Direction On Assembly

OJSC “BELAZ” – Management Company of Holding
“BELAZ-HOLDING”
MINING DUMP TRUCKS

BELAZ-7513 series:
BELAZ-7513, BELAZ-75135, BELAZ-75131,
BELAZ-75139, BELAZ-75137, BELAZ-7513А,
BELAZ-7513B
DIRECTIONS ON ASSEMBLY, STURT-UP AND ADJUSTMENT
7513-3902016 DA
Republic of Belarus
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DIRECTIONS ON ASSEMBLY, START-UP AND ADJUSTMENT
7513-3902016 DA
These Instructions describe the units, mechanisms and systems of the

BelAZ-7513 dump trucks that are removed from the dump truck for handling and
transportation by railway, and give recommendations how to mount these compo-
nents. The procedure is described for the the dump truck testing before commission-
ing for operation. The key safety requirements, including those concerning electric
safety, are described.
The Manual is intended for the drivers, technicians and all the persons in-
volved in mounting, operation and maintenance of BelAZ mining dump trucks.
The manufacturer is continually improving the design of its dump trucks and re-
serves the right of making modifications to improve their quality and to prolong their life-
time.
For the most comprehensive information on all the modifications please visit the
site www.belaz.by .
Please send your comments regarding the design and operation of the dump truck
and your proposals with regard to these Instructions:
OJSC “BELAZ” – Management Company of Holding “BELAZ-HOLDING”, 40 Let
Oktyabrya St., 4 Zhodino, Minsk Region 222160, Republic of Belarus.
OJSC “BELAZ” – Management Company of Holding “BELAZ-HOLDING”
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TABLE OF CONTENTS
1 SAFETY REQUIREMENTS AND WARNINGS .......................................................................................................................... 1-1
1.1 Safety requirements ......................................................................................................................................................... 1-1
1.2 Fire Safety ....................................................................................................................................................................... 1-2
1.3 Warnings ......................................................................................................................................................................... 1-2
1.4 Safety Rules and Precautions for Welding ....................................................................................................................... 1-3
2 PREPARATION FOR MOUNTING ............................................................................................................................................ 2-1
3 MOUNTING ............................................................................................................................................................................... 3-1
3.1 Installing the front axle and suspension ............................................................................................................................ 3-1
3.2 Installing the electric power-wheels .................................................................................................................................. 3-1
3.3 Installing the fuel tank ...................................................................................................................................................... 3-4
3.4 Installing the front wheels ................................................................................................................................................. 3-5
3.5 Installing the rear wheels.................................................................................................................................................. 3-6
3.6 Installing the fenders ........................................................................................................................................................ 3-7
3.7 Installing the engine air supply system ............................................................................................................................3-11
3.8 Installing the cab .............................................................................................................................................................3-14
3.9 Connecting the cab equipment ........................................................................................................................................3-14
3.10 Installing the traction electric drive control cabinet ...........................................................................................................3-18
3.11 Connecting the traction electric drive harnesses and wires .............................................................................................3-20
3.12 Installing the exterior lighting and light signalling equipment ............................................................................................3-21
3.13 Installing the rear lights and lamps ..................................................................................................................................3-21
3.14 Assembling and welding the body ...................................................................................................................................3-25
3.15 Assembling and welding the body for the coal-carrier dump truck ...................................................................................3-33
3.16 Installing the body and the body position sensors ...........................................................................................................3-37
3.17 Installing the mud guards ................................................................................................................................................3-40
3.18 Assembling the centralized automatic lubrication system ................................................................................................3-42
3.19 Installing the telemetric control system (TCS)..................................................................................................................3-42
3.20 Installing the video surveillance system ...........................................................................................................................3-45
3.21 Installation of warning tags and labels .............................................................................................................................3-49
3.22 Installing the fire extinguishing system ............................................................................................................................3-49
3.23 Installing the stone shields ..............................................................................................................................................3-50
3.24 Installation of antennas alarming approaching the overhead power line ..........................................................................3-51
3.25 Installation of the bonnet shroud .....................................................................................................................................3-52
3.26 Installation of the fire extinguisher ...................................................................................................................................3-54
3.27 Installation of the service monitoring system ...................................................................................................................3-54
3.28 Installation of the load control system..............................................................................................................................3-55
3.29 Installation of the wheels chocks .....................................................................................................................................3-56
4 DUMP TRUCK COMMISSIONING COMPREHENSIVE TEST .................................................................................................. 4-1
5 APPENDICES ........................................................................................................................................................................... 5-1
5.1 APPENDIX A – Main transportable parts of the dump truck slinging diagrams ................................................................ 5-1
5.2 APPENDIX B – Main transportable parts of the dump truck weight ................................................................................. 5-6
5.3 APPENDIX C – Hydraulic drive circuit diagram ............................................................................................................... 5-7
5.4 APPENDIX D – Equipment and accessories necessary to handle and mount the chassis, body units and components ..5-10
5.5 APPENDIX E – Installation requirements for hydraulic piping connections .....................................................................5-11
5.6 APPENDIX F – Installation of labels ...............................................................................................................................5-12
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To carry out the mounting works, test the dump truck systems, run the dump truck and commission it,
use the documents as follows along with these Instructions:
– Dump Truck Operation Manual, 75131-3902015 OM;
– Dump Truck Service Manual, 7513-3902080 RM;
– set of documents for the engine;
– set of documents for the traction electric drive;
– operation manuals and instructions for the supplementary units and systems installed on the dump
truck.
These operational documents are shipped with the dump track as a part of the delivery.
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1 SAFETY REQUIREMENTS AND WARNINGS

1.1 Safety requirements
Before the dump truck assembling, operation, maintenance or repair, the drivers and service personnel
must be instructed in occupational safety, fire safety, electric safety, safe working procedures and techniques,
general safety requirements for motor vehicles.
Here it is also necessary to adhere the following documentation: “Safety Regulations for Open-Cast Min-
ing Works and for Solid Mineral Deposits Processing Operations”, “Operating Rules for Consumers’ Electrical
Installations”, “Safety Rules for Operating the Consumers’ Electrical Installations”, Rules for Design and Safe
Operation of Pressure Vessels”, “Operation Manual for mining and industrial tires of radial and bias design”.
The drivers and service personnel shall be provided with protective clothes, safe footwear, protective
helmets, goggles and other personal protection equipment.
At the enterprises operating the dump trucks, safe occupational conditions must be provided; also, main-
tenance and repair instructions must be prepared, including the provisions stipulating the written permissions
for works that involve special requirements in terms of safety.
BESIDES, IT IS NECESSARY TO OBSERVE THE BELOW STATED REQUIREMENTS CONDITIONED BY THE
DUMP TRUCK DESIGN – AS IGNORING SUCH REQUIREMENTS CAUSE DANGER FOR SERVICE PERSONNEL OR
RISK OF DUMP TRUCK DAMAGE:
1.1.1 The dump truck is equipped with ladders, footsteps, handrails and bodies to ensure the safety of
the works for assembling, adjustment and maintenance.
When performing the works without enclosures and/or handrails, the safety belt as well as portable lad-
ders and stands should be used. When doing this, the safety requirements shall be observed.
1.1.2 When moving on the ladders and top bodies (fenders), it is necessary to hold the handrails fitted
on the ladders, fenders, bonnets and cab so that there would be three supporting points at any time (either two
hands and one foot or two feet and one hand). The ladders and bodies shall be cleaned from dirt, snow and
ice. Never jump from the dump truck.
It is recommended to walk up and down the truck ladders while facing the truck.
1.1.3 Never stand or walk on the ladders, footboards, upper bodies (fenders or bonnets) and bodies in-
tended for servicing the truck.
1.1.4 Never walk up or down the truck on the ladders or footsteps while holding tools or other things in
the hands. To lift or lower the tools and other things, use the lifting equipment ensuring the safety of the said
operations. When performing any works while standing on the ladders and/or bodies, nobody shall stand under
them.
1.1.5 When the body lifting mechanism test is in progress, never stand near the truck or carry out any
work under the lifted body.
Use the special rope to lock the lifted body. Place both ends of the rope into the lugs on the axle housing
and use the towing pins to fasten them. Never work under the lifted body locked by the rope if there is more
than 3 tons of stuck soil in it, or if the tailwind speed exceeds 6.5 m/s.
THE LOCKING ROPE IS DESIGNED FOR LOCKING THE EMPTY BODY ONLY.
Do not leave the cab when the body is being lowered or lifted.
1.1.6 Prior to charging the suspension cylinders and hydropneumatic accumulators with gas, make sure
that the charging device is faultless and the cylinder with compressed gas is marked properly. The cylinder
shall be marked with the word “NITROGEN” and brown circular stripe.
IT IS STRICTLY PROHIBITED TO CHARGE THE SUSPENSION CYLINDERS AND HYDROPNEUMATIC AC-
CUMULATORS WITH OXYGEN, BECAUSE IT WOULD RESULT IN EXPLOSION.
1.1.7 Prior to fitting the wheel check the pressure in tyre. If the pressure drops lower than 0.08 MPa in-
flate the tyre up to the pressure of 0.25 – 0.3 MPa and make sure that the lock ring is fitted properly. It is only
allowed to inflate the tyre to the rated pressure after fastening the wheel on the hub. There shall be nobody
near the tyre being inflated.
Prior to unfastening the wheel from the truck, deflate the tyre completely. If it is necessary to unfasten
the twinned rear wheels, deflate the tyres of both wheels.
NEVER DETACH OR FIT THE WHEELS WITH THE TYRES INFLATED.
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1.1.8 Never dismantle and/or disassemble the components of the brake systems and steering control
being under the working fluid pressure. To depressurize the front and rear circuits of the service brake system,
turn out the obturating needles on the brake valve.
The working fluid pressure in the hydraulic system of the steering control and parking brake is released
automatically within 80 seconds after scheduled stopping of the engine. The hydropneumatic accumulators
shall be only installed and dismantled with the gas chamber depressurized.
1.1.9 Never eliminate the faults, disassemble the fittings and/or perform the welding works in the pres-
surized pneumatic starting system and pneumatic system of the dump truck. The pressure shall be released
through the condensate drain cocks; when doing this the shutoff valves of the air cylinders shall be open.
1.1.10 It is prohibited to adjust and/or operate the pneumatic starting system with faulty pressure gauges
and without seals on the safety valves.
1.1.11 When servicing and repairing the storage batteries, keep in mind that the electrolyte, when in
contact with the skin, can cause severe burns.
1.1.12 When checking the working fluid level in the suspension cylinder, unscrew the check hole plug slowly
to release the excessive gas pressure in the chamber. During this operation, never stand in front of the plug.
1.1.13 For the electric safety rules that must be observed while setting or adjusting the traction electric
drive, see the documents delivered with the traction electric drive.
THE TRACTION ELECTRIC DRIVE OPERATES UNDER DANGEROUS VOLTAGE. FAILURE TO OBSERVE
THE SAFETY REQUIREMENTS COULD CAUSE AN ELECTRIC SHOCK OR DEATH.
1.2 Fire Safety

To avoid the fire on the truck, it is necessary to observe the general Regulations of Fire Safety when
handling the flammable substances and follow the requirements stated below:
1.2.1 Check regularly the leak-tightness of fuel and oil pipelines of the systems of the engine, steering
control, dumping mechanism and braking systems.
1.2.2 The dump truck shall be cleaned regularly from flammable materials: stains of fuels and lubricants,
coal dust, etc.
1.2.3 Do not leave the dump truck when the engine starting pre-heater is running.
1.2.4 The truck is equipped with the fire extinguishing system. To extinguish the fire, use the combined
fire extinguishing system having stopped previously the engine.
NEVER USE THE SOLUTION FIRE-EXTINGUISHING LINE FOR EXTINGUISHING THE ENERGIZED ELECTRIC
EQUIPMENT AND SPILLAGE OF FUEL AND OIL. NEVER USE THE POWDER FIRE-EXTINGUISHING LINE, IF THERE
IS ANYBODY WITHIN THE ZONE PROTECTED BY THE ABOVE SYSTEM.
1.2.5 OPERATION OF THE TRUCK WITH FAULTY FIRE EXTINGUISHING SYSTEM IS PROHIBITED. THE
MAINTENANCE OF THE FIRE EXTINGUISHING SYSTEM SHALL BE PERFORMED IN STRICT COMPLIANCE WITH
THE REQUIREMENTS STIPULATED IN THE DUMP TRUCK OPERATION MANUAL.
1.2.6 To avoid the ignition of gases, never use open flame when checking the cooling fluid level in the
expansion tank of the engine cooling system.
1.2.7 Never use open flame when inspecting the storage batteries.
1.3 Warnings
1.3.1 If the dump truck units and assemblies are removed from it for transportation in a partially
knocked-down condition, the ends of hoses, hydraulic system pipelines, centralized automated lubrication sys-
tem pipelines and electric harnesses disconnected from each other shall be tagged, with the connection num-
bers inscribed on the tags.
When the dump truck is assembled in the field, the hoses and the hydraulic system pipelines shall be
connected in accordance with the labels on tags and with the hydraulic drive circuit diagram (see Appendix C).
High-pressure pipelines and hoses must never be in contact with the chassis elements or with each
other (except for their fastening locations). Also, no play shall remain in the fastening elements. During the
high-pressure hose mounting, they shall never be twisted. To eliminate the defects, rotate the angle piece,
move the pipelines or move the high-pressure hoses. For this purpose, the pipe edges may be slightly bent.
When installing hydraulic pipelines connections, the requirements described in the Appendix E must be
observed.
The electric equipment wire harnesses shall be connected in accordance with the labels of the mounting
diagram (traction electric drive) and the electric circuit diagram.
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1.3.2 If the threaded connection tightening torques are not specified, see the relevant normative docu-
ments in the instruction on tightening of the threaded joints 7547-3900030 and in the site www.belaz.by.
1.3.3 Loading-unloading operations and transportation of tires (wheels):
– perform loading-unloading operations and transportation of tires (wheels) so that to avoid tires damage;
– lifting and transportation of tires (wheels) using forklift with flat grippers is to be performed gripping outer
perimeter, in vertical position with slight tilt towards forklift avoiding damage of surface rubber;
– when performing loading-unloading operations by means of crane, fasten tires (wheels) using soft flat
tape type slings with enough strength, with width not less than 140 mm and length not less than 6m, or using ap-
pliances specially designed by trucks manufacturer.
IT IS FORBIDDEN TO FASTEN TIRES (WHEELS) USING STEEL ROPES AND CHAIN SLINGS, HOOKING
THE RIM OR WIRE FRAMEWORK APPLIED WHEN TRANSPORTING BY RAILWAY
1.4 Safety Rules and Precautions for Welding

