surface) or in the heated working fluid;
– install the rod with piston 15 into the inner space of tube 16. It is recommended to perform installation
in a vertical position to center the rod and to avoid damage of seals, be careful;
– install rings 46 and safety rings 47, guide rings 11, rod seal 8, wiper 2 into the grooves of rod
bushing 13;
– install rod bushing assy. into the inner space of tube 16 and fix it by restrictive nut 3 having tightenied the
nut with torque of 2000 – 2500 Nm. Lock the nut by rolling the edge of the tube into the slots of restrictive nut;
– screw the threaded bushing 22 into tube 17. Tightening torque is of 500 – 1000 Nm. Lock nut by bolts
23 (Mcr. 25 – 40 Nm), which in their turn are to be locked in pairs by bending the edges of plates 39;
– install rings 44, 48 and safety rings 45 and 49 into the grooves of the cylinder head 1;
– screw the head 1 into the rod with piston 15. Tightening torque is of 2500 – 3000 Nm. Prior to installing
cover the head portion (20 ± 3 mm, see picture) with a thin layer of sealant Aн-8к;
– install stem 31 with valve 21 into the cylinder cover 28 and secure the stem by plates 27 with bolts 26
(Mcr. 26 – 42 Nm), having locked bolts by bending the edges of the plates 24;
– install rings 40 and protective washer 41 into the grooves of the cylinder head 28;
– install the cylinder head 28 assy. into the internal space of the outer tube 18 and secure it by bolts 25
(Mcr. 210 – 340 Nm) with washers.
Testing of dumping mechanism cylinders.
To supply working fluid into chamber IV from pumping installation capacitated 120 – 140 l/min and pres-
sure value at safety valve not exceeding 3 MPa. Chamber I is to be connected to drainage. To separate hy-
draulic cylinder in full and to wash it out for three minutes.
+1
Checking for leakage is to be done by supplying working fluid under pressure of 15 MPa simultaneous-
ly into chambers I and IV of hydraulic cylinder. Proving time should be 3 minutes. Moisture on outer faces is
not allowed.
Leakage from piston chamber into rod end should not exceed 0,4 l/min assumed that pressure in rod
end makes up (15±1) MPa. Checking is to be done when both–way action stage is not in advanced position.
Positioning of other stages can be disregarded.
The working fluid temperature should be of (40+10) С.
0
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14.6.2 Assembly of hydraulic distributor

Assembly of hydraulic distributor safety valve.
Assembly of hydraulic distributor safety valve is to be performed in the following sequence:
– to place protective ring 3 into annular grooves on valve 4 (see figure 14.5), previously greasing it by Li-
tol–24 lubricant;
– to place valve into body 1. Valve should travel in the body without any jerks;
– to place spring 5;
– to place ring 6 into groove on cover 7 and to place cover into valve body.
Assembly of auxiliary valve of hydraulic distributor.

Assembly of auxiliary valve of hydraulic distributor is to be performed in the following sequence:
– to place rubber rings 8 and 9 previously greased with Litol–24 lubricant into annular grooves on seat 7
(see figure 14.6);
– to place two rubber rings 6 into annular groove on rod 5;
– to place rod 5 into valve seat 7(before placing of rubber ring, rod should travel in valve seat without
any jerks);
– to place seat with rod into valve body 14;
– to place rubber ring 4 into annular groove on plug 3;
– to place plug into body;
– to place cover 2 and to secure it using bolts 1 with spring lock washers;
– to place adjusting valve 10 complete with washer 11 and spring 12;
– to place rubber ring 13 into annular groove on piston 15;
– to place piston into casing;
– to place cover 16 and to secure it with bolts 17 complete with spring lock washers;
– to place adjusting bolt 19 complete with nut into cover.
Assembly of hydraulic distributor is to be performed in the following sequence:
– to assemble casing block 11 (see figure 14.4), by placing O–rings 12 and to tighten with bolts 18 with
torque of 100 – 115 Nm;
– to place plugs 14 into bores on body, protective washers 7 and rings 8 being previously placed into
annular grooves on plugs;
– to place covers 9 on body and to draw up bolts 10 with torque of 30 – 36 Nm complete with spring lock
washers;
– to place spool 24 into body 11, previously greased with И–20А oil, and to check spool travel in 4 posi-
tions every 90 degrees. Spool should travel driven by its own weight smoothly and jerk–free. Spool should fea-
ture the same serial number as casing block;
– to place successively spring support 20, spring 25, spring support 20 onto spool face;
– to insert shank 21 into openings on spring support and to screw it in into face bore of spool 24.
Threaded area of shank is to be previously covered with УГ–9 proofing compound;
– to place successively spring support 27, spring 25, spring support 27 onto spool face;
– to insert shank 26 into openings on spring supports and to screw it in into face bore of spool 24.
Threaded area of shank is to be previously covered with УГ–9 proofing compound;
– to place rings 23 previously greased with Litol–24 lubricant into annular groove on covers 19;
– to connect covers 19 to casing block and to secure with bolts 13 complete with spring lock washers
with torque of 95 – 115 Nm;
– to assemble the second section of hydraulic distributor similarly;
– to place O–rings 8 into annular grooves on safety valves 6;
– to secure valves 6 to body with bolts 5 complete with spring lock washers and to tighten with bolts with tor-
que of 38 – 45 Nm;
– to place O–rings 1 into annular grooves on additional valves 4 and 15;
– to connect auxiliary valves 4, 15 and valves 6 with bolts 6 complete with spring lock washers;
– to place O–ring 1 into annular grooves on crossover plate 2;
– to bolt tog-ether auxiliary valve 4, crossover plate 2 and safety valve 6 with bolts 3 complete with
spring lock washers;
– to place O–rings 8 into annular grooves on overflow valves 30;
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– to bolt valves 30 to semi–assembled unit with bolts 31 complete with spring lock washers and to tighten
with bolts with torque of 55 – 65 Nm;
– to bolt cover 29 to semi–assembled unit with bolts 28 with spring lock washers.
Testing of hydraulic distributor (dumping mechanism) is to be performed in the following sequence:
Test for outer impermeability. Outer leaks are not allowed at pressure of (24±0.5) MPa.
Test for inner impermeability. Supply working fluid by turns into chambers А1, А2, В1, В2 under pres-
3
sure of (16±0,5) MPa, leakage from single chamber should not exceed 100 sm during (60±5) sec.
After checking of inner impermeability has been completed, safety valves are to be adjusted for pressure
at discharge rate not less than (100±20) l/min using adjusting bolts C:
– chamber Р1 of P2 – (22±0,5) MPa;
– chamber В2 – (8±0,5) MPa.
Test for functional serviceability. Working fluid is to be supplied into chamber P1 at discharge rate not
less than (100±20) l/min and under pressure of (16,5±0,5) MPa, leakage from chambers Т1, Т2 should not ex-
3
ceed 100 sm within (60±5) sec. Apply control pressure (2,5±0,5) MPa in turns in chambers Y1 and X1, drai-
nage must be provided through chambers В1 and А1 accordingly. Break–loose pressure on spool should not
exceed 0,65 MPa.
Working fluid is to be supplied into chamber P2 at discharge rate not less than (100±20) l/min with pres-
sure of (16,5±0,5) MPa. Leaks from chambers Т1, Т2 should not exceed 100 sm within (60±5) sec. Apply
3
control pressure of (2,5±0,5) MPa in turns in chambers Y2, X2, drainage from chambers Т1, Т2 should be pro-
vided through chambers В2 and А2 accordingly. Break–loose pressure on spool should not exceed 0,65 MPa.
14.6.3 Assembly of dumping mechanism control unit

