Contents

General information

Dump truck specifications

General repair instructions

• Disassembly
• Fault detection
• Build

Safety regulations and fire safety requirements for repair work

• Security requirement
• Fire safety rules
• Safety rules and warnings when performing welding work

Engine systems

• Removal and engine installation
• Cooling system repair and maintenance
• Pumping the fuel supply system
• Cleaning the dust from the air filter
• Repair of the electric starter engine start system
• Possible malfunctions of the exhaust system
• Possible malfunctions of the engine preheater

Hydromechanical transmission

• General information
• Possible malfunctions of hydromechanical transmission and ways to eliminate them
• Removing the hydromechanical transmission from the dump truck
• Disassembly of the hydromechanical transmission
• Dismantling the torque converter
• Dismantling the gearbox
• Dismantling the clutch
• Disassembly of units of the hydraulic system of the hydromechanical transmission
• Checking the technical condition of hydromechanical transmission parts
• Hydromechanical transmission assembly
• Assembling the oil pump
• Assembling the oil intake and full-flow filter
• Spool box and control assembly assembly
• Assembling the relief valve
• Assembling the torque converter lockup control drive mechanism
• Assembling the retarder control mechanism
• Relief valve assembly
• Filter assembly
• Hydromechanical transmission shaft assembly
• Hydromechanical transmission clutch assembly
• Hydromechanical transmission assembly
• Break-in and control check of a six-speed hydromechanical transmission
• Installing a hydromechanical transmission on a dump truck

Cardan drive

• General information
• Possible malfunctions of cardan shafts, flexible couplings and how to fix them
• Removing propeller shafts and flexible coupling from a dump truck
• Removing the propeller shaft of the hydromechanical transmission
• Removing the flexible coupling
• Removing the drive axle propeller shaft
• Dismantling propeller shafts and flexible couplings
• Dismantling the propeller shaft of the hydromechanical transmission
• Dismantling the flexible coupling
• Dismantling the drive axle propeller shaft
• Checking the technical condition of elastic coupling parts and propeller shafts
• Assembling propeller shafts and flexible couplings
• Assembling the flexible coupling
• Hydromechanical transmission propeller shaft assembly
• Assembling the drive axle propeller shaft
• Installing cardan shafts and flexible couplings on a dump truck

Drive axle

• General information
• Possible drive axle malfunctions and remedies
• Dismantling the drive axle
• Removal and disassembly of wheel gears and wheel hubs
• Removal and disassembly of the final drive
• Removing and disassembling the drive axle housing
• Checking the technical condition of the drive axle parts
• Drive axle assembly
• Assembly and installation of drive axle housing
• Building and installing the final drive
• Assembly and installation of wheel hubs and wheel gears
• Drive axle running in

Suspension

• General information
• Possible malfunctions of the suspension cylinders and how to fix them
• Safety measures when removing, repairing and installing suspension cylinders on a dump truck
• Removing the suspension cylinders from the dump truck
• Disassembly of suspension cylinders
• Dismantling the front suspension center pivot
• Dismantling the rear suspension center pivot
• Removing and disassembling the front and rear crossbars
• Checking the technical condition of suspension parts
• Assembly of suspension cylinders
• Assembling the top and pump cover and bottom cover
• Main Cylinder Assembly
• General assembly of suspension cylinders
• Installing the suspension cylinders on a dump truck
• Assembling the front suspension center pivot
• Assembling the center pivot of the rear suspension on a dump truck
• Assembly and installation of front and rear suspension transverse bars

Front axle. Wheels and tires

• Front axle
• Removing the front axle from a dump truck
• Dismantling the front axle
• Checking the technical condition of the front axle parts
• Front axle assembly
• Installing the front axle on a dump truck
• Wheels and tires
• Removing wheels from a dump truck
• Disassembly and assembly of wheels
• Installing wheels on a dump truck