1.4.1 Prior to beginning the welding works directly on the assembled truck, it is necessary to disconnect
both the “minus” and “plus” terminals of power supply of the trucks from the respective terminals of the storage
batteries. When disconnecting the storage batteries first disconnect the negative cable and after that do the
positive one.
1.4.2 To avoid fire when welding, make sure that there are no flammable engineering maintenance ma-
terials (fuel, oil etc.) in the immediate vicinity of the welding place (on the chassis members or ground) and pro-
tect the fire-hazardous parts (hoses, wires, etc.) against the molten metal spatter.
1.4.3 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 ca-
bles of the traction electric drive control, payload and fuel consumption control system, video survey system, cylin-
ders 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.
1.4.4 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.
1.4.5 When performing welding operations close to electronic units of payload and fuel consumption control
system, video survey system certain units are to be dismantled.
1.4.6 When welding on the dump truck, the circuit breakers of the control and auxiliary circuits in the control
cabinet shall be open. When welding near the electric wires and cables, the measures shall be taken to prevent
them from being damaged.
Do not remove any control boards or disconnect the plug-and-socket units of the traction electric drive con-
trol system; otherwise the contact could be broken that would cause the failure of the system.
The welding works related to the power cabinet shall be performed under supervision of the qualified spe-
cialist in the field of electric drives and in such way that penetration of the molten metal spatter into the cabinet
would be excluded.
1.4.7 When welding on the truck with the engine equipped with an electronic control system, observe the
following rules to protect the electronic components against damages:
– prior to beginning the welding works, disconnect all the plug-and-socket units connecting the circuits of
the control, power supply, alarm and data transmission of the engine with the respective circuits of the truck;
– never fasten the “ground” wire to the bracket of the electronic module of the engine (ECM) or ECM
module itself;
– should it be necessary to perform the welding works on the attached units of the engine or assemblies
mounted immediately in the engine, these units shall be removed from the engine.
If such removal is impossible, all the ЕСМ plug-and-socket units shall be disconnected prior to beginning
the welding works. Should the engine be equipped with several ECMs, the plug-and-socket units shall from all
the modules.
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1.4.8 When reconnecting the engine circuits to the truck circuitry (both after performing the welding
works and when assembling the truck), the following rules shall be observed:
– all the plug-and-socket units connecting the circuits of the control, power supply, alarm and data
transmission of the engine with the respective circuits of the truck shall be connected prior to connecting the
storage batteries;
– when connecting the storage batteries the “plus” cable shall be connected first and then the “minus” one;
– Never set the key in the ignition switch to the working position before connecting the cables to both
terminals of the storage batteries;
– it is only allowed to disconnect the plug-and-socket units connecting the circuits of the engine with
those of the truck (for example, for troubleshooting) provided the key is removed from the ignition switch and
the "grounding" is disconnected.
1.4.9 Never perform the welding works near the fuel and oil tanks, charged hydropneumatic accumulators
and pipelines connected with them, gas cylinders of the fire extinguishing system and/or near the suspension
cylinders charged with gas and filled with oil.
1.4.10 Never perform the welding works in the pressurized pneumatic starting system and pneumatic
system of the truck. The pressure shall be released through the condensate drain cocks; when doing this the
shutoff valves of the air cylinders shall be open.
1.4.11 Prior to performing the welding works, make sure that the hydraulic system pipelines are not
pressurized. To depressurize the front and rear circuits of the service brake system, turn out the obturating
needles on the brake valve. The working fluid pressure in the hydraulic system of the steering control and
parking brake is released automatically within 80 seconds after scheduled stopping of the engine.
1.4.12 When welding, protect the chromium-plated surfaces of the dump truck assemblies (cylinders of the
suspension, hydraulic system, etc.) against the molten metal spatter.
1.4.13 Never perform the repair works involving the welding on the wheel rim assembled fitted the tyre.
1.4.14 When welding for repairing the cab equipment, it is necessary to take measures for preventing
the inflammation of the parts of upholstery and noise insulation of the cab interior.
1.4.15 Prior to welding near the boxes of storage batteries, special attention should be paid to obser-
vance of the fire safety rules and necessary safety precautions.
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2 PREPARATION FOR MOUNTING

Before unloading the dump truck components, the customer must ensure that the seals on the cargo are
intact, and that all the components listed in the accompanying sheets are available. Before installing the com-
ponents on the dump truck, remove packaging and protective lubrication. In the accompanying sheets, the
number and locations of seals are specified, the parts removed from the dump truck are listed, and locations
are listed where these parts have been placed. One accompanying sheet is available on the left side glass in-
side the cab; other sheets are available on the box with the parts for fastening the components.
When the dump truck is shipped, several fastening and positioning parts are fastened at their appropri-
ate positions; several parts are used to fasten the pads under the cab and the chassis front; and other parts
are placed in the box for parts in the cab or in the tool box.
The electric equipment devices, removed from the dump truck, with their fastening parts are placed in
the spare parts and tools box.
The sequence of mounting, setting and adjustment procedures shall be in accordance with this Instruc-
tion. The sequence of these procedures may be varied; however, safety shall not be affected.
The site used for mounting works shall be flat, horizontal; its surface shall be solid and shall have ap-
propriate load-carrying capacity which provides safety assembling operations. The site sizes shall be sufficient
for the dump truck components. The mounting site shall not be crossed by the electric power transmission
lines and communication lines.
In winter, mounting works should be carried out indoors, in heated premises. The components shall be
put on the mounting site in sequence meeting the mounting procedure, in such a manner to make them freely
accessible.
ATTENTION! LOADING AND UNLOADING OPERATIONS AND TRANSPORTATION OF PARTS AND UNITS
COMPRISED IN DUMP TRUCK SHIPMENT KIT AS WELL AS DUMP TRUCK IN ASSEMBLY SHOULD BE PER-
FORMED SO TO AVOID THEIR DAMAGE.
A gantry crane or overhead crane shall be available as main hoisting equipment for the dump truck
mounting. The hoisting equipment technical condition and rated capacity shall be appropriate for the weight of
units or assemblies to be handled.
WARNING: WHEN USING TEXTILE SLINGS TO FASTEN UNITS WHEN DUMP TRUCK ASSEMBLING NEVER
LET CONTACT OF SLINGS WITH SHARP EDGES OF UNITS TO AVOID DAMAGE AND BREAKAGE OF SLINGS AND
FALLS OF THE FASTENED LOAD WHICH IS DANGEROUS FOR THE PERSONNEL AND CAN LEAD TO THE DUMP
TRUCK DAMAGE
If the jib crane is used, its capacity shall be chosen in accordance with the weight of components to be
handled and the required boom reach.
Along with the main hoisting equipment, the equipment as follows shall be available at the mounting site:
the wheel fitting handler, two hoisting jacks, the set of hoisting fixtures and the set of hoisting ropes made of
steel, and various pneumatic and manual fitter's tools. Use only the tools being in good operating condition.
The electric equipment shall be mounted and adjusted in accordance with the electric circuit diagrams
and instructions available with the operating documents.
To assemble and weld the body, the equipment as follows is necessary: the DC electric welding unit, the
gas welding and cutting unit, the pneumatic grinding machine (it shall be used to grind the edges for the pur-
pose of preparation for welding), and the fitter's tools.
Prior to performing welding operations grind the weld points removing the painted coating. Grind the
weld seams and paint them with the same color applying the attached paint materials.
Before mounting remove transportation brackets, protective frameworks and boots, polyethylene film,
plugs from fittings, knee-pieces, ends of hoses, protective lubrication (if any) from parts and assemblies to be
mounted, and ensure that they are in good operating conditions.
Fastening points of the units when unloading from the railcar should be marked with black enamel close
to the fastening point.
Look the fastening diagrams of main shipped dump truck units in the Appendix A.
For the weights of the main transportable parts of the dump truck, see Appendix B, for the schedule of
equipment and accessories necessary to handle and mount the chassis and the body components, see Ap-
pendix D.
Appendix С contains the schematic diagram of the dump truck hydraulic drive.
When installing hydraulic pipelines connections, the requirements described in the Appendix E must be
observed.
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3 MOUNTING
3.1 Installing the front axle and suspension
Fasten the front axle with hubs using slinging appliance (look the Appendix D) and set it onto the sup-
ports over the place where it will be joined to the chassis. Place two supports (145-268) under the front axle
beam; place the support (145-290) under the lever.
Fasten the dump truck chassis using slinging appliances and set it onto the technological supports, two
supports (145-291) for the frame crossbar N1, the support (145-292) under the rear axle housing to provide
possibility to adjoin the front axle with its slight movement.
Disconnect the transportation support from the chassis front.
Move the front axle beam lever to place the eye ring 10 (see Figure 1) inside the frame bracket to align
the holes in the eye ring bearing and in the bracket. Press the pin 11 to insert it as deeply as possible.
The process conic pin is recommended to be used to align the holes in the eye ring bearing and in the
bracket.
Mount the lock plate 14 and use the bolts 15 with flat and spring washers applying the torque of
450 – 560 N.m. to fasten it. The lock plate must be mounted with no play at its butts; rotate the pin 11 to elimi-
nate the play if any.
Mount the disk 9 and use the bolts 8 with washers to fasten the pin. The torque shall be
1100 – 1250 N.m; also, no axial play shall remain at both sides of the inner racers.
ATTENTION! TO ENSURE THERE IS NO GAP WHEN TIGHTENING THE BOLTS, DYNAMIC LOAD SHOULD
BE APPLIED TO THE PIN END AT THE SIDE OF THE LARGE DIAMETER.
Remove the technological support from under the front axle lever.
Connect the rod 3 with the pin on the front axle beam, and use the bolts 4 (M14x1,5-6gx45, 4 pcs) with spring
washers. The tightening torque for bolts shall be 161 – 199 N.m.
Fasten using slinging appliance and secure the left 1 and right 12 brackets, fastening the fender to the
posts of the frame’s second crossbeam. For this purpose, the seam N1 State Standard 5264-80-H1 shall be
made, with the leg 20+2 (D view).
Tighten nuts of the spherical supports of the front suspension cylinders, tightening torque is of
2700 – 3150 N.m. Use M14x1.5 nuts, with the sleeves for lubrication of the suspension cylinders’ upper and
lower spherical supports, to connect the high-pressure hoses.
Fasten the suspension cylinder 2, move it to the brackets 1 or 12 that fasten the fenders, match and se-
cure the upper bracket 7 to the brackets 1 or 12 using bolts 6 (M24x2-6gx60, 8 pcs) with spring washers. The
tightening torque for bolts shall be of 920 – 1020 N.m.
Align the matching surfaces of the steering knuckles and of the suspension cylinder’s lower bracket 13
and secure them using the bolts 6 (M24x2-6gx60, 8 pcs) with spring washers. The tightening torque for bolts
shall be of 920 – 1020 N.m.
Connect the hose of the service brake system of front wheels to the tee on the front axle beam, do the
hoses of the steering hydraulic system to the steering cylinders (figure 2) in accordance with marks on the
hoses ends. Tighten screws (M10x35) evenly by three attempts till the torque of 62 – 70 N.m. is reached.
Use the plug-in connector to attach the wiring harness to the speedometer sensor mounted in the left
steering knuckle journal.
Refill the front suspension cylinders with oil and nitrogen using the reference ruler after the dump truck is
assembled completely.
3.2 Installing the electric power-wheels
Installing the electric power-wheels with the reduction gear manufactured by BELAZ OJSC.
Before the electric power-wheels installation, tighten the bolts fastening the traction electric motor on
the power-wheel reduction gear applying the torque of 800 – 1000 N.m;
Remove the pieces of dunnage from under the brushes and unseal the traction electric motor vent holes.
Sling the electric power-wheel 2, flange it with the rear axle housing 4 (see Figure 3) and use bolts 3
(M30x2-6gx105, 62 pcs) with spring washers to fasten the wheel motor. The tightening torque for bolts shall be
1200 – 1300 N.m.
Connect the hoses 9, 12 in the rear axle housing to the tees 18 on the cheek 17 of the service brake sys-
tem and do the hoses 10 and 13 to the knee-pieces 19 of the parking brake cylinder.
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Fasten in the upper part of housing inner space the terminals of traction electromotors power cables on
the connection panels in accordance with diagram for mounting the cables over the chassis (attached to the
operation documentation), connect the cables in accordance with connection scheme.
Connect the hoses 5 cooling the electric wheels motors to the branch-pipes in the rear axle housing and
fasten them using clamps 6 and 7.
Attach the connecting hoses to the breathers on the rear axle housing and use clamps 14 to fasten the
hoses. The connecting hoses must be free of slacks; otherwise, they can be clogged with oil resulting in block-
ing the air flow. To make the hoses free of slacks, cut them as appropriate.
Figure 1 – Installing the front suspension:

1 – left bracket fastening the fender; 2 – air-hydraulic cylinder; 3 – transverse rod with pins; 4, 6, 8, 15, 16 – bolts; 5 – cover;
7 – suspension cylinder’s top bracket; 9 – disk; 10 – eye ring with a base; 11 – pin; 12 – right rear bracket fastening the fender; 13 – sus-
pension cylinder’s bottom bracket; 14 – lock plate
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Figure 2 – Connection of the steering hydraulic system hoses to the steering cylinders:
1 – frame girder; 2, 3 – hoses; 4 – steering cylinder; 5 – front axle; 6 – pipe; 7 – ring; 8 – hold-down; 9 – screw
Figure 3 – Installation of the motor-wheel with reduction gear manufactured by BELAZ Company:
1 – check plug; 2 – electric motor-wheel; 3 – bolt; 4 – rear axle housing; 5 – hose; 6, 7, 14 – clamps; 8 – band; 9, 10, 12, 13 – high
pressure hoses; 11 – connection valve; 15 – parking brake cylinder; 16 – service brake cylinder; 17 – service brake cheek; 18 – tee;
19 – knee-piece
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Installing the electric power-wheels for BELAZ-7513 and BELAZ-7513A dump trucks, with the
complete “General Electric” electric transmission.
Sling the electric power-wheel 2 (see Figure 3a; for the slinging diagrams, see the documents provided with
the traction electric drive), flange it with the rear axle housing 9 and use bolts 3 (M33x2-6gx130) with washers to
fasten the power-wheel. The tightening torque for bolts shall be 1728 – 1936 N.m.
In the rear axle housing, connect the hoses to the service brake gear and the parking brake gear nipples
(in accordance with labels); the power conductors and the speed sensor wires, to the respective terminals (see
the connection diagram); the hoses 1, to the breathers 6; the hoses 8, to the cocks 4.
The connecting hoses for the breathers must be free of slacks; otherwise, they can be clogged with oil
resulting in blocking the air flow. To make the hoses free of slacks, cut them as appropriate.
Figure 3a – Installing the electric power-wheels with the complete “General Electric” transmission:
1, 5, 8 – connecting hoses; 2 – electric power-wheel; 3 – bolt; 4 – cock; 6 – breather; 7 – plug; 9 – rear wheel housing
3.3 Installing the fuel tank