Assembly of control unit is to be performed in the following sequence:
– install rubber sealing rings 8 (see figure 14.7) onto sleeve 10;
– to install sleeve 10 into casing 21 from the side of bore, marked by letter Р, previously lubricating
rubber rings, (sleeve face must match face plane of casing);
– install rubber ring 13 into sleeve plug 14;
– install sleeve plug 14 into sleeve bore, holding sleeve from the opposite side;
– install cover 12, drawing up bolts 20 with washers;
– install rubber sealing ring 5 into groove on spring plug 6;
– install rubber sealing ring 10 into groove on spring cover 3;
– install spring plug 4 with sealing ring into bore on spring cover 3 up to the full stop;
– screw adjusting bolt 1 with nut 2 into threaded bore of spring cover 3;
– install spool–valve 11 with spring thrust 9 into the sleeve 10 bore;
Caution: throttle bores of spool-valve 11 are to be located from sleeve 14 cover side.
– install spring 6 into the spring cover;
– install semi–assembled spring cover 3 into the hole of casing 21 and to secure using cover 7by bolts
20 with washers;
– install hydraulic distributors 15, 19 on casing 21 and to secure with screws 18 with washers;
– install plugs 24 and valve 25. Prior to assembling the reduction valve 25lubricate by grease Lithol-24
the rubber rings, mated surfaces of casing and locking needle. The valve should be leak proofed. Outer leaks
are not allowed.
Testing of dumping mechanism control unit.
To check serviceability and to adjust the reduction valve 25 create pressure of 4 – 20 MPa in channel Р,
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 (4±0.2) MPa using bolt 1.
Channels X, Y, А. В, Т, Т2 must be open for leakage evaluation and measuring: 0 – 100 sm³/min pres-
sure in chamber Р (10±1) MPa.
Having connected manometers to chambers X and Y, one is to check distribution valve 15 performance,
activating its magnets by turns and tracking drainage of working fluid from chambers X and Y.
Check the distributor 19 operation when pressure value of 16 – 20 MPa is supplied (through throttle
1,5 mm in diameter) to chambers А and В.
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Actuation of the magnets activation should lead to pressure reduction in chambers down to 0 – 0,5 MPa.
Drainages Т and Т2 at this moment should be connected to tank and pressure Р should not be used.
14.6.4 Assembly of pump release automaton

Assembly of pump release automaton is to be carried out in the following order:
– insert rings into circular grooves of plugs 1, 9, 19 (see Figure 14.8), sleeves 5 and 13;
– put sleeve 13 with spool-valve 12, ball 11, spring 10 and plug 9 into casing 14 of control unit and fas-
ten cover 8 to casing 14 by bolts 7 with spring washers;
– from the other side put, ball 15, block 16, spring 18 and plug 19 into casing 14 and fasten cover 20 to
casing 14 by bolts 7 with spring washers;
– put two rings 29 and ring 24 into circular grooves of casing 2;
– fasten control unit to casing 2 by bolts 17 with spring washers;
– mount sleeve 5 with spool-valve 6, spring 3 into casing 2 and screw in plug 1.
Testing of pump release automaton.
Check outer impermeability with working fluid pressure of 20 – 21 МPа. Supply working fluid via output
P, other outputs are to be plugged; adjusting bolt 22 without lock-nut is to be screwed in up to stop.
Pump release automaton is to be adjusted for actuation pressure of 17 – 17,5 МPа – stop of working flu-
id supply from output P to output A; at this working fluid flow from output A to output T should be free. Adjust-
ment is to be performed by adjusting bolt 22.
When pressure supplied to output P drops up to 13,5 – 14 МPа passage from output A to the output T is
to be shut up, and pressure from output P should delivered to output A.
Inner leaks of working fluid from space of output P at pressure of 14,5 – 15,5 МPа (before actuation of
3
pump release automaton) into output T should not exceed 2 sm /sec.
While testing supply working fluid to output P; output T is to be connected with drainage to tank, and
output A is to be connected with manometer checking pressure.
14.6.5 Assembling of double way valve

Assembling of double way valve is to be carried out in the following order:
– put sealing rings 5 into circular grooves of sleeve 2 (figure 14.9) do sealing ring 5 and safety ring 6 into
circular groove of cover 7. Mount safety ring 6 from outer side of cover 7;
– mount thrust 1, sleeve 2 with spool-valve 3 into casing 4 and screw in cover 7.
Testing of double way valve.
Check the valve for outer impermeability. Outer leaks at pressure of (24 + 0,5) МPа are not admitted.
Test the valve on serviceability:
– connect manometer to space II;
– deliver pressure of 18 – 20 МPа into space I, manometer in the space II should indicate value of
3
18 – 20 МPа, leaks in space III should not exceed 100 sm during (60 + 5) seс. When pressure in the space I
drops up to 0 – 0,2 МPа pressure in the space II should be of 0 – 0,2 МPа;
– deliver pressure of 18 – 20 МPа into space III, manometer in the space II should indicate value of
3
18 – 20 МPа, leaks in space I should not exceed 100 sm during (60 + 5) seс. When pressure in the space III
drops up to 0 – 0,2 МPа pressure in the space II should be of 0 – 0,2 МPа.
14.7 Mounting of dumping mechanism units onto dump truck

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

Before mounting dumping mechanism cylinders into dump truck, articulated spherical bearings of head 1
(see figure 14.3) and cylinder cover 28 are to be mounted in the following sequence:
– to install one retainer ring 3 (see figure 14.1) into cylinder head and cover and to force articulated
spherical bearings 2 and 15 into retainer rings up to the full stop;
– to install one more retainer ring having secured articulated bearings into cylinder head and cover;
– to grease spherical surfaces of bearings with Litol–24 lubricant and to pack it into gland spaces;
– to press glands 7 and 16 (two pieces) into cylinder head and cover accordingly.
Mounting of dumping mechanism cylinders into dump truck is to be performed in the following sequence:
– to install 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 be-
tween frame and lifted body;
– to place spacer bushings 8 into cylinder cover;
– to place appliance for removal and mounting of cylinders (see figure 14.2) onto cylinder and to secure
it safely;
– to place cylinder onto lower frame support;
– to place hold–down cover 13 (see figure 14.1) of cylinder head and to secure it with bolts 14;
– to match cylinder cover with body ears;
– to place pin 9 complete with spacer bushings 8, cover 4 and to draw up bolts 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.
14.8 Diagnostics of hydraulic system