Steering

• General information
• Possible malfunctions of the steering and how to fix them
• Removing steering assemblies from a dump truck
• Removing the steering column
• Removing the steering gear
• Removing the regulator valve
• Removing the filter
• Removing the steering and steering linkage hydraulic cylinders
• Removing the emergency steering drive
• Disassembly of steering assemblies
• Dismantling the steering column
• Disassembly of the steering propeller shaft
• Dismantling the hydraulic steering gear
• Disassembly of the regulator valve
• Disassembly of the swing hydraulic cylinder
• Dismantling the steering linkage
• Filter disassembly
• Dismantling the emergency steering actuator
• Checking the technical condition of steering parts
• Steering assembly assembly
• Assembling the steering column
• Steering propeller shaft assembly
• Assembling the hydraulic steering gear
• Assembling the regulator valve
• Swing Hydraulic Cylinder Assembly
• Assembling the steering linkage
• Filter assembly
• Assembling emergency steering actuator
• Installing steering assemblies on a dump truck
• Installing a steering column with a propeller shaft
• Installing the steering gear
• Installing the control valve
• Installing a filter
• Installation of hydraulic cylinders for steering and steering linkage
• Installing emergency steering actuator

Braking systems

• General information
• Service brake system
• Parking brake system
• Possible malfunctions of brake systems and how to fix them
• Repair of brake systems
• Repair of the brake mechanism of the front wheels
• Rear wheel brake repair
• Repair of multi-disc wet brakes of rear wheels
• Parking brake system repair
• Repair of hydraulic brake system units
• Brake valve
• Automatic pump unloading
• Double safety valve
• Pneumatic hydroaccumulator
• Two-way valve
• Retarder control valve
• Parking brake control valve
• Checking the technical condition of brake system parts

Pneumatic system

• General information
• Possible malfunctions of the pneumatic system and methods of their elimination
• Repair of pneumatic system devices
• Pressure regulator repair
• Safety valve repair
• Anti-freeze repair

Electrical equipment

• Possible malfunctions of electrical equipment
• Troubleshooting security issues
• Energy saving troubleshooting and repair
• Possible malfunctions and repair of batteries
• Repair and maintenance of outdoor and indoor lighting systems

Cab, cab equipment and empennage

• Removal of plumage, cockpit and their repair
• Cabin equipment repair

Frame and platform

• Checking the technical condition of the frame (platform) and determining defects
• Preparing the frame (platform) for repair
• Frame (platform) repair
• Welding in the down position
• Vertical welding
• Horizontal welding
• Overhead welding
• Welding quality control and elimination of defects
• Removing and installing the platform

Tipping mechanism

• General information
• Possible malfunctions of the tipping mechanism and methods of their elimination
• Removing the tipper assembly from the tipper
• Disassembly of the tipping mechanism components
• Dismantling the tipping cylinder
• Dismantling the tipping mechanism control panel
• Dismantling the tipping mechanism safety valve
• Disassembly of the tipping mechanism auxiliary valve
• Checking the technical condition of the tipping mechanism parts
• Tipping mechanism assembly
• Assembling the tipping cylinder
• Assembling the tipping mechanism control unit
• Assembling the tipping mechanism control panel
• Assembling the tipping mechanism safety valve
• Tipping auxiliary valve assembly
• Installing the tipper assembly on the tipper
• Installing the tipper assembly on the tipper
• Installing the tipper cylinders on the tipper

Fire extinguishing system

• General information and safety requirements
• Device and principle of operation
• Security requirements
• Technical condition of the fire extinguishing system and identification of malfunctions
• Possible malfunctions of the fire extinguishing system, causes and methods of their elimination
• Fire extinguishing system repair
• Dismantling the fire extinguishing system
• Fire extinguishing system assembly

Dump truck check after repair

Operating materials

• Fuel
• Lubricants
• Coolant
• Nitrogen
• Ethyl technical alcohol

Applications

• Appendix A Tightening torques for the most critical threaded connections
• Appendix B List of equipment for the repair of mining dump trucks BelAZ-7555V, BelAZ-7555E and their modifications