Sling fuel tank 1 (Figure 4), set it onto the stud 7 and fix it (loosely) by nut 9 (M36x2) with spring washer
preliminarily having installed support 8 into the hole of the tank bracket.
Install brackets 2 and 4 and secure them to the frame girder using bolts 10 (M24x2-6gx70) with nuts and
spring washers.
Install brackets 3 and secure them to the tank using bolts 5 (loosely) with flat 6 and spring washers, hav-
ing eliminated the gap between mating faces of brackets and tank.
Install upper vibroinsulators 12 with protective housings 14, set bolts 11 (M24x2-6gx110) with locking
plates 13, do lower vibroinsulators, screw bolts into the threaded holes of plates 15, selecting adjusting gas-
kets 16 providing the size 2 ± 2 (view D).
Tighten bolts 11 with torque of 200 – 250 Nm and fix them to avoid loosening by locking plates 13. Final-
ly, tighten the bolts 5.
Finally tighten the nut 9. Tightening torque is of 1165 – 1883 Nm
Install the fuel pump onto the bracket on the tank rear wall and secure using two clamps and nuts M6
with spring washers. Connect the fuel pipelines to the fuel tank valve and to the fuel pump. Connect the drain
pipeline to the knee-piece on the fuel tank.
Pull the wire harness 20 over the fuel tank side wall and secure it by cleats 21, 23, 24, bolts 22 (М6х16)
and washers. Install and connect to the harness the light 17 controlling fuel top level and fuel level sensors
19 (2 pcs.).Connect fuel tank wire harness to the girder wire harness.
Connect the wiring harness to the fuel pump.
Open the valve of the fuel tank.
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Figure 4 – Installation of the fuel tank:

1 – fuel tank; 2, 3, 4 – brackets; 5, 10, 11 – bolts; 6 – washer; 7 – stud; 8 – support; 9 – nut; 12 – vibroinsulators; 13 – locking
plate; 14, 18 – protective housing; 15 – plate; 16 – adjusting gaskets; 17 – light controlling fuel top level; 19 – fuel level sensors; 20 – wir-
ing harness; 21, 23, 24 – cleats
3.4 Installing the front wheels

Before the wheel installation, ensure that the connection between the valve and the extension tube is
tight (for this purpose, use the soap emulsion test). Position the hub with its groove facing down, and put the
wheel, with the extension tube 11 of the valve 1 (see Figure 5) on the hub, with the wheel rim stop aligned
with the hub groove. Be careful not to damage the valve 1 and the extension tube 11.
Mount the upper and lower clamps 2; then, mount the left and right clamps 2. Tack the clamps; for this
purpose, tighten the nuts 4 uniformly, one by one, in diametrically opposite directions or locations to set the re-
quired torque, 200 – 300 N.m. Avoid any wheel misalignment on the hub.
The wheel wobble on the tyre casing side wall shall not exceed 10 mm.
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Mount the other clamps and tighten the nuts. Tighten the nuts uniformly, one by one, in diametrically op-
posite directions, in three or four steps, to set the required torque, 1150 – 1300 N.m. Use the plate 12 and
bolts 13 with spring washers to fasten the extension tube 11 on the hub.
Inflate the tyre to set the required pressure.
WARNING: BEFORE INFLATING THE TYRE TO SET THE OPERATING PRESSURE IN IT, ENSURE THAT IT IS
FASTENED SECURELY ON THE HUB. NEVER STAND OR PERMIT OTHER PERSONS TO STAND NEAR THE TYRE
WHILE THE INFLATION IS IN PROGRESS.
Figure 5 – Installing the front wheel:

1 – valve; 2 – clamp fastening the wheel; 3 – pin; 4 – nut fastening the wheel; 5 – wheel rim lock ring; 6 – sealing ring; 7 – bead
ring; 8 – tyre; 9 – rim; 10 – tyre bead seat; 11 – extension tube; 12 – plate fastening the extension tube; 13 – bolt
3.5 Installing the rear wheels

Place the hub with its groove facing down, and put the assembled near-side wheel (see Figure 6) with the
valve extension tube 1, the spacing collar 10 and the assembled outer wheel. Before the inner wheel installation,
carry out the soap emulsion test to ensure that the connection between the valve and the extension tube is tight.
Mount the upper and lower clamps 7; then, mount the left and right clamps 7. Tack the clamps; for this
purpose, tighten the nuts 5 uniformly, one by one, in diametrically opposite directions or locations to set the re-
quired torque, 200 – 300 N.m. Avoid any wheel misalignment on the hub.
The wheel wobble on the tyre casing side wall shall not exceed 10 mm.
When fastening the rear wheels, it is necessary to fit serially four clamps having an additional М24х2
threaded hole on each side to facilitate the removal of the clamps when dismantling the rear wheels. To facili-
tate the removal of the clamps when dismantling the rear wheels, use the 340758 (М24х2) bolt included spe-
cially in the spare parts, tools and accessories kit.
Mount the other clamps and tighten the nuts. Tighten the nuts uniformly, one by one, in diametrically op-
posite directions, in three or four steps, to set the required torque, 800 – 900 N.m, for dump trucks
BELAZ–7513 (-01, -06) of BELAZ–7513A (-01, -02) with the full complete “GE” electric transmission
1300 – 1400 Н.м.
Use the plate 14 and nuts 12 to fasten the outer wheel valve extension tube 1 to the valve 13. Inflate the
tyre to set the required pressure.
WARNING: BEFORE INFLATING THE TYRE TO SET THE OPERATING PRESSURE IN IT, ENSURE THAT IT IS
FASTENED SECURELY ON THE HUB. NEVER STAND OR PERMIT OTHER PERSONS TO STAND NEAR THE TYRE
WHILE THE INFLATION IS IN PROGRESS.
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Figure 6 – Installing the rear wheels:

1 – extension tube; 2 – tyre; 3 – bead ring; 4 – rim; 5 – nut fastening the wheel; 6 – pin; 7 – rear wheel clamp; 8 – tyre bead seat;
9 – lock ring; 10 – distance ring; 11 – sealing ring; 12 – nut; 13, 15 – valves; 14 – plate fastening the extension tube
3.6 Installing the fenders

When mounting the fenders, adjust joint gap within (10 + 5) mm by out-of-round holes between: rear
bonnet 18 (figure 7) and right fenders 21, rear bonnet 18 and cab, left fender 31 and cab.
Difference in planes of mating parts – rear bonnet 18, right fenders 21, left fender 31 and auxiliary left
fender 29 is up to 15 mm.
When mounting the fenders parts and components, install flat washers and spring washers under bolt
heads and nuts, as shown at figure 7. Fenders fastening parts are given in the тable 1.
Mount and fasten right support bracket 13 and left support bracket 13 to frame legs by bolts 35 (М24x2-
6gx60, 16 bolts) in accordance with section D – D.
Join left support bracket 13 to rear left fastening bracket 3 through brackets support 16 and fasten by
bolts 41 (М24x2-6gx70, 8 bolts) and nuts in accordance with section S1 – S1, by bolts 41 (М24x2-6gx70,
8 bolts) or 47 (М24x2-6gx110, 8 bolts) and nuts in accordance with section T1 – T1, having mounted, if re-
quired, adjusting plates 51 or 52 in accordance with the sections.
Weld on bracket supports 16 by welds N1 State Standard 5264-80-Н1, weld leg 8+1,5 (see figure).
Join right support bracket 25 and left support bracket 27 to support beam 26 and fasten them by bolts 41
(М24x2-6gx70, 8 bolts) and nuts in accordance with section H1 – H1.
Mount braces 4 and adjusting plates 40 under right and left support brackets. Fasten them by bolts 41
(М24х2-6gx70, 8 bolts) and nuts in accordance with section M – M. Mount left fender 31 and fasten it by bolts
50 (М16-6gx50, 2 bolts) and nuts in accordance with section R1 – R1.
Mount auxiliary left fender 29 and fasten it by bolts 35 (М24х2–6gx60, 6 bolts) and nuts in accordance
with sections G1–G1 and L1–L1, by bolts 50 (М16-6gx50, 2 bolts) and nuts in accordance with section N1–N1.
Mount right fender 21 assy with the handrails 7, 20, 23, 24 and fasten it by bolts 47 (М24х2–6gx110,
10 bolts), nuts and locknuts according to sections C1 – C1, D1 – D1 and J1 – J1; mount, if required, adjusting
plates 48 (section D1 – D1).
Install and secure the handrails 9, 30 and 33 to the left fender 31 using bolts 36 (M10-6gh30, 36 pcs.)
according to the section L – L. Fasten the handrails 9 and 33 together by bolts 39 (M8-6gh25, 3 pieces, one
bolt on top, others two are below) with nuts according to the section J – J. In addition, connect handrails with
coupler 43 using bolts 36 (M10-6gh30, 2 pcs.) with nuts according to the section A1 – A1, having secured the
holders 44 and 45 on handrails by screws 46 (M8-6gh20, 4 pcs.) with nuts according to the section B1 – B1.
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Figure 7 – Installing the fins (sheet 1 of three):

1 – front bonnet; 2, 4 – braces; 3, 22 – rear fender fastening brackets; 5, 14 – ladders; 6, 13 – fender support brackets; 7, 8, 9, 10,
17, 19, 20, 23, 24, 28, 30, 33 – handrails; 11, 48, 52 – plates; 12 – auxiliary fender; 15 – step plate; 16 – bracket support; 18 – rear bonnet;
21 – right fender; 25, 27, 37 – brackets; 26 – support beam; 29, 32 – auxiliary left fenders; 31 – left fenders; 34, 35, 36, 38, 39, 41, 42, 47,
49, 50 – bolts; 40, 51 – adjusting plates; 43 – struts; 44, 45 – holders; 46 – screw (М8х20)
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Figure 7 – Installing the fins (sheet 2 of three)
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Figure 7 – Installing the fins (sheet 3 of three)
Table 1 – Fins fastening parts

Position (see Figure) Description Position (see Figure) Description
34 Bolt М10-6gx35 41 Bolt М24x2-6gx70
35 Bolt М24x2-6gx60 42 Bolt М12-6gх30
36 Bolt М10-6gx30 47 Bolt М24х2-6gx110
38 Bolt М12-6gx45 49 Bolt М10-6gx25
39 Bolt М8-6gx25 50 Bolt М16-6gx50
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Install and secure handrail 28 to the additional left fender 29 using bolts 42 (M12-6gh30, 3 pcs.)
according to the section K1 – K1; fasten the handrails 30 and 28 together by bolts 42 (M12-6gh30,2 pcs.) in
according to the section M1– M1.
Install the handrails 19, 8 and 17 on front bonnet 1 similarly to the above mentioned in accordance with
sections K1– K1, J – J having installed holders 44, 45 and struts 43 in accordance with sections B1 – B1 and
A1 – A1.
Mount auxiliary fenders 12, 32 and plate 11 and fasten them to left fender and between each other by
bolts 36 (М10-6gх30, 4 bolts) in accordance with section К – К, by bolts 39 (М8-6gх25, 3 bolts) in accordance
with section O1 – O1, bolts 39 (M8-6gh25, 5 pcs.) with nuts according to the sections H – H and G – G.
Fasten step plates 15 by bolts 42 (М12-6gx30, 8 bolts) to bumper according to section N – N.
Fasten ladders 5 and 14 by bolts 34 (М10-6gх35, 8 bolts) according to section С – С.
Fasten guard rail 10 by bolts 34 (М10-6gх35, 2 bolts) and nuts according to view P1, by bolts 39
(М8-6gх25, 2 bolts) and nuts according to section Q1 – Q1.
Install and secure the braces 2 in the brackets 37 between the bracket of the fender 6 support and the
right fender 21, bracket 13 of the fender support and left fender 31 in accordance with cross-section F – F us-
ing 38 (М12-6gх45, 4 pcs.) with nuts.
Join air cylinders that are fastened at the right fender with the air ducts of the pneumatic starting system
as well as with the receiver of the pneumatic system. Fasten pipes by cleats.
After fenders elements mounting unscrew the ring bolts.
Fasten ladder at oil tank by bolts М12x25 (4 bolts) with washers.
3.7 Installing the engine air supply system

Installing the engine air supply system for BELAZ-75131, BELAZ-75135 and BELAZ-75139 dump
trucks.
Place the air filters 4 (see Figure 8) into the front fender stays’ bracket recesses and use the bolts 10
(M16-6gx40, 8 pcs) to fasten them.
Install the pipelines 2 and use the hoses 3 and 7 to connect them with the air filter nozzles and pipelines
1 and 8. Tighten the bolts to fasten the hoses on pipelines by clamps. Mount the supports 6 (2 pcs) on the
pipelines and use the clamps with nuts and washers to fasten them.
Figure 8 – Installing the engine air supply system for BELAZ-75131, BELAZ-75135 and BELAZ-75139 dump trucks:
1, 2, 8 – pipelines; 3, 7 – hoses; 4 – air filter; 5 – bracket; 6 – support; 9, 12 – nuts; 10, 11 – bolts
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Installing the engine air supply system for BELAZ-75137, BELAZ-7513A and BELAZ-7513B dump
trucks.
Place the air filters 4 (see Figure 8a) into the hollows of the fenders front supports and fasten them using
bolts 16 (M16-6gx40, 16 pcs).
Install the pipelines 8 into the brackets 7. Connect pipelines 8 with the air filters 4 branch –pipes using
hoses 5 as do using hoses 10 with pipelines 1 and 2.
Interconnect additionally the pipelines 1 and 8, 2 and 8 using supports 3 (2 pcs).
Fasten pipelines 8 in the brackets 7 using clamps 6 (2 pcs), tighten the nuts on the clamps applying the
torque of 15 – 20 N.m.
Fasten hoses 5 using clamps 15 (16 pcs) as do the hoses 10 using clamps 9 (4 pcs). Tighten the nuts of
the clamps 9 applying the torque of 10 – 12 N.m.
Figure 8a – Installing the engine air supply system for BELAZ-75137, BELAZ-7513A and BELAZ-7513B dump trucks:
1, 2, 8, 12, 14 – pipelines; 3 – support; 4 – air filter; 5 – hose; 6, 9, 15 – clamps;7 – bracket; 10 – hose; 11 – branch-pipe; 13 – air
filter clogging sensor; 16 – bolt
Installing the engine air supply system for BELAZ-7513 dump trucks.
Place the air filters 1 (see Figure 8b) into the front fender stays’ bracket recesses and use the bolts
(M16-6gx40, 16 pcs) to fasten them. Install the pipelines 5 into the brackets 4.
Use the hoses 2 to connect the pipelines with the air filter nozzles, and use the hoses 6, nozzles 8 and
elbows 9 to connect the pipelines 11 and 14. Tighten the bolts to fasten the hoses on pipelines by clamps.
Mount the supports 7 (2 pcs) on the pipelines and use the clamps with nuts and washers to fasten them.
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Figure 8b – Installing the engine air supply system for BELAZ-7513 dump trucks:
1 – air filter; 2 – hose; 3, 10 – clamps; 4 – bracket; 5, 11, 14 – pipelines; 6 – hose; 7 – support; 8 – nozzle; 9, 13 – elbows;
12 – clogging sensors; 15 – cover
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3.8 Installing the cab