After repair of units and apparatuses of hydraulic system (steering, brake systems and dumping gear)
perform if necessary diagnostics of hydraulic system.
Diagnostics operations and order is described in the Operation Manual, Part “Dumping Gear”.
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Cab, cab equipment and fendering
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15 CAB, CAB EQUIPMENT AND FENDERING

15.1 General data
The cab is of two-seated, two-doors, all-metal type with mounted protection system when topple over in-
cidents occur at (ROPS), with heat and noise insulation and soft internal lining. It is installed on the left on the
brackets and fastened to them at four points by means of the bolts 3 (Figure 15.1) through the rubber cushions
4 damping the cab oscillations during the motion.
The cab comprises the pneumatically sprung driver's seat and passenger seat with folding backrest,
which can be transformed into a table for eating.
The cab is completed with a molded instrumentation panels. The cab is equipped with electrical washer
and wiper for front and rear windscreens, heater for rear windscreen, heating and air-conditioning unit located
in the right-hand compartment under the panel.
The cab also is equipped with a dimmer screen, a dome light, a hanger for clothes, a pocket for docu-
ments and operator’s fan. There is place for the medical first aid kit.
The cab glazing provides good visibility from the driver's seat. The windscreen is fitted with flat three-
layer glass (two polished glasses with transparent plastic film between them), the rear and side windows are
fitted with hardened safe glasses.
The doors are equipped with locks and moulded linings with built-in pocket for documents. The cab
doors are provided with sliding quarter vents. The doors are also provided with external and internal handles.
The air-tightness of the door and windows is provided by the rubber seals.
Installation of fenders on the truck deck is shown in the figure 15.2.
Fendering grounds of the dump truck are made of special steel sheet (with effect «antislip») of thickness
from 3 up to 4 mm.
During the operation, on the parts of fendering and cab 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 fendering 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.
Insignificant damage of cab and fendering is repaired without dismantling of units from dump truck chas-
sis, but for clearing the substantial damage, it is necessary to remove the cab and fendering parts from the
dump truck.
Figure 15.1 – Mounting of cab and fendering:

1 – left wing; 2 – front bonnet; 3 –rear bonnet; 4 –right wing; 5 –left rear wing; 6 – bolt of cab fastening; 7, 11 –plates; 8 – pad of
cab fastening; 9 – bracket; 10 –bolt
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Figure 15.2 – Fendering grounds mounting:

1 – right fender; 2 – left additional fender; 3 – left fender; 4 – rear bonnet; 5 – front bonnet
15.2 Removing of cab, fendering and its repair

Before removing the cab or fendering, it is necessary to lift and stop the body by the special cable, two
ends of which bring in the ears on the axle housing and fasten by towing pivots as depicted in figure 15.3. For
preventing drop of pins from the ears, they must be fastened. The body should be fully unloaded. Check the
condition of cable and welding seams of stopping device bracket before each stopping.
LOCKING CABLE IS DESIGNED FOR EMPTY BODY LOCKING ONLY.
The diagram of cab fastening is shown in figure 15.4.
Before cab removal it’ s necessary to do the following:
–disconnect electric wiring, which goes from units and assemblies to the cab;
–discharge pneumohydraulic accumulators;
–discharge air tanks;
–disconnect the drive of fuel supply control;
–disconnect the hoses of supply to the hydro steering, previously having made marking on clamps, fas-
tened on both ends of cutoff point (if marking is absent);
– disconnect the hoses of cab heater from the heat exchanger;
–disconnect the hoses of air conditioner (over the quick-disconnect couplings under the cab). Perform
disconnecting in accordance with requirements of the air conditioner Operation Manual.
– disconnect the air pipe–line from the square of pneumo–cushioned seat powering;
– unscrew bolts (see figure 15.1) with nuts, by which the cab is fastened to the beams of rest;
– for joining of pull adaptation screw into the holes, located on the cab roof (figure 15.4), four ring–bolts
(ring–bolts are put into kit of spare parts);
–remove cab and place it onto the special stand.
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Figure 15.3 – Body stopping:

1 – cable for stopping the body; 2 – body; 3 – cotter-pin; 4 – pivot; 5 – rear-axle housing bracket for fastening the cable; 6 – stop-
ping bolt; 7 – warning notice
The fendering is taken off by means of any fastening devices, corresponded to load capacity and met
safety requirements. Left and right wing are removed by turn in assembly with brackets. Beforehand, it’s ne-
cessary to disconnect the bolts with nuts, by which the fendering is fastened to the frame.
Figure 15.4 – Diagram of cab fastening when removing from dump truck:
1 – dump truck cab; 2 – eye bolt; 3 – fastening device (with four hooks)
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Repair of cab and fendering.

Dents and bends on the cab parts are cleared by method of driver and straightening of damaged surface
by means of special tool kit (figure 15.5).
Figure 15.5 – Kit of tools for dent flattening:

1-6 – hammers; 7,8 – mauls; 9-16 – mandrels; 17–19 – props
The example of dent flattening is shown at the figure 15.6.
Figure 15.6 – Dent flattening:

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

Immobile cab glasses (windshield and rear) are mounted into the rubber seas 5
(figure 15.7) and fastened by rubber locking inserts 4.
For removal of glass, unscrew nuts 6, extract screw 3 and take off clamps 2, take
out locking insert 4 and, pushing by hand onto the upper top of glass, press it out (this op-
eration would be better carried out by two persons in order to prevent the glass fall at the
moment of its outcome from aperture).
Figure 15.7 – Mounting of immobile cab glasses:

1 – glass; 2 – clamp; 3 – screw; 4 – insert; 5 – sealing; 6 – nut
Mounting of glass should be carried out in the following sequence:

– lay the sealing 5 along the whole outline of the window opening so as the joints are located under
clamps;
– mount outside the cab the glass into the lower sealing slot and, little by little inserting the sealing edge
by means of wooden trowel beyond the glass border, put the glass into its position.
The mounting of the windshield should be carried out by two persons: the one inserts the glass into the
sealing and press it tightly to the window opening, the other one inserts the sealing edge beyond the glass
border;
– insert the locking insert 4 by means of mandrel (figure 15.8) into the sealing slot along the whole
length;
– insert clamps 2 (figure 15.7), screws 3 and fasten it by nuts 6.
The hermiticity of cab windows is ensured by greasing the sealings

by mastic АВТО 6-94 ТУ 5770-101-05744716 in the points of glass and
flange. It is allowed to glue the sealing to the window opening flanges by
adhesive 88-СА ТУ 38.
When installing the glasses, the joints of sealings should be glued
by adhesive 88-СА ТУ 38 1051760.
Figure 15.8 – Mounting of locking insert by means of mandrel:
а – installation of locking insert; б – mandrel
Replacement of glass and sliding door window.

