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BELAZ 7540 / 7548 / 7547, repair e-manual (in Russian)

BELAZ 7540 / 7548 / 7547, repair e-manual (in Russian)
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Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
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Publisher: © "TechProsvet"
ISBN: 978-005-700-032-1
Number of pages: 268
Format: file PDF

About the manual

Engine type: YaMZ-240PM2 / TMZ-8424.10-07 / YaMZ-240NM2 / YaMZ-8401.10-06 / KTA-19S / YaMZ-240NM2 / YaMZ-8401.10-06 / KTA-19S

Engine power: 309 / 312 / 368 / 405 / 441 / 368 kW

In the manual you will find

  • Information on self-service tractor
  • Information on the design of the tractor and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible
Publisher: TechProsvet
Categories: Dump trucks
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "TechProsvet"
ISBN: 978-005-700-032-1
Number of pages: 268
Format: file PDF

About the manual

Engine type: YaMZ-240PM2 / TMZ-8424.10-07 / YaMZ-240NM2 / YaMZ-8401.10-06 / KTA-19S / YaMZ-240NM2 / YaMZ-8401.10-06 / KTA-19S

Engine power: 309 / 312 / 368 / 405 / 441 / 368 kW

In the manual you will find

  • Information on self-service tractor
  • Information on the design of the tractor and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible

Contents

General information

Dump truck specifications

General repair instructions

  • Disassembly
  • Fault detection
  • Build

Safety regulations and fire safety requirements for repair work

Engine systems

  • Maintenance and repair of the cooling system
  • Power system maintenance
  • Cleaning the dust from the air filter
  • Maintenance of the exhaust system
  • Service and repair of the pneumatic starter engine start system
  • Engine preheater maintenance

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
  • Removing and disassembling the matching gear
  • Dismantling the torque converter
  • Dismantling the gearbox
  • Dismantling the clutch
  • Disassembly of the hydraulic system components
  • Dismantling the oil pump
  • Dismantling the oil intake and full-flow filter
  • Disassembly of the valve body
  • Disassembling the compensating valve
  • Disassembly of the control mechanism
  • Disassembly of the torque converter release mechanism
  • Disassembly of the retarder control drive mechanism
  • Disassembly of the retarder control mechanism
  • Checking the technical condition of hydromechanical transmission parts
  • Hydromechanical transmission assembly
  • Assembling the matching gear
  • 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 release mechanism
  • Assembling the control drive mechanism and the retarder control mechanism
  • Hydromechanical transmission shaft assembly
  • Hydromechanical transmission clutch assembly
  • Hydromechanical transmission assembly
  • Running-in and control check of a five-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
  • Dismantling propeller shafts and flexible couplings
  • Checking the technical condition of elastic coupling parts and propeller shafts
  • Assembling propeller shafts and flexible couplings
  • Installing cardan shafts and flexible couplings on a dump truck

Drive axle

  • General information
  • Possible drive axle malfunctions and remedies
  • Dismantling of the drive axle of BelAZ-7540A, 75404 dump trucks
  • Removing and disassembling wheel gears
  • Removing and disassembling wheel hubs
  • Removal and disassembly of the final drive
  • Dismantling of the drive axle of BelAZ-7548A, 75481, 75483, 7547, 75471, 75473 dump trucks
  • Checking the technical condition of the drive axle parts
  • Assembling the drive axle of BelAZ-7540A, 75404 dump trucks
  • Building and installing the final drive
  • Assembly and installation of wheel hubs and wheel gears
  • Assembling the drive axle of BelAZ-7548A, 75481, 75483, 7547, 75471, 75473 dump trucks
  • Drive axle running in