Turn off the temporary bolts, fasten the cab and dismantle it from the prop which being used during the
transportation. Install the cab 1 (Figure 9) with the cushion 4 on the bracket fastening the left-hand fender and
fasten the cab by means of the bolts 3 (М30х2-6gх135, 12 pcs) with the nuts and the lock nuts 5, installing the
upper plates 2 and the bottom plates 6. The tighten torque of the nuts is 400 – 500 N.m.
Perform adjustment of doors 7 in open position to reach the maximal open state avoiding contact of
doors with fenders elements and other elements (see view B). Perform adjustment by means of position of
stoppers 10. With unavailability of elements preventing maximal possible opening state of door 7 at extreme
position of the stopper 10 the gap value is not regulated.
Figure 9 – Installation of cabin:

1 – cabin; 2, 6 – plates; 3, 9 – bolts; 4 – pad of the cabin support; 5 – nut; 7 – cabin door; 8 – handrail; 10 –stopper
3.9 Connecting the cab equipment

If the cab is removed for the dump truck transportation in a partially disassembled condition, the ends of
hoses, hydraulic system pipelines and electric harnesses disconnected from each other shall be tagged, with
the connection numbers inscribed on the tags.
After the cab installation, as a part of the dump truck reassembling procedure, connect the high-
pressure hoses to the nipples of the pump batcher 1 (see Figure 10), to the elbows of the parking brake control
valve 4, and to the elbows of the brakes control valve 6. Fasten the hoses under the bottom using inserts 10,
plates 8, studs 11, 12 and nuts 9.
Connect the air line from the pneumatic system receiver to the driver seat’s pneumatic cushioning gear
and use the clips to fasten the air line.
Pull the cab heater hoses through the holes in the cab bottom and use the clamps to fasten them on the
branch-pipes of the heater radiator. The hoses shall be inclined to the engine throughout their full length.
Perform assembling of air conditioner hoses from the cabin to the compressor over the dump truck
chassis (on the inner side of the second cross-bar left stanchion), preliminarily having interconnected them by
means of quick-split couplings 1 and 2 (see in figure 11).
Charging the air conditioner with Freon, its commissioning and repair shall be performed in ac-
cordance with the Operating Manual for the air conditioner by the specialists of the air conditioner suppli-
er company or their regional representatives.
ATTENTION: PRIOR TO STARTING THE ENGINE AFTER ASSEMBLING IS FINISHED MAKE SHURE THAT
AIR CONDITIONER HOSES ARE INTERCONNECTED CORRECTLY BY MEANS OF QUICK-SPLIT COUPLINGS
EVEN SHORT TIME TRANFER OF THE ENGINE TORQUE TO THE AIR CONDITIONER COMPRESSOR WHEN
HOSES ARE NOT CONNECTED (OR CONNECTED IN A WRONG WAY) WOULD LEAD TO AIR CONDITIONER
FAULT AND TO THE SEALING FAILURE OF THE AIR CONDITIONING SYSTEM.
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Figure 10 – Connecting the hydraulic system hoses

a) for the steering gear; b) for the brake systems:
1 – pump batcher; 2 – steering gear high pressure hoses; 3 – chute; 4 – parking brake control valve; 5 – console with controls;
6 – brakes control valve; 7 – brake system high pressure hoses;. 8 – plate; 9 – nut; 10 – insert; 11, 12 – studs; 13 – nipple;
I – to the rear brakes hydropneumatic accumulator; II – to the rear brakes’ wheel cylinders; III – to the front brakes hydropneu-
matic accumulator; IV – to the front brakes wheel cylinders; V – drainage to the oil tank (via brakes control valve); VI – to the hydropneu-
matic accumulators of the parking brake and steering gear; VII – to the parking brake cylinders; VIII – drainage to the oil tank;
IX – drainage from the parking brake control valve
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Figure 11 – Connection of the air conditioner hoses:

1, 2 – quick-split couplings
After fastening the pipelines under the cab fit the protective shroud 3 of the cab floor which gets opened
over the hinges 2 and protects units mounted under the cabin from dirt through the bracket 1 (Figure 12) and
fasten it to the cab floor stiffeners by means of the bolts 9 (М10х30, 3 pcs,).
When repairing or servicing to provide access to the units under the cab turn off the thumb nuts 5 and
take down the protective shroud 3.
Figure 12 – The installation of the protective shroud of the cab floor:

1 – bracket; 2 – hinge; 3 – protective shroud; 4 – front bracket; 5 – thumb nut; 6 – plate; 7, 8, 9 – bolts
Connect the harnesses of the electric equipment mounted on the chassis to the connectors in the cab
rear in accordance with tags (or labels) and the electric wiring diagram.
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Mount brush holders 1 and 5 (figure 13) ready-fitted with brushes 3 and 6 so that the brushes are in
lowermost position when wiper is turned off.
Figure 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
Mount and fasten the rear view mirrors (see Figure 14). When installing the rear view mirrors with elec-
trical heating pull the wire harnesses from the cabin to the mirrors and fasten the harnesses to the fenders
parts using cleats with gaskets and clamps (on the stanchions).
Figure 14 – Installing the rear view mirrors:

1, 2 – exterior mirrors; 3 – shield; 4 – link; 5 – nut; 6 – bolt
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3.10 Installing the traction electric drive control cabinet

Installing the control cabinet for BELAZ-75131, BELAZ-75135 and BELAZ-75137 dump trucks
(AC/DC electric transmissions).
Use the bolts12 (M24x2x52, 8 pcs, see Figure 15) with flat and spring washers (see B view) to fasten
the cabinet fastener brackets 2 and 4 on the frame crossbeam.
Sling the traction electric drive control cabinet 1 and put it on the brackets. Connect the suction air duct
6 on the control cabinet rear wall with pipeline 8 by hose 7 and fasten it by clamps having tightened clamps
nuts.
Fasten the cabinet on the brackets 2, 4 and on the brackets 3 mounted on the frame crossbeam using
bolts 13 (M16x60, 8 pcs) with nuts, flat and spring washers. Use the adjusting washers 14 to eliminate the
cabinet door misalignment during the cabinet installation procedure.
Figure 15 – Installing the control cabinet for BELAZ-75131, BELAZ-75135 and BELAZ-75137 dump trucks:
1 – control cabinet; 2, 3, 4 – brackets; 5, 6 – suction air ducts; 7 – hose; 8 – pipeline; 9 – branch-pipe; 10 – traction generator;
11 – the engine; 12, 13 – bolts; 14 – adjusting washers
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Installing the control cabinet for BELAZ-7513 and BELAZ-7513A dump trucks (AC electric trans-
missions manufactured by “General Electric” Сompany).
Sling the control cabinet 2 (see Figure 15a) and put it on the brackets mounted on the frame crossbeam
6. Use the adjusting washers 5 to set the cabinet position.
Use the bolts 4 (M24x2x100, 4 pcs) with nuts, flat washers and spring washers to fasten the cabinet on
the brackets. Connect the suction air ducts and the power cabinet ventilation systems (С view).
Figure 15a – Installing the control cabinet for BELAZ-7513 and BELAZ-7513A dump trucks:
1 – dynamic braking unit; 2 – control cabinet; 3, 4 – bolts; 5 – washer; 6 – crossbeam; 7, 18 – air ducts; 8, 11, 17, 20 – hoses;
9, 13 – branch-pipes; 10, 12, 15, 16, 19, 21, 22, 23 – hold-downs; 14 – traction generator
Installing the control cabinet for BELAZ-75139 and BELAZ-7513B dump trucks (AC electric
transmissions manufactured by “Power Machines” Сompany).
Sling the control cabinet 2 (see Figure 15b) and put it on the brackets mounted on the frame crossbeam.
Use the adjusting washers 9 to set the cabinet position.
Use the bolts 10 (M24x2x100, 4 pcs) with nuts, flat washers and spring washers to fasten the cabinet on
the brackets. Use the hose 3 to connect the suction air duct 4 with the nozzle 6. Use the clamps 16 to fasten
the hose.
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Figure 15c – Installing the control cabinet for BELAZ-75139 and BELAZ-7513B dump trucks:
1 – braking unit to be ventilated; 2 – control cabinet; 3 – hose; 4 – air duct; 5 – mesh; 6, 8 – nozzles; 7 – traction generator; 9, 12,
13 – washers; 10, 14, 18 – bolts; 11, 17 – nuts; 15 – gasket; 16 – clamp
3.11 Connecting the traction electric drive harnesses and wires

Wiring shall be carried out in accordance with the wiring diagrams; the wires shall be connected to the
electric machines and equipment in accordance with electric circuit diagrams available with operation docu-
ments. Appropriate drawings and circuit diagrams are delivered with each dump truck model.
General requirements for wiring:
– wires and harnesses must never be sharply bent, broken, bared or damaged otherwise;
– wires must never be in contact with hydraulic hoses and metal parts, sharp edges of the truck units
beyond fastening points and sharp edges of the input holes. Wires must never be in contact with hot parts of
the truck;
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– wiring bends radii must never be less than five times the wire diameter;
– if the ambient temperature is below -40ºC, the wires having the outer diameter more than 20 mm shall
be pre-heated to make them more flexible. However, the pre-heating temperature must not exceed 20ºC;
– place wires and harnesses in their appropriate positions and use rubber-padded clips, clamps and
cramps to fasten them;
– fasten additionally power cables connected to the vented brake unit to the rods of the unit framework
using plastic clamps with width of at least 8 mm and distance of 100mm.
Pass the wires into the traction electric drive control cabinet through the holes in the rear wall in accor-
dance with the mounting diagram and labels and connect the wires, in accordance with the electric circuit dia-
gram, to the terminal panels and electric devices.
3.12 Installing the exterior lighting and light signalling equipment

Perform installation and connection of the outer lighting instruments, light and sound signalization in ac-
cordance with figure 16, assembly diagram and electric diagrams, attached to the operation documentation.
Install and secure four low-beam headlights 18 (cross-section K – K and L – L) in brackets 17 (figure 16)
and two upper-beam headlights 15 (cross-section H – H) in brackets 16, adhering dimensions given in sections
during the installation.
Install and secure two front lanterns 19 (cross-section M – M) in brackets 20.
Install and secure two fog lamps 31 to the bumper bracket (section S – S).
Install lantern 3 illuminating ladder (cross section B – B) and fasten it to the side bonnet using screws 2
(М4х14) with flat and spring washers.
Fasten two side turn indicators 7 (cross section D – D) to the in brackets 6 using screws 8 (М4х10) with
nuts, flat and spring washers.
Install and secure working headlamp 14 of the deck illumination on the bracket 34 (view T) of the cabin
24 (view O). Beacon 37 (orange) is mounted at bracket 34 near headlamp 14 and fastened by bolts (М6х25)
with nuts and washers by customer order.
Install two working lights 4 (view C) illuminating side area and secure them on front side fender handrails.
Install three working headlamps 4 illuminating operation area and secure them on rear side handrails (view E)
and on the fenders bracket 12 (view F).
Install and secure two headlights 14 illuminating the engine compartment (view G) inside the motor area.
Install and fasten by nuts on the fuel tank 21 the lantern 22 (view N) for checking fuel overflow.
Install sound electrical signals 27 and 28 and secure them on the handrail 25 (view P) using bracket 26
and bolts 11 (M8x22, view V) with nuts and spring washers.
Install and fasten by nuts the sidelight with cat eye device 36 (view X) on the additional fenders bracket.
3.13 Installing the rear lights and lamps

Perform installation and connection of the taillights, instruments of the light and sound signalization in
accordance with figure 17, assembly diagram and electric diagrams, attached to the operation documentation.
Install turn indicators 24 and taillights 1 and secure them in the brackets of the rear lights 23 (Figure 17)
using nuts 19 (M6) (view L) with washers; fasten cover 18 to the brackets using bolts 12 (M6x16) with
washers.
Fasten the brackets of rear lights 23 with shock absorbers 21 and the clamping plates 22 (view M) using
bolts 20 (M6x25 ) with nuts to the body brackets.
Pull wire harnesses 11 through the protective pipes 15 on the body to brackets of rear lights 23, having
installed bushings 14 at the ends of the protective pipes.
Connect the wire harnesses sockets 10 with lanterns. Fasten wire harnesses on the body by means of
cleats 16 and 13 (views А and G) with gaskets and bolts 12 (M6x16) with washers.
Install and secure mudguards 17 of taillights using bolts 7 (M8x22) (view K) with nuts and washers.
Install rear lights 1 (3 pieces) and rear fog lamp 2 and secure them to the frame brackets using nuts
(M6) with washers, then do working light 6 (cross section C – C), reversing beep 8 (view D) securing by bolts 7
(M8x22) with nuts and washers.
Install marker light 4 (view B) with cat eye device and secure it to the fenders bracket using screws 3
M6x16) with nuts and washers.
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Figure 16 – Installation of units of outer illumination and light-signaling (sheet 1 of two)
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Figure 16 – Installation of units of outer illumination and light-signaling (sheet 2 of two):

1 – drain hole; 2, 8, 34 – screws; 3 – rear light; 4 – working light (5pcs); 5, 9, 11, 35 – bolts; 6, 12, 16, 17, 20, 32, 37 – brackets;
7 – side turn indicator (2 pcs); 10 – clamp; 13 – gasket; 14 – working light (3 pcs); 15 – upper-beam headlight (2 pcs); 18 – working light
(4 pcs); 19 – front light (2 pcs); 21 – fuel tank; 22 – additional side turn indicator; 23 – ring; 24 – cabin; 25 – handrail; 26 – bracket of sound
signals; 27, 28 – sound signals; 29 – cover; 30 – buffer; 31 – working light (2 pcs); 33 – bushing; 35 – switch; 36 – sidelight with cat eye
device; 37 – beacon
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Figure 17 – Installation of the rear lights and taillights:

1 – taillight; 2 – rear fog light; 3 – screw; 4 – rear marker light with cat eye device; 5 – bushing; 6 – working light; 7, 12, 20 – bolts;
8 – reverse motion beeper; 9 – pin type wedge-latch; 10 – pin type socket; 11 – wire harness; 13, 16 – cleats; 14 – bushing of the flexible
hose; 15 – wires protective tube; 17 – mudguard; 18 – cover; 19 – nut; 21 – bracket shock absorber; 22 – clamping plate; 23 – bracket of
taillights; 24 – rear turn indicator; 25 – cat-eye
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3.14 Assembling and welding the body