Replacement of glass and sliding door window should be carried out in the following sequence:
– pull out the inserts of sealings 12 and 14 (figure 15.9) from the sealings 11 and 13;
– pushing by hand on the upper part of the sliding window 7, press it out (this process should be carried
out by both persons, to prevent glass fall in the moment of taking it off);
– remove the rivets 2 (figure 15.10) of window frame profiles and replace the necessary glasses;
– for replacement of door glasses 5 (figure 15.9), push on the upper part and press it out (this process
should be carried out by both persons, to prevent glass fall in the moment of taking it off).
The mounting of window should be carried out in the reverse sequence (see above).
The hermiticity of door window is ensured by greasing the sealings by mastic АВТО 6-94 ТУ 5770-101-
05744716 in the points of window frame, glass and door flange. It is allowed to glue the sealing to the door
window opening flange by adhesive 88-СА ТУ 38 1051760 instead of greasing by mastic, when installing the
glass and door sliding window.
When installing the glass and sliding door window, the joints of sealings should be glued by adhesive
88-СА ТУ 38 1051760.
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Figure 15.9 – Cab door:

1 – pocket for tools; 2, 4, 8 – gaskets; 3, 9 – door thermo-insulation; 5 – door glass; 6 – door; 7 – sliding window; 10 – door uphols-
tery; 11, 13 – sealings; 12, 14 – sealings insert; 15 – glass fixator; 16, 25, 26, 27 – screws; 17 – bolt; 18 – lock drive; 19 – holder; 20 – in-
ner door handle; 21 – nut; 22 – operating rod of door lock; 23 – door lock; 24 – support; 28 – lock drive handle; 29 – handle facing;
30 – handle socket; 31 – set of handles; 32 – pin; 33 – washer; 34 – cotter-pin
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Figure 15.10 – Sliding window:

1 – left profile of window sliding frame; 2 – rivet; 3 – lining; 4 – stationary window glass; 5 – right profile of window sliding frame;
6 – sliding window glass; 7, 14, 15 – mobile glass sealing; 8 – glass frame; 9 – screw; 10 – handle lining; 11, 13 – immobile glass sealing;
12 – sliding glass handle;
I – place of punching while assembling (punch from both sides)
15.3 Cab equipment repair

Operator seat is pneumo-cushioned seat with the devices of seat height control, lengthwise movement,
turning and back fixation (figure 15.11). The pneumatic cushioning system is described in figure 15.12.
Figure 15.11 – Operator seat:

1 – handle of seat lengthwise movement mechanism; 2, 4 – handles of fixation of seat height regulation; 3 – seat rest with pneu-
matic equipment; 5 – regulation mechanism housing; 6 – handle of turning mechanism and seat back fixation; 7 – seat pad; 8 – seat back;
9 – threaded hole of lap belt fastening
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The mechanism of pneumatic cushioning is powered from the pneumatic system receiver, mounted at
the seat rest 3 (figure 15.11). It consists of pneumatic tank 6 (figure 15.12), pneumatic distributor 3, shock ab-
sorber 4, upper 1 and lower 2 levers and buffer 5.
For checking of serviceability of pneumatic cushioning system it’s required during the operative motor to
bring out the seat from the nominal static position by pushing or lifting it up. After termination the loading, the
seat should be returned to the original position (size 150 mm), and at that after lifting up, the noise of air outlet
from pneumatic distributor should be heard.
When the system is not operated, it’s required to dismantle it. Disconnect the pipe of air supply to the air
distributor from receiver, take off the rest with pneumatic equipment from the truck, check the condition of
pipes of air supply between pneumatic apparatuses and the condition of pneumatic tank (hermeticity).
Figure 15.12 – Seat rest with pneumatic equipment:

1 – upper lever; 2 – lower lever; 3 – pneumatic dis-
tributor; 4 – shock-absorber; 5 – buffer; 6 – pneumatic tank
Heating and air-conditioning unit.

Dump truck is equipped with heating-conditioning unit, which consists of heater, connected to the engine
cooling system, and system of air conditioning with compressor located on the engine, air cooling unit (evapo-
rator) located in the cabin, condensation unit located behind the cabin (on the rear wall). Units of conditioner
are interconnected by means of fittings using flexible pipelines made of frost resistant rubber.
Charging the air conditioner, its commissioning and repair shall be performed in accordance with the
Operating Manual for the air conditioner by the specialists of the air conditioner supplier company or their re-
gional representatives.
To replace air filter for cleaning air supplied into the cabin through heating-conditionig unit it is neces-
sary unscrew four screws fastening protective shroud, located in the cabin front side, remove protective
shroud, unscrew bolts fastening the filter, remove filter and replace it.
The windscreen wiper for the front windscreen is of two-brush type, it consists of the electric motor with
driving mechanism ( see figure 15.13), rods and levers with brushes fastened to the front panel of the cab. The
windscreen wiper for the rear windscreen is of single-brush type, it consists of the electric motor with driving
mechanism, and lever with brush fastened to the rear panel of the cab.
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 lever with brush, unscrew nut and take it off from the axe cone. Place the new lever with
brush and fasten it by nut. Mount brush holders 1 and 5 ready-fitted with brushes 3 and 6 so that the brushes
are in lowermost position when wiper is turned off.
During operation, the wiper blade of the brush must be clean and undamaged, brush in the the adapter
must swing freely and without jamming. It is not allowed to actuate the wiper when the brush is frozen to the
glass to avoid the drive damage. Recommended replacement of brushes is to be performed each 12 months,
as check of threaded joints tightening – each 6 months.
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Figure 15.13 – Installation of wiper arms and brushes:

1, 5 – brush holders; 2 – motor-reductor of windscreen wiper; 3, 6 – brushes; 4 –actuator of rear window wiper
The windscreen washers. The cab is equipped with electrical washer for front and rear windscreens
The windscreen washer consists of a polyethylene tank for the fluid and a pump with an electric motor installed
in this tank. The pump is connected with two nozzles by means of hoses.
When switching on the pump, the fluid fro the tank is fed via hoses to the nozzles which spray it onto the
glass. In the tank cap, there is a hole for equalizing the pressure in the tank when the pump is running. The flu-
id jet direction shall be adjusted by turning the ball in the plastic nozzle in such a way that the jet would be di-
rected to the upper zone of the sector wiped by the windscreen wiper brush.
To exclude the clogging of the jets and filter, the tank shall be filled with filtered fluid only and the jets
shall be regularly cleansed. As working fluid for the windscreen washer, use special low-freezing fluids mixed
with water in proportion according to the instructions for application of the fluid.
The windscreen washer tank (with the pump) is installed in the front lower corner of the cab, as one for
rear windscreen is installed near the cabin rear panel, behind the passenger’s seat inside the low-voltage con-
trol cabinet.
The repair of windshield washer is realized by replacement of out-of-order components: pump with elec-
tromotor, tank, jets and pipelines.
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Fire-Extinguishing System
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16 FIRE EXTINGUISHING SYSTEM