Chassis

  • 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
  • Removing from a dump truck and disassembling the reaction rods of the front and rear suspension and the forks with a pivot connection of the rear suspension
  • Checking the technical condition of suspension parts
  • Assembly of suspension cylinders
  • Installing the suspension cylinders on a dump truck
  • Assembling the reaction rods of the front and rear suspension and the rear suspension fork with a kingpin and installing them on a dump truck
  • 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 Relief Valve Steering Gear
  • Removing the filter
  • Removing the hydraulic steering cylinder, rods and steering linkage arms
  • Removing the emergency steering drive
  • Disassembly of steering assemblies
  • Dismantling the steering column
  • Disassembly of the steering propeller shaft
  • Dismantling the hydraulic steering gear with safety valve
  • Disassembly of the swing hydraulic cylinder
  • Dismantling the steering linkage
  • Dismantling the hydraulic filter
  • 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 with relief valve
  • Swing hydraulic cylinder assembly
  • Assembling the steering linkage
  • Hydraulic 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 with relief valve
  • Installing a filter
  • Installing the steering cylinder and steering linkage
  • Installing emergency steering actuator

Braking systems

  • General information
  • Possible malfunctions of brake systems and how to fix them
  • Service brake system
  • Dismantling the brake mechanism of the front wheels of dump trucks BelAZ-7548A, 75481, 75483, 7547 75471, 75473
  • Assembling the brake mechanism of the front wheels of the BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
  • Dismantling and assembly of the brake mechanism of the front wheels of BelAZ-7540A, 75404 dump trucks
  • Dismantling the brake mechanism of the rear wheels of BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
  • Assembling the brake mechanism of the rear wheels of BelAZ-7548A, 75481, 75483, 7547 75471, 75473 dump trucks
  • Dismantling and assembly of the brake mechanism of the rear wheels of BelAZ-7540A, 75404 dump trucks
  • Disassembling the brake cylinder
  • Assembling the brake cylinder
  • Dismantling the compressor
  • Compressor assembly
  • Dismantling the service brake control valve
  • Assembling and testing the service brake control valve
  • Dismantling the pressure regulator
  • Assembling, adjusting and testing the pressure regulator
  • Dismantling the water separator
  • Assembling and testing the water separator
  • Disassembly of the anti-freeze device
  • Anti-freeze assembly and testing
  • Disassembly of the single safety valve
  • Assembly, adjustment and testing of a single safety valve
  • Dismantling the double safety valve
  • Assembling and testing the double safety valve
  • Disassembly of the pressure relief valve
  • Pressure relief valve assembly
  • Dismantling the relief valve
  • Relief valve assembly
  • Replacing the brake pads
  • Parking brake system
  • Dismantling the brake mechanism of the parking brake system of BelAZ-7540A, 75404 dump trucks
  • Assembly, adjustment and testing of the brake mechanism of the parking brake system of dump trucks BelAZ-7540A, 75404
  • Dismantling and assembly of the brake mechanism of the parking brake system of dump trucks BelAZ-7548A, 75481, 75483, 7547, 75471, 75473
  • Dismantling the parking brake control valve
  • Assembling, adjusting and testing the parking brake control valve
  • Checking the technical condition of brake system parts

Electrical equipment

  • Troubleshooting security issues
  • Energy saving troubleshooting and repair
  • 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
  • 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 tipping mechanism assemblies
  • Disassembly of the tipping mechanism components
  • Dismantling the tipping cylinder
  • Disassembly of the electromagnetic control valve of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
  • Disassembly of the control panel of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
  • Dismantling the tipping mechanism safety valve
  • Disassembly of the tipping mechanism auxiliary valve
  • Dismantling the control unit of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
  • Dismantling the control panel of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
  • Checking the technical condition of the tipping mechanism parts
  • Tipping mechanism assembly
  • Assembling the tipping cylinder
  • Assembling the tipping mechanism safety valve
  • Tipping auxiliary valve assembly
  • Assembling the control panel of the tipping mechanism (installed on dump trucks manufactured before 03/31/2003)
  • Assembling the control unit of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
  • Assembling the control panel of the tipping mechanism (installed on dump trucks manufactured after 01.04.2003)
  • Testing the knots of the tipping mechanism
  • Testing the tipping mechanism cylinders
  • Testing the tipping mechanism control unit
  • Testing the tipping mechanism control panel
  • Installing the tipper cylinders on the tipper

Running in dump trucks after repair

Operating materials

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

Applications

  • Appendix A Tightening torques for main screw connections
  • Appendix B List of equipment for the repair of mining dump trucks BelAZ- 7540A, 75404, 7548A, 75481, 75483, 7547, 75471, 75473 and their modifications

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