At the site for welding works with the body made of high-strength steel, ambient temperature shall be
0
higher than 0 C, and the site shall be protected against precipitations and draught. For deriving a qualitative
welded connection quality of used electrodes and preparation of surface to welding has the important value.
The electrodes to be used for the body welding are placed in the SPTA box.
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
counteforts, for welding and repairing the frame elements;
о
Electrodes are to be stored in a dry heated premise with temperature not below plus 16 С and relative
humidity of air not exceeding 60 %. Directly before use electrodes should be baked according to regime rec-
ommended by manufacturers: Prior to baking, check electrodes cores whether there is no rust, destroying
coats of one – two electrodes of each brand. Rust is not admitted.
Use tightly closed containers to deliver the baked electrodes to the work site and to store them. The con-
tainer must protect electrodes from moisture and dirt.
The DC welding equipment with ammeters shall be used for body welding. The reversed-polarity current
shall be used for welding.
Right and left parts of body, as well as the protective baffle are marked with the same number.
Prior to assembling, places of seams and mating surfaces of body parts are to be cleaned of dirt, un-
oiled, smoothed by abrasive disk or sandblasting up to complete removal of rust, paint, scale and other dirt in-
gressions. Perform smoothing at place, equal to seam width plus 20 mm towards both sides
о
Prior to welding dry the edges to be welded and zone around seams by heating up to 60 – 80 С with
distance of 150 – 200 mm towards both sides.
See Table 2 for distinctive dimensions of dump truck bodies. For L1 and L2 dimensions see Figure 18.
Table 2 – Distinctive dimensions of bodies
Dimension 75131-8500006-32, 75137-8500006-12 75131-8500006-42, 75131-8500006-50, 75135-8500006-12
L1 (mm) 340 225
L2 (mm) 961 1076
The parameters of the weld seams depicted on Figure 18 must meet the values listed in Table 3.
Table 3 – Weld seam parameters
Seam No. Seam designation Seam leg (mm) Seam No. Seam designation Seam leg (mm)
1 State Standard 14771-76-T1 +2 11 State Standard 5264-80-C12
6 -1
2 State Standard 14771-76-T1 +2 12 State Standard 5264-80-C17
8 -1
3 State Standard 14771-76-T1 +2.5 13 State Standard 5264-80-C21
10 -1.5
4 State Standard 14771-76-T1 +2.5 14 State Standard 23518-79-T1
12 -1.5
5 State Standard 14771-76-T1 +3 18 See E-E sectional view
16 -2
6 State Standard 14771-76-H1 +2 19 See C-C sectional view
8 -1
7 State Standard 14771-76-H1 +2.5 20 See P sectional view
10 -1.5
8 State Standard 14771-76-H1 +2.5 21 State Standard 14771-76-T6
12 -1.5
9 State Standard 14771-76-H1 +3 22 State Standard 23518-79-У1
16 -2
10 State Standard 5264-80-C8
Notes
H1: lap weld, one-sided, full-penetrated
T1: tee weld, one-sided, full-penetrated
C8: butt weld, one-sided, single-bevel
C12: butt weld, double-sided, single-bevel
C17: butt weld, one-sided, double-bevel
C21: butt weld, double-sided, double-bevel, full-penetrated
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Figure 18 – Assembling and welding the body (sheet 1 of two):

1 – shield; 2, 12, 19 – reinforcement members; 3, 4, 5, 14 – straps; 6, 7 – left and right components of the body; 8, 15 – floor straps;
9, 18 – plates; 10, 13 – bolts; 11 – mounting bracket; 16 – front panel; 17 – inclined front reinforcement member of the floor
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Figure 18 – Assembling and welding the body (sheet 2 of two)
Figure 19 – Weld passes in a block and multi-pass seams
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Perform welding by electrodes applying short arc with fillets width not more than three electrode diame-
ters at regimes specified in table 4.
Table 4 – Welding modes

Current (a) vs electrode diameter (mm)
Seam spatial location
4.0 5.0 6.0
Flat vertical position 50 – 200 200 – 250 Flat welding position only, 220 – 280
Horizontal overhead position 120 – 160 160 – 200
When the arc is broken while welding clean the crater of cinder and only after that actuate the arc.
Replace electrode and finish the fillet only after the crater is filled with metal.
Welding of floor butt is to be performed by module method with dividing of seam length into 6 – 8 mod-
ules with length of 800 – 1000 mm. Begin welding of floor from central module. After central module is welded,
welding of other modules is to be continued towards both sides from the center. When two welders work, they
weld two central modules simultaneously (one module to each welder), then they weld simultaneously one
next module by each welder.
Joining of modules in places of crossing with other seams is not admissible. The end of the extreme
module of front floor panel should be ended at distance of 50 – 100 mm from front body side.
Fillets passing within one module is carried out by run along or from the middle to the ends. When two
first runs performing, shift the beginning and the end of each fillet in the module relatively the previous one by
20 – 30 mm. A welding of each next module is to be performed with overlapping of previous module seams(by
20 – 30 mm (figure 19). Perform welding of the seam in module without pauses till the splicing is completely
filled.
The first fillet is to be made strengthened with the section height of 5 – 7 mm. Make first layer as well as
separate next layers using electrodes УОНИ 13/55 of Э50А type (“soft layers”). Total quantity of “soft” layers
should not exceed 25 – 30 % of total seam section. When welding with “soft” layers first runs are possible to be
performed without overlapping. Other layers of weld seam are made using electrodes АНП-2 of Э70 type or
УОНИ 13/65 of Э60 type.
Make the last layer using electrodes АНП-2 of Э70 type or УОНИ 13/65 of Э60 type.
Fillets of last weld seam layer should have smooth linking with each other as well as with surface of
base metal. The width of last layer fillets should not exceed 15 mm.
After welding of each fillet and a seam as a whole, thoroughly smooth out seam and area around it from
cinder and metal spits.
After welding is finished, maintain by heating the temperature of weld seam and area around it at
о
150 – 200 С during 30 – 40 minutes. The temperature of weld seam before heating should be not less than
о
200 С. With the purpose of reduction of cooling intensity, cover weld seam area by asbestos sheet.
Assembling and welding procedure:
– put the right component 7 (see Figure 18) and the left component 6, bottom up, on the side board rein-
forcement members. Place the plates 9 (130x80x40, 8 pcs), and use the bolts (M24x2x100, 16 pcs) with the nuts
to fasten the components on the mounting brackets. Here, the misalignment between the roots of grooves in butt
joints must not exceed 2 mm. Fasten the front board on the mounting brackets and use the bolts (М24х2х52,
8 pcs) with the nuts;
– use the electrodes, УОНИ 13/55 of Э50А type, to weld the coupling plates to the side shelves of
crossbeams in the counterforces of the left component.
The plate in the area of supporting brackets is to be welded by strengthened seam;
– use the electrodes, УОНИ 13/55 of Э50А type, to weld the upper shelves of crossbeams in counter-
forces to the coupling plates and to each other (see C – C and E – E sectional views);
– loosen the body floor mounting brackets (unscrew the nuts by one turn). Turn the body over (bottom
down) and place the body front part on the pads to position the floor approximately horizontally;
– weld the body floor along the mounting joint (see C – C and E – E sectional views). Before welding,
pre-heat the edges to be jointed by welding, and the area near the seam;
– remove the body front part from the pads and place the supports under the rear part to tilt the body
front board;
– weld the body front board along the mounting joint (see M – M and K – K sectional views). Observe
the recommendations listed for the body floor welding procedure; however, heating before and after the weld-
ing is not required.
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The board seam length shall be subdivided into 2 – 3 blocks, 800 – 1200 mm each. Within each blocks,
beads shall pass throughfeed. Weld the bottom block, starting from the incompletely penetrated section
(500 – 100 mm) of the front panel of the body floor. Use УОНИ 13/55 of Э50А type electrodes (4 mm diame-
ter) to make the first pass.
Two welders should be invited to weld the joint between the floor and the board in order to complete the
butt seam within one working shift, observing the required heating parameters within the weld area;
– with the front board joint welded completely, put and weld the diamond straps 14. Before placing the
straps 3, 4, 5, 14, use a grinding wheel to remove the seam reinforcement down to the plane of surfaces of
parts to be jointed;
– put and weld the rectangular strap 15 (see N – N sectional view);
– fasten the shield parts. For this purpose, use the bolts M12x38 (for the mounting brackets 1, see Fig-
ure 20), the bolts M12x30 (for the mounting brackets 2), and the bolts M24 (for the mounting brackets 3).
Then, weld along the joints see figure. Upon welding completion, remove the mounting brackets 3 and grind
their welding areas;
– mount the protective shield 1 (see Figure 18) and use the mounting brackets to fasten it on the side
boards. For this purpose, place the plates (130x80x40 mm, 4 pcs), and use the bolts 10 (M24x2x100, 8 pcs, G
– G sectional view) with the nuts to fasten the protective shield. Use the bolts 13 (M16x70, H – H sectional
view) with nuts and flat washers to fasten the shield on the front board. The shield plane I must be parallel to
the plane II (nonparallelism must not exceed 20 mm at end points);
– use УОНИ 13/55 of Э50А type electrodes to weld the shield to the side boards and to the front board
(see G – G and H – H sectional views);
– make seams No.2 and No.6 (see H – H sectional view) to weld the reinforcement members 12 to the
shield and to the front board. Turn the body over (bottom up) and completely weld the shield and the rein-
forcement members 2;
Figure 20 – Assembling and welding the protective shield:

1, 2, 3 – mounting brackets
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– place and weld six octagonal straps 3 (10 mm thickness), one strap 5 and one strap 4 (16 mm thick-
ness) at six faces;
– remove the bolts with nuts from the mounting brackets, and remove the plates 9;
– use УОНИ 13/55 of Э50А type electrodes to make a back weld for the mounting weld seam of the floor
and front board. Before making a back weld, a grinding wheel should be used to remove the weld root (2 – 3 mm
depth).
Upon welding completion, remove the mounting brackets from the body bottom and inner surfaces, flush
with the floor and boards. Grind the nicks to make them lustring. Then, use ANP-2 of type Э70 or УОНИ 13/55
of Э50А type electrodes to seal the nicks, and use a grinding wheel to grind them flush. Never remove mount-
ing brackets, parts or welded assembling accessories by impacts or by breaking them off;
– install and weld the latches 20 (view F and L–L);
– turn the body over (bottom down).
– remove the mounting brackets fastening the protective shield with the side boards, and make a back
weld for the weld seam made earlier;
– place and weld two front reinforcement members 19 (see G–G sectional view) and the plates 18 (see
O view) to the front board and side boards;
– use the gas cutting unit to remove (flash with the floor and boards) the parts that were welded to the
body inner surfaces for fastening during transportation by railway.
Visually inspect the weld seams and check their dimensions to ensure that the quality of welded joints is
appropriate. Each seam shall be visually inspected throughout its full length.
Welded joints must be free of defects as follows:
– cracks (irrespective of their types and directions);
– areas of incomplete fusion or poor penetration;
– porous areas or areas containing slag inclusions;
– separate pores and inclusions, more than 1 mm diameter, if there are more than 4 defects within
400 mm seam length, and the distance between defects is less than 50 mm;
– unfilled craters;
– nicks on the base metal;
– base metal undercuts deeper than 0.5 mm.
Use gas cutting to remove the seam sections with impermissible defects (such as cracks, areas of in-
complete fusion or poor penetration, porous areas), grind and weld up the resulting grooves. Also, weld up the
seam sections with undercuts and incomplete cross-sections.
If, as a part of the defective seam welding-up procedure, metal shall be removed from the seam area,
pre-welding and post-welding heating is necessary.
Use paint delivered with the dump truck to cover the weld seams and areas near the seams.
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Installing the put-on boards, supplementary shield and body lining.

To provide more space in the body for transportation of overburden rocks, minerals and other less-
dense materials, put-on boards may be mounted on the dump truck body. For the location of parts of put-on
boards and for the weld seams parameters, see Figure 21 and Table 5.
Figure 21 – Installing the put-on boards:

1 – front right put-on board; 2 – front left put-on board; 3, 4, 9 – panels (10 mm thickness); 5 – middle right put-on board;
6 – middle left put-on board; 7, 8 – pad; 10 – rear right put-on board; 11 – rear left put-on board; 12, 13 – plugs
Seam Seam
Seam designation Note Seam designation Note
No. No.
1 See B detail 8 See D detail
section section
2 See C-C 10 State Standard 5264-80-C10 S=10 mm
sectional view
3 State Standard 11534-75-T1 β=1000 11 State Standard 5264-80-C10 S=12 mm
4 See G-G 12 State Standard 11534-75-У1
sectional view
5 State Standard 11534-75-T1 β=1350 13 State Standard 5264-80-У4
6 See G-G 14 +2
State Standard 5264-80-T1-Δ10 -1
sectional view
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Optionally, to prolong service life of the body, floor covering (lining) may be provided. For the floor cover-
ing sheets location and weld seams parameters, see Figure 22.
Figure 22 – Installing the floor covering:

1 – body; 2, 3, 4 – floor covering sheets (sheets thickness: 12 mm)
Optionally, to protect the driver's cab, the supplementary shield may be provided. For the supplementary
shield location and weld seams parameters, see Figure 23.
Figure 23 – Installing the supplementary shield:

1 – supplementary shield; 2 – body;
N1 – State Standard 5264-80-T1- Δ6; N2 – State Standard 11534-75-T1
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3.15 Assembling and welding the body for the coal-carrier dump truck
See above (Section 3.14, Assembling and welding the body) for the requirements concerning the condi-
tion of electrodes, surface preparation for welding, welding procedures and weld seam inspection.
The parameters of the weld seams depicted on Figure 24 must meet the values listed in Table 6.