16.1 Technical condition of fire-extinguishing system and trouble shooting
AT OPERATION, TECHNICAL MAINTENANCE AND REPAIR OF FIRE-EXTINGUISHING SYSTEM IT IS NE-
CESSARY TO FOLLOW THE ATTACHED OPERATION MANUAL.
Overall information, specifications, arrangement and work fire-extinguishing systems give also in opera-
tion manual of dump truck.
Technical intactness of fire-extinguishing system and its constant availability in case of fire risk ensure
safe operation of the dump truck.
Technical condition of the system depends on proper and timely technical maintenance in compliance
with the system operation manual and dump truck operation manual.
Technical condition of the system is to be determined every shift by visual examination. During the
examination of system units’ condition, safety of threaded joints, availability of seals on cylinders and reduc-
ers are to be checked up. At finding of dents, cracks, damage of threaded joints of bottles, tanks and reduc-
ers, they are subject to repair.
Hoses featuring swellings or cracking are to be checked for leakage by gaining pressure of 1,2 MPa for
three minutes and if necessary they should be replaced. Damaged pipelines, which open flow area has les-
sened in the result of deformation, are subject to replacement. If leakage has been spotted in solution line
units, it requires remedy.
Once in three months it is required to wash out solution tank intake, to fluff up powder in tank by supplying air
or nitrogen under pressure of 0,5 – 1,2 MPa, to blow out powder line and piping.
Figure 16.1 – Combined fire-extinguishing system with remote control of powder line and rear axle protection:
1 – powder tank; 2 – bolt; 3 – filling neck; 4 – powder line; 5 – spray circuit; 6 – diaphragm safeguard; 7, 15 – gas pipelines;
8, 14 – reducers; 9 – locking and starting head; 10 – manual start button; 11, 13 – gas bottles; 12 – cables; 16, 18 – hoses; 17 – drum;
19 – locking device; 20 – intake; 21 – solution tank; 22 – control unit; 23 – button of electric starting of control unit; 24 – button of electric
starting of remote control of powder line in the engine compartment; 25 – button of electric starting of remote control of powder line for rear
axle; 26 – cold gas reservoir with electric igniter; 27 – signaling-starting device;
I – control deck; II – powder line in the engine compartment; III – solution line; IV – powder line for rear axle
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Every six months it is required to check pressure in gas bottles and if necessary to charge them.
Gas bottle charging is to be effected in the following order:
– to disconnect reducers 8 or 14 (see figure 16.1) from bottles 11 or 13;
– to connect bottle through gas pipeline 4 (figure 16.2) to T-joint 3, and T-joint to transport cylinder 1;
– to connect gauging device 5 to T-joint 3;
– to open valves on transporting 1 and charged 2 cylinders;
– when pressure value is reached (checking by pressure gauge of gauging device 5) in compliance with
Table 16.2, for correspondent ambient temperature, to close valves on transporting and charged cylinders. By
pressing button, to deflate residual gas out of gauging device.
To disconnect gas pipeline 4 from T-joint 3. To screw plug on operative outlet and to seal the cylinder.
Figure 16.2 – Scheme of bottle charging of fire-extinguishing system

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

Gas bottles and tanks are subject to compulsory scheduled technical survey by special control board
and should undergo hydraulic testing.
Data about system faults, assembly repairs, component system replacement, and maintenance, tech-
nical condition monitoring and technical survey are to be filled into the logbook for fire-extinguishing system de-
livered with dump truck.
16.2 Possible faults in fire-extinguishing system, reasons and their remedy

To determine possible faults in the fire-extinguishing system and their remedy is to be guided by Table
16.1.
Table 16.1 – Possible failures in fire-extinguishing system, reasons and their remedy
Fault and its features Their reasons Remedy

To check gas pressure in bottle, if neces-
No gas in bottle
sary to charge or to replace bottle
Extinguishing substance is not sprayed
Frozen solution To replace solution
out
To do servicing of whole line: to blow out
Clogging up of line channels
powder line and piping
On control unit the LED shows failure Absence of starting gas generating element To install starting gas generating element
Break in circuit of starting gas generating To check cables and connections
element, heat indicators or electric igniter of
cold gas reservoir, signaling-starting device,
remote control
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16.3 Repair of fire-extinguishing system

Repair of bottles, tanks and reducers and locking-starting head is to be done at specialized plants hav-
ing a license for such kind of works.
Faulty control units, remote control, heat indicators and signaling-starting devices are to be removed and
replaced by new ones.
Defective hoses and pipelines are to be removed and replaced by new ones.
In chapter for description of the repair of fire-extinguishing system with remote actuation of the powder
line and rear axle protection. Carry out the repair of other fire-extinguishing systems with different means of
switching-on by analogy given above.
16.3.1 Disassembly of fire-extinguishing system with Remote Actuation of the Powder

Line and Rear Axle Protection
Carry out disassembling of powder line of the engine compartment in the following order:
– to disconnect electric wires from locking-starting head 9 (see figure 16.1) of bottle;
– to disconnect reducer 8 from bottle 11;
– to disconnect gas pipeline 7 from reducer 8 and powder tank 1;
– to disconnect powder line 4 from tank and spraying circuit 5 and to remove it;
– to unscrew bolts fixing gas bottle bracket and to remove bracket with bottle;
– to unscrew bolts fixing powder tank and to remove tank;
– to disconnect hose in spraying circuit from pipeline;
– to disconnect bolting of pipelines and hoses and to remove them.
Carry out disassembling of solution line in the following order:
– to disconnect reducer 14 from gas bottle 13;
– to disconnect gas pipeline 15 from reducer 14 and tank 21 and to remove it;
– to disconnect hose 16 from tank and drum 17 and to remove it;
– to unscrew bolts fixing gas bottle bracket and to remove bracket with bottle;
– to unscrew bolts fixing solution tank and to remove tank;
– to remove split pin 3 (Figure 16.3) out of opening of drum shaft 5 and to remove washer 7;
– to remove drum 17 (see Figure 16.1) with hose 18 and locking device 19 from shaft 5 (see Figure
16.3);
– to disconnect hose 18 (see Figure 16.1) from drum and locking device.
Figure 16.3 – Drum of powder line:

1, 2 – clamps for fixing locking device; 3 – split pin; 4 – handle; 5 – drum shaft; 6 – collar; 7 – washer; 8 – bushing; 9 – drum
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Carry out disassembling of powder line for rear axle in the following order:
– to disconnect electric wires from cold gas 26 (see Figure 16.1) reservoir of powder tank;
– to disconnect hose from tank and pipeline;
– to unscrew bolts of tank fixing and remove it;
– to disconnect fastenings of pipeline and hose and remove them.
16.3.2 Repair of fire-extinguishing system units

Repair of solution line drum.
Major defect of the drum is collar wear out, what in the result leads to leakage in operating solution line.
Replacement of drum collars is to be effected in the following order:
– to remove split pin 3 (figure 16.3) out of drum shaft 5 and to remove washer 7;
– to remove drum 9 from drum shaft 5;
– to press-out brass bushings 8 from both side of drum;
– to remove collars 6 from grooves on both side of drum;
– to place new collars into grooves on the drum;
– to press-in brass bushings;
– to grease drum shaft 5 with Litol-24 lubricant and to place drum 9 onto it;
– to place washer 7 onto drum shaft and to lock with split pin 3.
Collars are to be checked for leakage by hydraulic pressure of 1,2 MPa within three minutes. Leakage is
not allowed.
Repair of solution line locking device.
Major defect of locking device is wearing out of rubber spherical valve cup, O-rings what leads to lea-
kage in operating solution line.
Replacement of valve and O-rings of locking device is to be effected in the following order:
– to disconnect hose 18 (see Figure 16.1) from locking device 19;
– to bore out pin 10 (figure 16.4) of upper lever;
– to remove upper lever 2;
– to unscrew connecting branch 9;
– to remove valve 6 out of housing 3;
– to replace valve and O-ring 4;
– to grease valve spindle with Litol-24 lubricant, to put spring 5 on spindle and to place valve back into
opening on housing;
– to replace O-ring 8 and to screw connecting branch 9 up to the full stop against housing 3;
– to place upper lever 2;
– to place new pin 10 and to center punch it.
After assembly the locking device is to be checked up for leakage by supplying hydraulic pressure of
1,2 MPa into chamber I within three minutes. Leakage is not allowed.
Figure 16.4 – Locking device:

1 – handle; 2 – lever; 3 – housing; 4, 8 – rings; 5 – spring; 6 – valve; 7 – valve cup; 9 – connecting branch; 10 – pin; I – chamber
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16.3.3 Assembly of fire-extinguishing system

Prior to system assembly:
– to check system units by visual examination for damage, gas bottles and reducers for seals, check the
reliability of the threaded connections and presence of the seals on the cylinder and reducers;
– to check hoses and pipelines passability, if necessary to blow them out by compressed air;
– to check gas pressure (air or nitrogen) in gas bottles. Pressure should comply with the data stated in
table 16.2. If necessary to raise up pressure to the required value;
– to check powder line tank for availability of extinguishing powder. If necessary to fill in tank with powd-
er through filling neck. Powder should in no case feature lumps exceeding 2 mm to avoid clogging up of powd-
er 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 16.3. If necessary to fill in tank with solution through any
opening in the tank. Solution should feature no mechanical particles exceeding 2 mm.
Table 16.2 – Operating pressure in bottles depending on ambient temperature
Operating pressure in bottles, MPa Operating pressure in bottles, MPa

Ambient Ambient
temperature, 0С temperature, 0С
minimal maximum minimal maximum
55 below zero 9 10 0 11 12,7
50 below zero 9,5 11 10 11,3 13,1
40 below zero 9,7 11,3 20 11,7 13,5
30 below zero 10 11,6 30 12,1 14
20 below zero 10,3 11,9 40 12,5 14,5
10 below zero 10,6 12,3 50 13 15
Table 16.3 – Freezing temperature of calcium chloride solution
Mass concentration of solution Content of calcium chloride in

Freezing temperature, 0С
(at 150С), g/sm3 100g of water, g
1,13 10 below zero 17,5
1,19 20 below zero 27,5
1,24 30 below zero 34
1,285 55 below zero 42,7
Assembly of powder line of the engine compartment.

Carry out the assembly of powder line in the following order:
– to fasten powder tank 1 (see Figure 16.1) on the dump truck;
– to fasten gas bottle 11 with bracket on the dump truck;
– to connect reducer 8 to gas bottle;
– to connect gas pipeline 7 to reducer and tank and to fasten it;
– to install pipelines of spraying circuit. Openings for powder spillage should be directed onto protected
surfaces;
– to connect pipelines between themselves by hose and to fasten it;
– to place diaphragm guard at the output of powder tank, to connect tank and pipeline of spraying circuit
5 by powder pipeline 4 and to fasten it.
– to connect electric wires to locking-starting head of bottle.
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Assembly of solution line.

Carry out the assembly of solution line in the following order:
– to fasten solution tank 21 on the dump truck;
– to fasten gas bottle 13 with bracket on the dump truck;
– to connect reducer 14 to gas bottle;
– to connect gas pipeline 15 to reducer and tank and to fasten it;
– to connect hose 18 of solution line to drum and locking device, to wind hose round drum;
– to grease drum shaft 5 (see Figure 16.3) by Litol-24 and to place drum onto it;
– to put washer 7 on drum shaft and to fix by split pin 3;
– to connect hose 16 (see Figure 16.1) to tank and drum and to fasten it.
Assembly of rear axle powder line.
Carry out the assembly of powder line for rear axle in the following order:
– to fasten powder tank on the dump truck;
– to connect hose to tank;
– to mount pipeline;
– to connect hose to pipeline and to fasten it;
– to connect electric wires to cold gas reservoir of powder tank.
AFTER INSTALLATION OF THE SYSTEM AND CHECKING THE INTEGRITY OF THE ELECTRIC CIRCUITS,
REMOVE THE SAFETY COTTER PIN FROM THE SIGNALLING AND TRIGGERING DEVICE.
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Running in of Dump Trucks after Repairs
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17 RUNNING IN OF DUMP TRUCKS AFTER REPAIRS
In the initial period after repairing dump truck, surfaces of repaired assemblies coming into friction need
time for grinding-in and lubrication modes should get to standard. Good grinding-in of part faces ensures relia-
bility and handsome life service of assemblies and systems.
Prior to operating of dump truck check its common serviceability paying special attention to repaired as-
semblies and systems:
– 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);
In case of replacement of parts and units of suspension, which are listed in appendix B, all the opera-
tions on tightening of threaded joints are to be performed as at running-in of new truck.
– 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 (look Operation Manual);
– 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 elec-
tro-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 lowering 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;
– check pressure in tires. Air pressure should be measured in completely cooled tires;
– check serviceability of suspension cylinders;
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Running in of Dump Trucks after Repairs
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– checking and testing of traction electrical drive is to be performed in accordance with adjustment direc-
tions;
– when wheels replacement tighten nuts after first ride, and then do after two-three rides up to stabiliza-
tion of torque at all the nuts;
At starting operation period it is recommended to pay special attention to repaired assemblies and sys-
tems, to stop dump truck at regular intervals after every 10 – 20 km and to check temperature and tightening of
outer threaded joints of repaired assemblies and systems;
Engine temperature mode, oil pressure in lubricating systems, rotation speed of engine crankshaft,
compressed air pressure in pneumatic system receivers, oil pressure in pneumatic hydraulic accumulators
should comply with data recommended in dump truck operation manual.
Temperature at motor wheel reduction gears, seating place of traction alternator bearings, traction elec-
tric motors, power take-off box, front wheel hubs, braking drums and plates should not exceed 60 С (one can
0
hold his hand for a long time touching supervised units). Should any deviation in units performance arise, one
is to stop operating dump truck at once and to remedy deviation.
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Operational Materials
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18 OPERATIONAL MATERIALS
WHEN OPERATING OF THE DUMP TRUCKS, USE ONLY THE OPERATION MATERIALS OF THE RECOM-
MENDED BRANDS, THE QUALITY OF WHICH SHALL BE CONFIRMED BY THE RECOMMENDATIONS STATED IN
THE OPERATING MANUAL FOR THE ENGINE.
18.1 Fuel
Fuel for the engine shall be used in accordance with the recommendations stated in the Operating Ma-
nual for the engine.
To prevent the fuel equipment failure due to presence of water in fuel, it is recommended to fill the tank
with fuel having settled at least 10 days.
18.2 Lubricants
Universal all seasons motor oil BELAZ G-Profi Mining 15W-40 or one in accordance with the operating
manual should be be used for the engine.
The oil for reduction gears of the power-wheels manufactured by General Electric Company shall be
used in accordance with the documentation for the traction electric motor.
The transmission oils, working fluids for the hydraulic systems (hydraulic oils) and plastic lubricants shall
be used in accordance with the season and climatic conditions of operation of the dump trucks.
The lubricants and recommendations for their use depending on the temperature of the ambient tem-
perature are listed in Table 18.1.
The brands of the lubricants and their equivalents are listed in Table 18.2.
Table 18.1- Using the lubricants depending on the ambient temperature
State Standard (ГОСТ), Temperature range