Seam leg Seam leg
Seam No. Seam designation Seam No. Seam designation
(mm) (mm)
1 State Standard 14771-76-C8 See T view. 11 State Standard 23518-79-T1
2 +2.5 12
State Standard 14771-76-T1 10 -1.5 State Standard 23518-79-T2
3 +2.5 13
State Standard 14771-76-T1 12 -1.5 State Standard 14771-76-C19
4 +3 15 See L-L sectional view
State Standard 14771-76-T1 14 -2
5 +2 16 See P detail section
State Standard 14771-76-H1 6 -1
6 +2.5 17 See Q detail section
State Standard 14771-76-H1 10 -1.5
7 +2.5 19 See R-R sectional view
State Standard 14771-76-T1 12 -1.5
8 +3 20 See N-N sectional view
State Standard 14771-76-H1 16 -2
9 State Standard 14771-76-C17 22 See G-G sectional view
10 State Standard 14771-76-C21 23 See H-H sectional view
Notes:
T1 – tee weld, one-sided, square-edged;
T2 – tee weld;
H1 – lap weld, one-sided, square-edged;
C8 – butt weld, one-sided, single-bevel;
C17 – butt weld, one-sided, double-bevel
C19 – butt weld, one-sided, double-bevel, on the permanent backing;
C21 – butt weld, double-sided, double-bevel.
Body assembling and welding procedure:

– mount the body right component 16 (Figure 24) and the left component 11, bottom up, on the access
supports. Mount the middle component 8 and use the mounting brackets to fasten it to the left and right com-
ponents; for this purpose, place the plates 9 (180x130x40 mm, 12 pcs) and use the bolts M24x2x100 (48 pcs).
Mount the front board 15 and use the mounting brackets to fasten it to the side components; for this
purpose, place the plates 9 and use the bolts M24x2x100 (16 pcs). Also, use the mounting brackets and the
bolts M24x2x52 (6 pcs) with nuts to fasten the front wall 15 to the bottom panel;
– weld the crossbeams of the body floor to the coupling plates of the crossbeams in counterforces of the
side components along the upper shelves (L-L sectional view, seam N15) and the side shelves (seam N3).
Only with the butt weld completed, weld the floor crossbeams to the floor, and make other fillet welds, lap
welds and tee welds in the butt mounting weld area;
– use АНП-2 of Э70 type or УОНИ 13/65 of Э60 type electrodes to weld the front board reinforcement
members along the mounting joint;
– unscrew the nuts by one turn to loosen the body floor mounting brackets. Turn the body over, with the
body floor facing down. Unscrew the nuts by half-turn to loosen the front board mounting brackets;
– weld the body floor along the mounting joint (K – K sectional view), seam N10.
For the floor joints welding, block-by-block welding technique shall be used: the seam length shall be
subdivided into 6 – 7 blocks, 1000 – 1200 mm each. Welding shall be started from the central block. Upon the
central block welding completion, other blocks shall be welded, one by one, alternating the directions. If two
welders are working, two central blocks shall be welded at the same time (each welder shall work with one
block); then, the welders must proceed simultaneously to the next block, one by one.
The blocks must never be joined in the locations where they are crossed by other seams. The edge of
the last block in the front of the floor panel must be at 50 – 100 mm from the front board.
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Figure 24 – Assembling and welding the coal-carrier dump truck body (sheet 1 of two):
1, 9 – plates; 2 – protective shield; 3 – end plate; 4 – front beam; 5, 6, 7, 10, 12, 13, 19 – straps; 8 – body middle component;
11 – left component; 14 – reinforcement member; 15 – front board; 16 – right component; 17 – inclined floor reinforcement member;
18 – plug
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Figure 24 – Assembling and welding the coal-carrier dump truck body (sheet 2 of two)
Within a block, beads must pass throughfeed or from the middle to the edges. For the first two welding
runs, the start and end of each pass in the block must be shifted by 20 – 30 mm relative to the preceding pass.
The subsequent blocks shall be welded overlaying ("binding") the seams in the preceding block by 20 – 30 mm
(see Figure 19). The seam in the block must be welded without pauses until the groove filled completely.
The first bead must be made reinforced. The first bead cross-section height must be 5 – 7 mm. Use
УОНИ 13/55 of Э50А type electrodes to make the first pass and several separate subsequent passes ("soft"
passes). The total number of "soft" passes throughout the weld seam cross-section must not exceed
25 – 30%. If the "soft" passes are used, "binding" is not necessary for the first runs.
To make other passes in the butt weld, АНП-2 of Э70 type or УОНИ 13/65 of Э60 type electrodes shall
be used.
The beads in the seam last pass must be smoothly mated between each other and with the base metal
surface. Width of beads in the last pass must not exceed 15 mm;
– weld the body front board along the mounting joints (seams N9 and N10, see Figure 23, B view). Ob-
serve the recommendations listed for the body floor welding procedure. The board seam length shall be subdi-
vided into 3 blocks, 1000 – 1100 mm each. Within each blocks, beads shall pass throughfeed. Weld the bot-
tom block, starting from the incompletely penetrated section (50 – 100 m) of the body floor front. Use УОНИ
13/55 of Э50А type electrodes to make the first pass in the seam.
Two welders should be invited to weld the joint between the floor and the board in order to complete the
butt seam within one working shift, observing the required heating parameters within the weld area;
– place the straps 13 (275x275x10, 2 pcs), with the dimension observed (50 + 5 mm), and weld the
straps (seam N6).
Before placing the straps 5, 6, 7, 10, 12, 13, use a grinding wheel to remove the seam reinforcement
down to the plane of surfaces of parts to be jointed;
– weld the front board to the floor: seam N12 for the board, B view; seam N20 (N – N sectional view) for
the board stands;
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– weld the inclined floor reinforcement member 17, with the dimension observed (D – D sectional view,
seams N16, N17);
– weld the plugs 18 (E view, seams N3, N11, N19);
– place the strap 19, with the dimension observed (85±3 mm, B view), and weld the strap (seams N11,
N8);
– turn the body over, with the body floor facing up. Remove the bolts with nuts from the mounting brack-
ets, and remove the plates 9;
– place the straps 12 (2 pcs) and weld to the front board reinforcement member (seam N6), with the di-
mension observed (50±5 mm);
– use УОНИ 13/55 of Э50А type electrodes to make the back weld for the mounting weld seams of the
floor and the front board (seams N13 and N10). Before making the back weld, use a grinder to remove the
weld root by 2 – 3 mm depth. With the mountings weld completed, use the gas cutting unit to remove, flash
with the floor panels, the mounting brackets on the body bottom;
– weld the crossbeams to the floor panel in the butt welds area (seam N3, A view);
– place and weld the straps 5, 6, 7, 10, with the dimension observed (A view);
– place and weld the front beams 4 (6 pcs) and end plates 3 (6 pcs), seams N2 (A view);
– place the protective shield 2. Use the plates 1 (2 pcs), the bolts M24x2 (12 pcs) with spring washers
and the electric tacks to fasten the shield. The surface I nonparallelism relative to the surface II must not ex-
ceed 20 mm. Fitting may be carried out at the surface III;
– weld the protective shield to the body (M – M sectional view, seams N3, N4, N5, N19);
– weld the reinforcement members 14 (seams N2, N11);
use the gas cutting unit to remove (flash with the floor and boards) the parts that were welded to the
body inner surfaces for fastening during transportation by railway.
Installation of the impeding rails in the body.
To provide the optimal unloading weld the impeding rails 2 – 4 at the inner side surfaces as well as do at
the body bottom in accordance with figure 24a.
Figure 24а – Installation of the impeding rails in the body:

1 – body; 2 – rail 75138-8501934 (50х50х2500, 2 pcs); 3 – rail 75138-8501932 (50х50х2000, 2 pcs); 4 – rail 75138-8501936
(50х50х3000, 4 pcs);
№1 – State Standard 14771-76-Т1-Δ20+2
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3.16 Installing the body and the body position sensors

Before installing the body on the dump truck, apply lubricant (Litol-24) to the pins 18 (see Figure 25).
Sling the body. Align the body bracket holes with the frame bracket holes. The special hoisting fixture
and two tension members (for manipulations during the body transportation and installation) shall be used to
lift and install the body.
Mount the pins 18 on the outer sides. Previously, place the adjusting washers 19 between the bracket
supports and bosses to set the axial clearance in the support joints not exceeding 2 mm. The clearance shall
be determined in the zone of the least distance between the planes. Align the pin lock plate with the latch slit
and use the cover 17 and the bolts 16 (M16-6gx40, 4 pcs) with spring washers to fasten the lock plate.
Align, as far as possible, the discharge pipe nozzles with the hole in the bottom sheet of the body gas in-
take. For alignment, use oval holes in the bracket fastening the nozzle. The alignment tolerance between the
exhaust pipe and the hole И (А view) shall be Ø10 mm max.
Place the access pads between the frame side members and the body. Place the body on the pads.
Use Litol-24 lubricant to fill the cavities in the bearings of the upper heads of cylinders 2 in the dumping
mechanism. Align the head holes of the cylinder with the ear holes of the brackets. Place the cylinder upper sup-
port pins 12 and use the bolts 10 (M14-6gx42, 8 pcs) with spring washers. Place the ring 22 under the bolts.
Lift the body and remove the safety pads. Remove the suspension and the tension members from the
body.
Lubricate the joints in the body rear supports and in the dumping mechanism cylinders upper su p-
ports.
Use a crane to lift the body front and place the access pads between the frame and the body. Place the
shock absorbers 14 and use the bolts 15 (M10-6gx35, 64 pcs) with spring washers. Use the shims 13 to place
the shock absorbers 14 uniformly against the bearing surface of the frame side members.
The clearance between the shock absorber and the frame shall not exceed 1 mm. In several locations, a
wedge-shaped clearance, up to 3 mm, is permissible. Minimum compression of the shock absorber shall be
37 mm.
Measure the dimensions H between the discharge the support flanges of the pipes and the bottom sheets
of the gas intakes in four positions around the flange. Apply the marks at the respective points on the thrust rings
of the gas intakes, H+20 mm from the ring end, and use these marks to draw the setting line that shall be used to
weld the thrust rings. Place and weld the thrust rings of the gas intakes along the marking lines.
+1.2
Check the clearance (0 mm) between the body guides and the contact plates 6 (B – B sectional
view). Use the adjusting plates 5 if necessary.
Paint the weld seam and the area near the seams.
The engine exhaust is routed on the right side of the truck body tail through the openings between the
floor bearers closed by reflector plates.
Place the stone ejectors 21, use the pins 20 to fasten them to the brackets 20, install washers 23 and cot-
ter pins 24.
With the body mounted, install the body position sensor and the body lifting limiting sensor. To avoid the
sensors damage, install the sensors only when the body has been already mounted.
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Figure 25 – Installing the body:

1 – body; 2 – dumping mechanism cylinder; 3 – thrust ring; 4 – exhaust pipe; 5, 13 – adjusting plates; 6 – contact plate; 7, 10, 15,
16 – bolts; 8 – hopper cover; 9 – gasket; 11 – distance bushing; 12, 18, 20 – pins; 14 – shock absorber; 17 – cover; 19 – adjusting washer;
21 – stone ejector; 22 – ring; 23 – washer; 24 – cotter-pin
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Installing the body position sensor.

Install the body position sensor 2 (see Figure 26) at the frame rear crossbeam. Observe the dimension
+3
5 (A view).
The distance B from the body rear support axle to the axle of the bolts 3 (fastening the bracket 4) shall be
672 mm (for the coal carrier body,1200 mm).
Should the body be lifted to the angle exceeding 3°, the sensor operates; at this moment the pilot lamp
on the instrumentation panel lights up to warn the driver that the body is in the lifted position.
Figure 26 – Installing the body position sensor:

1 – body; 2 – sensor; 3 – bolt; 4 – bracket; В – dimension
Installing the body lifting limiting mechanism.

To ensure the automatic stopping of the body lifting, the limiting mechanism is intended. When the body
is lifted by 43 – 45° (lifting complete), it presses the movable part of the switch lever 13 (see Figure 27). The
lever rotates around its axis, activating the contactless sensor 7. It breaks the electrical circuit supplying the lift-
ing solenoid and the body stops automatically; as a result, the dynamical loads on the hydraulic cylinders de-
crease.
Before being installed, the switch lever 13 must rotate freely around its axis by half-turn. Install the
bracket 6 assembled with the mechanism parts, and use the bolts 5 to fasten it. Install the sensor 7 in the
bracket 9, with the dimension C observed (5±1 mm). The tightening torque for the sensor nuts shall be
40 – 52 N.m.
Within the scope of the comprehensive test, run the engine and operate the sensor as follows:
– loosen the nut 3 by one turn;
– list the body to separate the cylinders as far as possible;
– lower the body by 80 – 90 mm in the cylinder stroke direction. The dimension Н must be (700+20) mm;
– rotate the switch bracket 11 around its axle, with the dimension C = (10 ± 1) observed.
– tighten the nut 3 (the tightening torque shall be 320 – 510 N.m);
– to check the body operability, lift it and ensure that the body lifting limiting sensor operates. The di-
mension Н shall be (700 + 30) mm.
Apply Litol-24 lubricant of the threaded surfaces of pins 4, and insert the pins.
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Figure 27 – Installing the body lifting limiting mechanism:

1 – screw; 2, 5, 8 – bolts; 3 – nut; 4 – pin; 6, 9 – brackets; 7 – sensor; 10 – spring; 11 – switch bracket; 12 – spring tensioner;
13 – switch lever
3.17 Installing the mud guards

Install the front wheels mud guards 6, 9, 10, 11, 16 (see Figure 28) and the rear wheels mud guards 3.
Use the bolts, nuts, flat washers and spring washers to fasten the mud guards on the fastening brackets avail-
able on the fins, fenders and the body.
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Figure 28 – Installing the mud guards:

1, 2 – brackets fastening the mud guard; 3, 6, 9, 10, 11, 16 – mud guards; 4 – right bracket fastening the mud guard; 5, 15 – plate;
7, 8, 12 – mud guard brackets; 13 – brace; 14 – bracket ; 17 – reinforcement member
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3.18 Assembling the centralized automatic lubrication system

Connect the automatic lubrication system pipelines in accordance with numbers on the edges of discon-
nected pipelines and the hydraulic circuit diagram (see Operation Manual). Test the lubrication system opera-
tion in accordance with the Operation Manual.
Perform the installation of the lubrication system piping on the body for lubrication of the upper supports
of the dumping mechanism cylinders after the body is been installed. The length of hoses to the left support is
of (7260 + 50) mm, as to the right one is of (8560 + 50) mm. Secure hoses using cleats, bolts and washers.
Prior to installing the system, check the availability of lubricant in the truck units. Filling with grease
should be performed till its exit from safety valves or gaps.
Separate models and modifications of dump trucks are equipped with centralized automatic lubrication
system “Lincoln Centromatic”. The design, operation principle, adjustment and installation of the system ele-
ments and pipelines are given in the dump truck operation manual.
3.19 Installing the telemetric control system (TCS)

The system is intended for automatic tyre pressure monitoring, giving the driver visible and audible
warning signals and recording the date and time of occurrence and elimination of the fault.
For the technical specification of the system, description, maintenance and repair, see the operating
manual included in the operating documentation set and supplied with the shipment.
See Figure 29 for the front wheels TCS housings and transmitting modules installation procedure;
Figure 30, for the rear wheels TCS housings and transmitting modules installation procedure; see Figure 31
for the tyre telemetric control system mounting procedure.
To install the front wheels TCS housings and transmitting modules, proceed as follows:
– with the wheel installed and fastened, remove the adapter from the extension tube and screw it into
the TCS housing 6 (see Figure 29);
– use the captive nut to join the TCS housing to the extension tube;
– screw the transmitting module 5 into the TCS housing 6;
– inflate the tyre to set the rated pressure;
– carry out the soap emulsion test to ensure that the threaded connections are tight;
– use the bolts 4 to fasten the protective housing 3.
Figure 29 – Installing the front wheels TCS housings:

1 – wheel; 2 – front axle; 3 – housing; 4 – bolt; 5 – transmitting module; 6 – front wheels TCS housing
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To install the rear wheels TСS collectors and transmitting modules, proceed as follows:
– with the wheel installed and fastened, remove the adapter from the extension tube and screw it into
the TСS collectors 7 (see Figure 30);
– use the captive nuts to join the TСS collectors to the extension tube and the valve;
– use the bolts 6 to fasten the plate 4 fastening the TMS housing, to the wheel rim;
– use the nuts to fasten the TMS housings to the plate 4;
– screw the transmitting modules 3 into the TСS collectors 7;
– inflate the tyre to set the rated pressure;
– carry out the soap emulsion test to ensure that the threaded connections are tight;
– use the bolts 5 and 8 to fasten the protective housing 9.
For dump tracks BELAZ–7513-01 and BELAZ–7513-06 weld in thread bushing 12, use the bolts 5 and
11 to fasten the protective housing 10.
Figure 30 – Installing the rear wheels TСS collectors:

1 – wheel; 2 – rear axle; 3 – transmitting module; 4 – plate fastening the TCS housing; 5, 6, 8, 11 – bolts; 7 – collector;
9, 10 – protective housings; 12 – thread bushing;
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Figure 31 – Mounting the tyre telemetric control system:

1, 5 – clips; 2, 6 – gaskets; 3, 9 – bolts; 4 – washer; 7 – right side antenna; 8 – left side antenna; 10 – basic module; 11 – cable
strap; 12 – "CAN" wire harness; 13 – antenna cover; 14 – left fender
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3.20 Installing the video surveillance system

The truck is equipped with the video surveillance system consisting of four cameras, the monitor located
in the cab and the complete set of additional equipment.
See Figures 32 and 33 for the video surveillance system installation on the chassis and in the dump
truck cab.
Two side cameras are installed on the first vertical railing of the fender handrail under the upper horizon-
tal handrail on both sides of the dump truck and should be directed perpendicularly to the traffic and see the
situation from the distance of one meter from the dump truck.
Figure 32 – Installation of the video surveillance system on the chassis:

1, 2, 3, 4 – video cables; 5 – wiring clamp; 6 – tie; 7 – camcorder housing; 8, 16 – nuts; 9, 10, 17 – washers; 11, 18 – cameras;
12 – cleat; 13 – gasket; 14 – wire harness over the girder; 15 – bolt
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The front camera is installed on the central vertical railing under the upper horizontal handrail and
should be directed along to the traffic and see the situation from the distance of one meter from the dump truck
The rear camera should see the situation behind the dump truck, including the rear wheels.
Figure 33 – Installing the video surveillance system at the cab

1 – cab; 2 – wire harness; 3, 9 – bolts; 4 – clip; 5 – monitor; 6 – bracket; 7 – antivibration unit; 8 – light-protection cap; 10 – basic
unit for mounting; 11 – hinge bracket
Active Video Survey System.

Separate models and modifications of dump trucks are equipped with Active Video Survey System.
The System installation over the chassis and cabin of the dump truck is shown in figures 32а and 33а.
Installation of the video survey cameras is similar to describe bed above.
In addition to four cameras 17 there are the radar modules 3 installed on the dump truck chassis which
are intended for detection of distance to the stationary and moving objects within Operator’s survey area and
around the dump truck and for information transfer in addition to video cameras to the display installed in the
cabin.
After assembling of the dump truck fenders fasten the cameras and radar modules in brackets, pull and
secure cables according to figures, connect cables to the cameras and radar modules according to the
scheme of connections (attached to the set of the operation documentation).
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Figure 32а – Installation of the Active Video Survey System over chassis (sheet 1 of 2):
1 – cable tie; 2, 22 – brackets; 3 – radar module; 4, 6, 7 – cables (to radars); 5 – bolt; 8 – gasket; 9 – cleat; 10 – video camera
housing; 11, 18 – nuts; 12 – tie; 13, 26 – screws; 14 – radar bracket; 15 – cover; 16 – bushing; 17 – camera; 19, 20, 21 – armored cables
(to video cameras); 23 – terminator; 24 – power cable; 25 – wire harness over the cabin; 27 – interface cabinet
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Figure 32а – Installation of the Active Video Survey System over chassis (sheet 2 of 2)
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Figure 33а – Installation of the Active Video Survey System in the cabin:
1 – cleat; 2 – gasket; 3 – bolt; 4 – monitor; 5 – sealing bushing; 6 – wire harness of the low voltage equipment; 7 – wire harness;
8 – power cable; 9 – switching unit; 10 – bracket; 11 – screw
3.21 Installation of warning tags and labels

For information on the potential hazards associated with maintenance, repair of unit or performing works
in the dangerous there are warning tags installed at dump truck units.
The tag describes the precautions and ( or) the necessary actions to prevent the danger in the tag instal-
lation area.
When shipping the dump truck tags are stored in a box for operational documents .
Installation of warning tags at the truck units is to be performed in accordance with the figures given in
Chapter 2, " Safety precautions and warnings" of the Operation Manual, install the labels on the body in ac-
cordance with current manual Appendix F.
Before sticking degrease tags and labels surface, remove the technological film. Stuck tags should not
have bubbles, sags, gaps.
In case of dirtying clean the tag with rag wet by suds. Never use solvent, gasoline and other caustic liq-
uids.
3.22 Installing the fire extinguishing system
The fire extinguishing system shall be mounted, the electric equipment shall be connected to the power
supply system, and technical condition tests shall be carried out in accordance with the dump truck operation
manual and the system operation instructions.
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3.23 Installing the stone shields

Optionally, to provide further protection of tyres against the falling rock pieces during the dump truck
loading, the stone shields are welded to the body. For the stone shield location and weld seam parameters,
see Figures 34 (front wheels) and 35 (rear wheels).
Figure 34 – Installing the stone shields for front wheels:

1, 2, 3 – stone shields
Figure 35 – Installing the stone shields for rear wheels:

1 – body; 2, 4 – reinforcement member; 3 – stone shield;
N1 – State Standard 5264-80-T1- Δ8; N2 – State Standard 11534-75-T1; N3 – State Standard 11534-75-У3
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3.24 Installation of antennas alarming approaching the overhead power line

Installation of antennas alarming approaching the overhead power line is shown in Figure 36.
Figure 36 – Installation of antennas alarming approaching the overhead power line:

1, 5 – cleats; 2 – gasket; 3, 4 – antennas; 6 – pipe; 7 – right support bracket; 8 – cable tie;
I – to the right fendering stanchion; II – the left fendering stanchion; III – to the cab
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3.25 Installation of the bonnet shroud

For dump trucks operated in the areas with cold climate the side and lower engine bonnet shrouds are
additionally applied. Mounting of the engine side and lower shrouds is shown in figures 37 and 38.
To maintain the optimum temperature of the engine operation mode at negative ambient temperature
the warmth-keeping shroud 2 should be installed onto the bonnet 1 (Figure 39); it should be is attached to the
front part of bonnet using with bolts 4 with flat washers 3 and spring ones 5. To adjust the temperature of the
engine operation mode at variations of cooling air temperature there are flaps in the shroud – valves of shroud.
When transiting to the spring and summer operation period the warmth-keeping shroud should be re-
moved from the truck.
Figure 37 – Mounting of the engine side shrouds:

1, 3, 4, 5 – engine shroud; 2 – frame cross-beam N2
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Figure 38 – Mounting of the engine lower shrouds:

1 – engine shroud; 2 – frame; 3 – front axle lever; 4 – front shroud; 5, 6, 7, 8 – bolts
Figure 39 – Installation of the bonnet shroud:

1 – bonnet; 2 – bonnet shroud; 3, 5 – washers; 4 – bolt
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3.26 Installation of the fire extinguisher

On the customers’ order the dump truck is equipped with fire extinguisher.
Fasten the plate 3 on the bonnet left side handrail 1 (figure 40) by means of ties 4 using nuts 5 (М6,
4pcs.) with washers. Fasten the fire extinguisher 2 on the plate using bolts 6 (М8х20, 4 pcs.), nuts 7 with
washers.
Figure 40 – Installation of the fire extinguisher:

1 – handrail; 2 – fire extinguisher; 3 – plate; 4 – tie; 5, 7 – nuts; 6 – bolt
3.27 Installation of the service monitoring system

The Service Monitoring System can be installed on the customers’ order and it is intended for determina-
tion of the truck location, condition control, operation and technical truck parameters, data transfer over the cell
network to the server and displaying the information on the operator’s panel.
Installation of the antenna and the navigation unit of the system on the dump truck chassis is shown in
the figure 41. Directions on arrangement, mounting and connection of the system as well as order of the
equipment installation look in the system Operation Manual.
Figure 41 – Installation of the Service Monitoring System on the dump truck chassis:
1 – antenna; 2 – cable clip; 3 – gasket; 4, 7 – cleats; 5 – wire harness, 6 – pipe; 8, 12, 14 – nuts; 9 – bracket; 10 – navigation unit;
11 – tie; 13 – screw
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3.28 Installation of the load control system

Pull the wire harnesses 9 and 10 (figure 42) over fenders having secured them using cleats, gaskets,
bolts ans washers; connect the harnesses to the lights 1, 2 and 3.
Pull the wire harnesses, secure and connect them to the pressure converters 13 of the front suspension
cylinders 5, fuel level sensor 18 of the fuel tank, to the sockets in the traction electric drive control cabinet.
Figure 42 – Installation of the Load Control System:

1, 2, 3 – lights; 4 – nut; 5 – suspension cylinder; 6, 21 – bolts; 7 – gasket; 8 – cleat; 9, 10, 11, 22 – wire harnesses; 12 – connect-
ing cable; 13 – pressure converter; 14 – cable tie; 15 – control cabinet; 16 – fuel tank; 17, 19, 20 – protective shroud; 18 – fuel level sensor
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The load control system for indication of the dump truck load (tones) can comprise two digital displays 1
(figure 43) instead of color lights. Displays are installed in brackets 4 on the left fender (at the front side) and
on the right fender (at the rear side) and covered by lids 2.
Figure 43 – Installation of the digital displays for Load Control System:

1 – digital displays; 2 – lid; 3, 6, 7 – bolts; 4 – bracket; 5 – ring
3.29 Installation of the wheels chocks

Wheels chocks 5 (figure 44) are installed on brackets 3 and 4, which are fastened by bolts 6 to the
brackets of the fenders supports 2 over both truck sides. Wheels chocks on brackets are locked by latches 7.
Figure 44 – Installation of wheels chocks:

1 – buffer; 2 – bracket of the fender support; 3, 4 – brackets; 5 – wheel chock; 6 – bolt; 7 – latch
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4 DUMP TRUCK COMMISSIONING COMPREHENSIVE

TEST
BEFORE THE COMPREHENSIVE TEST INVOLVING THE ADJUSTMENT AND START-UP PROCEDURES AND
THE TEST RUN, READ AND UNDERSTAND THE SAFETY REQUIREMENTS, WARNINGS AND SPECIAL REQUIRE-
MENTS FOR OPERATION LISTED IN THE DUMP TRUCK OPERATION MANUAL.
Comprehensive test scope:
– visually inspect the dump truck to check its technical condition. Pay special attention to ensure that all
external threaded connections are securely tightened (fastening the diesel generator set, wheels, suspension
parts and assemblies, cardan shaft and electric machines);
– check the oil level in the assemblies, units and systems, fuel level in the tank and coolant level in the
engine cooling system; also, inspect the friction units to ensure that they are properly greased. For these pur-
poses, use the lubrication chart and the list of applicable lubricants (see operation manual).
Tied with drainage of working fluid from the hydraulic system, after the oil tank shutter is open remove
the air from the suction pipelines as well as from the pump, having unscrewed the plug on the suction branch-
pipe with magnet and the plug on the pump casing;
– check serviceability of controls and banners of the electronic instrumentation panel (further the EIP) in
accordance with EIP Operation Manual, lighting systems, light and audible alarm systems. Check the cab
heater and windscreen wiper operation. Ensure that the engine fan can be switched on by the operator, and
test the engine stopping system;
– check whether the fuel feed control actuator is adjusted properly. The actuator adjustment must pro-
vide minimum and maximum engine RPM for the idling mode. The engine temperature mode, oil pressure, en-
gine crankcase RPM must meet the recommended values listed in the dump truck operation manual;
– check whether the low-voltage electric equipment power supply system operates properly. When the
-1
engine RPM is of 800 min or higher, the color of the control banner on the EIP indicating onboard circuit volt-
age must be green (24 – 30 V). If, with the banner color is red (voltage is <22V or >30V) or yellow motor it
means that the power supply system is faulty;
– adjust the body lifting limiting mechanism operation (see Section 3.16, Installing the body and sen-
sors);
– use the on-board filtering elements of the hydraulic system to clean working fluid in the hydraulic sys-
tem. For this purpose, lift and lower the empty body at least 10 times;
– check the operation of steering turning the steerable wheels to both sides with minimal stable engine
crankshaft speed as well as speed corresponding to the rated power;
– with the truck driving at 5 km/h, turn twice from one extreme position to another. The hydraulic system
must turn the steerable wheels smoothly, without any jerks or swings. The minimum turning radius in line with
the front outer wheel track shall meet the specifications. Check whether the pressure release system in the hy-
dropneumatic accumulators of the steering control operates properly. Check whether the emergency drive of the
steering control operates properly;
– carry out at least three stopping cycles using the electrodynamic brake, the service brake and the back
run as follows:
– with the truck driving at 35 – 40 km/h, use the electrodynamic brake to reduce the truck speed
to 10 km/hour;
– use the service brake to stop the truck completely;
– switch to the back run, and run back for at least 20 m;
– stop the truck completely;
– after stopping, accelerate to 35 – 40 km/h;
– check whether the service braking system operates properly. For this purpose, apply brakes to stop
the empty dump truck from the initial speed, 20 – 25 km/h, with straight-line movement. The service braking
system must brake all the truck wheels simultaneously, and the truck must not skid. A flat horizontal area with
solid dry pavement, free of potholes and slopes, shall be used to drive the dump truck for the steering control
tests and for the electrodynamic and service braking system tests. The test area shall be appropriate for safe
tests;
– check whether the parking brake system operates properly. The parking brake system shall prevent
the dump truck from movement at 16% slopes;
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– test and diagnose the hydraulic system of the dump truck. Lift the empty body completely two or three
times to test the dumping mechanism.
The unloading mechanism must move the body up and down smoothly, without any jerk or sticking, and
stop the body in any intermediate position if necessary.
When the body lifting or lowering, the pilot banners on the EIP must light up. The area used for tests
must be free of overhead power transmission lines and other communication facilities.
When the switch is in the neutral position, spontaneous downward movement of the body, not faster
than 0.01 m/min, shall be considered to be permissible;
– test the device for prevention of the body spontaneous lifting to ensure that the device is operable.
Set the switch handle to the “Lift” position, wait until the body lifts to 200 – 400 mm, and set the switch
to the neutral position. With the pressed button switching off the device for prevention of the body spontane-
ous lifting. Start the truck driving. The body must not move down;
– check the air-tightness of all hydraulic systems. All units, assemblies and connections shall be free of
discharges or leakages of lubricants, oil, fuel, brake fluids, cooling fluids or gases;
– check the air pressure in the tyres. Before measuring the air pressure in the tyres, wait until the tyres
become absolutely cold;
– visually inspect the suspension cylinders and check their dimensions to ensure that they are in good
technical condition;
– upon the truck mounting completion, inspect and check the parameters of the traction electric drive in
accordance with the documents delivered with the drive;
– after checking the dump truck systems check also in accordance with Operation Manuals additional
systems installed on the dump truck such as: centralized automatic lubrication system (CALS), combined fire
extinguishing system (CFES), air conditioning, electric power lines approach annunciator (EPLAA), fuel and
load control system (FaLCS), telemetric control system (TCS) used for changing pressure in tires, video survey
system and the system of the service monitoring, when they are installed on the dump truck;
– drive the dump truck for at least 25 km, as a final test.
For the truck driving, the limitations as follows must be met:
– the dump truck shall be empty and shall be driven on the roads with hard pavement;
– the driving speed shall be chosen in accordance with the road conditions, taking into consideration
that the load on the units and assemblies must grow gradually, and shall not exceed 40 km/h.
While the dump truck driving is in progress, observe the requirements as follows:
– keep the operating parameters of systems, units and assemblies within their optimal ranges, and ob-
serve the readings of the instruments on the instrumentation panel to monitor these parameters;
– adhere strictly to the specified thermal conditions. The engine, reduction gears of the power-wheels,
traction electric motors, front wheel hubs and brake disks must never be overheated.
Any inconsistencies revealed within the scope of the comprehensive test shall be eliminated, the dump
truck shall be delivered to the operator, and the commissioning report shall be duly prepared.
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5 APPENDICES
5.1 APPENDIX A – Main transportable parts of the dump truck slinging dia-
grams (obligatory)
Figure A1 – Chassis slinging diagram for lifting at the front part, using slinging device 7808-0436,
and at the rear part, using slinging device 7808-8595
Figure A2 – Front axle slinging diagram for loading to the rail flatcar, using slinging device 7808-9058
Figure А3 – Slinging diagram for brackets fastening fenders using slinging device 7808-6300 (or slings 4СТЛ-3т/3500):
1 – bracket, RH; 2 – bracket, LH
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Figure А4 – Slinging diagram for front suspension cylinder