Lubricant brand
Technical Specifications (ТУ) of using the lubricants
Shock absorber fluid LUKOIL-AZh Technical Specification (ТУ) 0253-025-00148599 Above minus 50°С
Shock absorber fluid МГП-12 Technical Specification (ТУ) 0253-052-00148843 Above minus 40°С
Shock absorber fluid ГРЖ-12 Technical Specification (ТУ) 0253-048-05767924 Above minus 50°С
Grease No. 158М ТУ 38.301-40-25 Above minus 30°С
Grease Lithol-24 ГОСТ 21150 Above minus 40°С
Grease Лита (Lita) ТУ 38.101808 Above minus 50°С
Grease МС-1000 Technical Specification (ТУ) 0254-003-45540231 Above minus 40 оС
Grease МС 1400 (NORD) Technical Specification (ТУ) 0254-028-45540231 Above minus 50°С
Note: For using the oils in the hydraulic system depending on the ambient air temperature, see the chapter “Dumping Mechanism”
Table 18.2 – List of equivalent lubricants
Equivalent lubricants
Lubricant brands Classification and
Manufacturer Description
specification
Lithol-24 MIL-G-18709A Shell Alvania EP 2;
MIL-G-10924C Retinax EP 2
Mobil Mobilux EP 2,
Mobilux EP 3
BP Energrease L2
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Operational Materials
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Table 21.2 (cont'd)
Equivalent lubricants
Lubricant brands Classification and
Manufacturer Description
specification
Лита (Lita) SM-1C-4515A Shell AeroShell Grease 6
(Ford) Mobil Mobilux EP 2
BP Energrease LT2
МС-1000 MIL-G-18709A Shell Alvania EP 2;
MIL-G-10924C Retinax EP 2
Mobil Mobilux EP 2,
Mobilux EP 3
BP Energrease L2
МС 1400 (NORD) – BP Energrease LТ2
Energrease L2
ЖРО MIL-G-10924C Shell Alvania RL 3
Mobil Mobilux EP 3
BP Energrease LS2
158М – Shell Alvania RL 1
BP Energrease LS-EP2
Note: For the equivalents of oils for the hydraulic system, refer to chapter “Dumping Mechanism”.
18.3 Cooling Fluid

It is recommended to use special low-freezing cooling fluids for the engine cooling system according to
the operating manual for the engine year round.
THE COOLING FLUIDS ARE TOXIC!
18.4 Nitrogen
For charging the suspension cylinders and hydropneumatic accumulators of the braking brake system
and steering control, use commercial gaseous nitrogen (State Standard (ГОСТ) 9293 “Gaseous and Liquid Ni-
trogen”).
Commercial gaseous nitrogen is delivered in steel seamless cylinders under the pressure of
(15.0±0.5) MPa. The cylinders are coloured black. At the top of the cylinder there is a yellow marking “NITRO-
GEN” and brown annular marking band.
18.5 Commercial Ethyl Alcohol

For filling the anti-freezer of the pneumatic system and washing the parts of the electrical machines and
equipment, use commercial rectified ethyl alcohol to the State Standard (ГОСТ) 18300.
THE RECOMMENDED ALCOHOL IS PRODUCED FROM NON-FOOD VEGETABLE RAW MATERIAL. AS RE-
GARDS THE SEVERITY OF THE HUMAN HEALTH IMPACT, IT IS RELATED TO THE FORTH CLASS OF DANGER TO
THE STATE STANDARD (ГОСТ) 12.1.007.
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Appendices
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19 APPENDICES
19.1 APPENDIX А – Assembly protocol of engine КТА 38С (КТА 50С) with alter-
nator ГС-525 (reference)
Chassis N__________________ Data ____________________
Engine N__________________ Alternator ____________________
1. Engine dimensions
1.1 Size of crankshaft axial movement (backlash) С __________________
1.2 Size А1 __________________
2. Alternator dimensions
2.1 Size of shaft axial movement (backlash) Е __________________
2.2 Size Г1 __________________
2.3 Size Гпр __________________
2.4 Size of rotor adapter К __________________
2.5 Size of fan wheel М __________________
2.6 Size for selection of gaskets Р __________________
2.7 Number of alternator adjusting gaskets
S=2 mm __________________
S=0,5 mm __________________
2.8 Size F __________________
2.9 Size В __________________
3. Assembly
3.1 Size П __________________
3.2 Number of engine adjusting gaskets
S=0,3 mm __________________
S=0,1 mm __________________
4. Results of assembly correctness check-up
4.1 Axial movement of crankshaft of diesel generator __________________
4.2 Radial runout of alternator rotor adapter __________________
4.3 Conclusion __________________________________________________________
________________________________________________________________________
________________________________________________________________________
Executor _______________________
Name, signature
Supervisor _________________________
Name, signature
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Appendices
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19.2 APPENDIX B – Tightening torques of the most responsible threaded con-

nections (reference)
Tightening torques of the most responsible threaded connections are resulted in the Table B.
Table B – Tightening torques of the most responsible threaded connections
Tightening torque
№ The name of the threaded connection
N.m
1 Fastening nut of the fan wheel on shaft of the traction generator dump trucks 882 – 980
BELAZ-75131, BELAZ-75135, BELAZ-75139, BELAZ-75137, BELAZ-7513B
2 Bolts fastening the electric motor-wheels to the rear axle housing of dump trucks 1728 – 1936
equipped with full-set transmission manufactured by “General Electric” Company
3 Bolts fastening the electric motor-wheels to the rear axle housing of dump trucks 1200 – 1300
equipped with reduction gears manufactured by “BELAZ” Company
4 Bolts fastening the traction electric motor to reducer of the motor - wheel manufac- 800 – 1000
tured by “BELAZ” Company
5 Bolts fastening the flanges on the traction electric motor shaft of dump trucks 260 – 320
equipped with reduction gears manufactured by “BELAZ” Company
6 Bolts fastening the thrust ring of electric motor-wheel reduction gear manufactured by 400 – 440
“BELAZ” Company
7 Spherical support nuts of the cylinder fastening the front suspension 2700 – 3150
8 Spherical support nuts of the cylinder fastening the rear suspension 2700 – 3150
9 Clamping nut of the suspension cylinder 9000 – 10000
10 Bolts fastening the lower arm of the front suspension cylinder to steering knuckle and 920 – 1020
upper arm to frame bracket
11 Bolts fastening the lug of the front suspension central hinge to the central lever 920 – 1020
12 Bolts fastening the finger of the central hinge of front suspension (axial gap from both 1100 – 1250
sides of inner bearing race is not admitted)
13 Nuts fastening the lug of the rear suspension central hinge to the central lever 1200 – 1400
14 Nut fastening finger of the rear suspension central hinge (after tightening the nut to 1800 – 2000
0
tighten on angle 60 (one side))
15 Bolts fastening the fingers of front suspension lateral rod (tighten several times evenly 1100 – 1250
around, simultaneously knocking over the end of finger from the bearing side, having
placed a pad made of color metal on the end of finger)
16 Bolts fastening locking plate to the finger of front suspension central hinge 450 – 560
17 Bolts fastening clamping plates to the finger of rear suspension lateral rod 450 – 560
18 Bolts fastening bearings covers of front and rear suspensions central hinges 270 -- 300
19 Bolts fastening covers to fingers of front suspension lateral rod 161 -- 199
20 Bolts fastening the pressure ring to a steering knuckle 100 – 140
21 Adjusting bushes (for adjustment of conic bearings of the front wheel hub ) 100 – 140
22 Nuts fastening the steering trapezoid lever to steering knuckle 800 – 1000
23 Terminal connections nuts of a traction steering trapezoid 110 – 140
24 Bolts fastening clamping plates to the fingers of turn cylinders and steering trapezoid 490 – 600
link
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Appendices
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Continuation of the table B
25 Fastening nuts of front wheels 1150 – 1300

26 Fastening nuts of rear wheels 800 – 900
Fastening nuts of rear wheels for dump trucks BELAZ–7513 (-01, -06) of 1300 – 1400
BELAZ–7513A (-01, -02) with the full complete General Motors electric transmission
27 Fastening bolts of the brake case of the front wheels to a steering knuckle 2500 – 3000
28 Fastening bolts of the brake mechanisms internal cheeks of rear wheels 550 – 700
29 Nuts fastening the brake mechanisms external cheeks of rear wheels of dump trucks 370 – 450
with electric motor-wheel reduction gear manufactured by “BELAZ” Company
30 Tightening torques for brake mechanisms of rear wheels of dump trucks
BELAZ-7513, BELAZ-7513A equipped with full-set transmission manufactured by
“General Electric” Company are given in the chapter “Brake Systems”
19-3 - 75131.0275-17
28.04.2017
BELAZ OJSC – Management Company of BELAZ–HOLDING
OPEN-CAST MINING DUMP TRUCKS Of BELAZ-7513 series
Repair Manual
Zhodino
Republic of Belarus
Лист регистрации изменений
Всего
Номера листов (страниц)
листов
№ доку-
Изм. (страниц) Подпись Дата
мента
изме- аннулиро- в доку-
замененных новых
ненных ванных менте
215 - 215 75131.977- 13.01.

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OJSC “BELAZ” – MANAGEMENT COMPANY OF HOLDING

OPEN-CAST MINING DUMP TRUCKS

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

OJSC “BELAZ” – Management Company of Holding “BELAZ–HOLDING”

9 STEERING ................................................................................................................................................................................. 9-1

13.4 Welding quality control and defects elimination ..................................................................................................................13-6

2 TECHNICAL SPECIFICATION OF DUMP TRUCKS

Figure 2.1 – BELAZ-75131 dump truck. Overall dimensions

Table 2.1 – Dump Truck Specification

Payload capacity, kg:

Continuation of table 2.1

Tires Tubeless, pneumatic

3 GENERAL INSTRUCTIONS AT REPAIRING

3.2 Fault detection

with one-time lubricant is admitted.

4 SAFETY PRECAUTIONS AND FIRE-PREVENTION REQUI-

4.2 Fire safety requirements

4.3 Safety precautions and warnings when performing welding operations

5.1 Removal and mounting of the diesel generator

Figure 5.1 – Fastening diagram of the dump truckс diesel generator

Perform mounting of diesel generator on the chassis in reverse sequence.

Removal and mounting of the traction generator.

Figure 5.2 – Fastening diagram of the traction generator

Figure 5.3 – Connection of engine with traction alternator engine

Figure 5.4: Figure 5.5:

Figure 5.6 – Diesel-generator assembly:

Perform coupling and centering of the engine

Figure 5.7 – Assembling of diesel-generator:

Mounting of the engine.

Size of the engine A1.

Figure 5.8 – Size of the engine А1:

Generator size Гпр.

Figure 5.9 – Preliminary size of the generator Гпр:

The size of the generator B1.

The resulting generator size B1 should necessarily be smaller

Figure 5.10 – Generator Size B1:

Installation of the generator.

Figure 5.11 – Diesel-generator assembly:

1. Check the fastening of hatches, which were re-

Figure 5.12 – Finite-size circuits of diesel-generator

5.5 Repair and service of the cooling system

Removal and installation of the radiators blocks.

Disassembly of radiators block.

Figure 5.13 – The Stand–turner for assembly–disassembly of the radiators block:

Figure 5.14 – Installation diagram for

1 – feeding compressed air cock; 2 – manome-

Figure 5.15 – Tube test on the tightness:

Figure 5.16 – Demountable radiator:

Adjusting shutters plates position.

Pneumatic switch repair.

Figure 5.17 – Pneumatic switch:

5.6 Repair of the engine pneumatic starter system

5.7 Engine preheater troubleshooting

Trouble and its symptom Possible reason Troubleshooting

Continuation of table 5.1

6 TRACTION ELECTRIC DRIVE

6.1 General data on traction electric drive

6.2 Description and operation of electric drive components

Traction electric motor.