sling СТЛ 1т/2000
Figure А5 – Cab slinging diagram, Figure А6 – Fuel tank slinging diagram

using slinging device 7808-6300 (or Sling 4СТЛ-3т/2000) (or Sling 4СТЛ-3т/2000) over two cramps
Figure А7 – Power-wheel slinging diagram Figure А8 – Slinging diagram for the right fender
using slinging device 7808-8495: using slinging device 7808-7052 (or Sling 4СТЛ-3т/3500)
1 – nut М33х2 (4pcs), 2 – bolt М30х2х70 (2pcs)
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Figure A9 – Traction electric drive power cabinet slinging Figure А9а – Slinging diagram for the box with,
diagram, using slinging device 7808-6300 (or Sling 4СТЛ-3т/3500) power cabinet (cabin) using slinging device 7808-7990
Figure А10 – Slinging diagram for wheels:

а) for transportation in horizontal position using slinging device 7808-6769;
b) for mounting of wheels using slinging device 7808-6770
Figure А11 – Slinging diagram for transportation of the body side component using slinging device 7808-8409
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Figure А12 – Slinging diagram for loading of the body side components in assembly using slinging device 7808-8735
Figure A13 – Body slinging diagram for turning to the side for welding and for returning into initial position,
using slinging device 7808-8486
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Figure A14 – Protective shield slinging

diagram, using slinging device
7808-9485
Figure A15 – Body slinging diagram for mounting on the dump truck, using slinging device 7808-8331
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APPENDICES
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5.2 APPENDIX B – Main transportable parts of the dump truck weight (obliga-
tory)
For the weights of the main transportable parts of the dump truck, see Table B.
Table B – Main transportable parts of the dump truck weight
Part name Weight (kg)

Chassis (prepared for transportation) 33370
Body with the shield, no more: 23760
Body right (left) component 9780
Body shield 2784
Side body components in the shipping set 26600
Fuel tank 650
Front suspension cylinder 370
Front axle assembled with hubs and pivots 8100
Wheel assembled with the tyre: 3100
Power-wheel with the reduction gear manufactured by BelAZ OJSC 8600
Power-wheel for the complete General Motors electric transmission 7700
Cab (assembled) 1600
Case with the cab 2130
Left fender prepared for transportation 345
Right fender prepared for transportation 1300
Fender bracket 700
Traction electric drive control cabinet 1300
Case with the traction electric drive control cabinet 1780
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5.3 APPENDIX C – Hydraulic drive circuit diagram (reference)
For the designations and descriptions of the hydraulic drive components, see Table C. For the hydraulic
drive diagram, see Figure C1.
Table C – Hydraulic drive components designations and descriptions
Designation Description Qty Note:

A2 Control unit 75132-8606410 1
РД Reducing valve 1 P=4 MPa
P9 Hydraulic distributor РГС5-6/3СЕ 34А Г24 1
P10 Hydraulic distributor РГС5-6/3СЕ 44А Г24 1
AK1, AK2 Hydropneumatic accumulator 75450-3415010 2 P=16 MPa

AK3 Hydropneumatic accumulator 75137-3415010 1 P=16 MPa
PД1 Pressure switch 1 P=10 MPa

PД2, РД3 Pressure switch 2 P=0.5 MPa
PД4, РД5 Pressure switch 2 P=12 MPa
ДД Pressure sensor 1 Р= 0 – 25 МРа
К08 Double safety valve 75125-3515110 1
3 -1
Н Pump А11VL0 260DRS/11R-NZD12N00 1 q=260 cm , n max =35 s
Ц1, Ц2 Parking brake cylinder 2

Ц3 – Ц6 Cylinders of the service brake gears, rear circuit 4
Ц7 – Ц10 Cylinders of the service brake gears, front circuit 4
Ц11, Ц12 Steering cylinder 75131-3429010-40 2
Ц13, Ц14 Dumping mechanism cylinders 75131-8603010 2
Ф1 Filter 75137-3442010 1 10 µm
Ф2 Filter 1 10 µm
Б Oil tank 1
А3 Steering gear OSPBX 500 LS 1

КО1 Check valve 1
НМ1 Hydraulic motor of the steering gear 1 q=500 cm3/turn
Р1 Hydraulic motor of the steering gear 1
А4 Flow amplifier OSQB 5 1

К1 Backup valve 1
КО2, КО3 Check valve 2
КО4 Check valve 1
КО5 Check valve 1
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APPENDICES
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Table C (cont'd)
Designation Description Qty Note:

КО6 Check valve 1
КП1, КП2 Safety valve 2 P=24 MPa
КП3 Safety valve 1 P=17.5 MPa
Р2 Turn direction selecting hydraulic distributor 1 Кampl.=5
Р3 Flow amplifier hydraulic distributor 1
Р4 Flow amplifier hydraulic distributor 1
Р5 Priority valve 1
А5 Service brake valve 7555А-3514010-01 1

ВН1 1
ВН2 1
Р6 1
Р7 1
А6 Parking brake valve LT 08MMA-2X/125/02M 1
А7 Manifold 75137-3408800 1
КО7 Check valve 1
Р8 Hydraulic distributor РГС5-6/3СЕ574АЕГ24 1
А1 Hydraulic distributor 75306-8606100-10 1

Р1 Distributor 1
Р2 Distributor 1
КП1 Safety valve 1 P=22 MPa
К1 Safety 2
А8 Automatic pump-unloading device 75131-3428010 1
А9 Distributor 7513B-3537070 1
К3 Two-line valve 78221-4619074 1
Drain manifold 75306-8609320 1
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Figure C1 – Hydraulic drive circuit diagram
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APPENDICES
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5.4 APPENDIX D – Equipment and accessories necessary to handle and mount

the chassis, body units and components (reference)
For the schedule of the equipment and accessories necessary to handle and mount the chassis, body
units and components, see Table D.
Table D – Equipment and accessories necessary to handle and mount the chassis, body units and components
Item Garage equipment

Garage equipment description Note:
No. number
1 Slinging device for lifting the chassis at its front part 7808-0436
2 Slinging device for lifting the vehicle at its rear part 7808-8595
3 Slinging device for slinging the electric power-wheel and the power- 7808-8495 Dump trucks with the re-
wheel reduction gear duction gears manufac-
tured by BelAZ OJSC
4 Slinging device for installing the electric power-wheel on the rear axle 7808-9610 Dump trucks with the re-
duction gears manufac-
tured by “General Electric”
Co
5 Slinging device for loading the front axle to the rail flatcar 7808-9058
6 Slinging device for installing the body on the vehicle 7808-8331
7 Slinging device for handling the set (side components) 7808-8735
8 Slinging device for handling the set (side components) 7808-8409
9 Slinging device for turning the body to the side and for returning into 7808-8486
initial position
10 Slinging device for the shield transportation, installation and turning 7808-9485
11 Slinging device for transportation of wheels in horizontal position 7808-6769
12 Slinging device for installing the wheels 7808-6770
13 Slinging device for the container 7808-6300
14 Slinging appliance for the box with power cabinet (cabin)) 7808-7990
15 Support (to be placed under the front axle) 145-290 1 pcs.
16 Support (to be placed under the front axle) 145-268 2 pcs.
17 Support to be placed under the front part of the vehicle (frame cross- 145-291 2 pcs.
beam No.1)
18 Support to be placed under the rear axle housing 145-292 1 pcs.
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5.5 APPENDIX E – Installation requirements for hydraulic piping connections

(reference)
Tightening fittings with female thread (high pressure hoses, pipes, branch-pipes).
Tighten the nut by hand up to stop, then tighten it using a wrench in accordance with the values given in
table E1. In all cases, before tightening the nut on the appropriate adapter, make sure that the hose is aligned
correctly. Twisting of high pressure hoses during tightening is not allowed.
Table E1 – Tightening torques for fittings with female thread
Tightening torque, N.m
Metric thread
Nominal Minimum–maximum
М14х1.5 26 25 – 28
М18х1.5 53 50 – 55
М27х1.5 94 90 – 99
М33х2 139 132 – 145
М42х2 263 250 – 275
М48х2 340 323 – 355
М52х2 368 350 – 385
Tightening fittings with male metric thread and sealing with a rubber ring in accordance with
State Standard 9833.
When installing the rubber rings protect them from distortions, twisting, mechanical damages and cuts.
The surfaces of the mating parts must be clean, free from abrasive products and corrosion products. It is
recommended to lubricate the surface with working fluid.
Tighten the fitting by hand up to stop. Make sure the o-ring is in the groove, then tighten the fitting using
a wrench in accordance with the values shown in the table E2.
Table E2 – Tightening torques for fittings with male metric thread
Tightening torque, N.m
Metric thread
Nominal Minimum–maximum
М14х1.5 42 40 – 44
М18х1.5 63 60 – 66
М27х1.5 115 110 – 121
М30х2 249 236 – 262
М33х2 273 260 – 286
М39х2 284 270 – 298
М42х2 294 280 – 308
М48х2 378 360 – 396
М52х2 410 390 – 429
Tightening fittings with tapered thread.

Prior to installing the connecting fittings (knee-pieces, nipples, tees), as well as tapered plugs, it is nec-
essary to clean the surface of the tapered thread from dirt, degrease and apply a layer of anaerobic sealant
“Fixator-3”, Technical Conditions 2257-006- 43007840 or Unifix Уг10 sealant, Technical Conditions 2257-005-
49784177 at the main plane over the three-four thread turns.
Re-turn the fittings with tapered thread, in case of misalignment of the fittings and pipelines directions to
the direction of thread tightening.
Tightening torques for tapered threads must comply with the values given in table E3.
Check the tightening torque in the direction of thread tightening no later than in 30 minutes after tighten-
ing.
Table E3 – Tightening torques for tapered thread fittings
Thread К1/8” К1/4” К3/8” К1/2” К3/4”

Tightening torque, N.m 60±5 80±5 100±10 140±10 370±10
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APPENDICES
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5.6 APPENDIX F – Installation of labels (reference)
Perform installation of the labels on the dump truck BELAZ-75131 body in accordance with the figure
F1. The view “b” shows installation of the labels on the body of coal-hauler (body 75138-8500006).
Perform installation of labels for the other trucks in the same way.
Figure F1 – Installation of labels:

1 – 4 – labels
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OJSC “BELAZ” – Management Company of Holding “BELAZ-HOLDING”
MINING DUMP TRUCKS BELAZ-7513 series
DIRECTIONS ON ASSEMBLY, STURT-UP AND ADJUSTMENT
Made in Belarus

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OJSC “BELAZ” – Management Company of Holding

MINING DUMP TRUCKS

DIRECTIONS ON ASSEMBLY, STURT-UP AND ADJUSTMENT

These Instructions describe the units, mechanisms and systems of the

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

1 SAFETY REQUIREMENTS AND WARNINGS

1.2 Fire Safety

1.4 Safety Rules and Precautions for Welding

2 PREPARATION FOR MOUNTING

Figure 1 – Installing the front suspension:

3.3 Installing the fuel tank

Figure 4 – Installation of the fuel tank:

3.4 Installing the front wheels

Figure 5 – Installing the front wheel:

3.5 Installing the rear wheels

Figure 6 – Installing the rear wheels:

3.6 Installing the fenders

Figure 7 – Installing the fins (sheet 1 of three):

Figure 7 – Installing the fins (sheet 2 of three)

Figure 7 – Installing the fins (sheet 3 of three)

Table 1 – Fins fastening parts

3.7 Installing the engine air supply system

3.8 Installing the cab

Figure 9 – Installation of cabin:

3.9 Connecting the cab equipment

Figure 10 – Connecting the hydraulic system hoses

Figure 11 – Connection of the air conditioner hoses:

Figure 12 – The installation of the protective shroud of the cab floor:

Figure 13 – Installation of wiper arms and brushes:

Figure 14 – Installing the rear view mirrors:

3.10 Installing the traction electric drive control cabinet

3.11 Connecting the traction electric drive harnesses and wires

3.12 Installing the exterior lighting and light signalling equipment

3.13 Installing the rear lights and lamps

Figure 16 – Installation of units of outer illumination and light-signaling (sheet 1 of two)

Figure 16 – Installation of units of outer illumination and light-signaling (sheet 2 of two):

Figure 17 – Installation of the rear lights and taillights:

3.14 Assembling and welding the body

Figure 18 – Assembling and welding the body (sheet 1 of two):

Figure 18 – Assembling and welding the body (sheet 2 of two)

Figure 19 – Weld passes in a block and multi-pass seams

Table 4 – Welding modes

Figure 20 – Assembling and welding the protective shield:

Installing the put-on boards, supplementary shield and body lining.

Figure 21 – Installing the put-on boards:

Table 5 – Weld seam parameters

Figure 22 – Installing the floor covering:

Figure 23 – Installing the supplementary shield:

Table 6 – Weld seam parameters

Body assembling and welding procedure:

Figure 24а – Installation of the impeding rails in the body:

3.16 Installing the body and the body position sensors

Figure 25 – Installing the body:

Installing the body position sensor.

Figure 26 – Installing the body position sensor:

Installing the body lifting limiting mechanism.

Figure 27 – Installing the body lifting limiting mechanism:

3.17 Installing the mud guards

Figure 28 – Installing the mud guards: