BelAZ-75600: technical characteristics

Doesn't happen anymore

This dump truck has no equal in terms of load capacity in the world.
The specialists of the Belarusian Automobile Plant far surpassed their colleagues - manufacturers of super-heavy equipment from Germany and the USA, by creating the giant BelAZ-75710. The carrying capacity of this model is 450 tons. At the beginning of 2014, BelAZ-75710 set an absolute record when it transported a load weighing 503 and a half tons across the test site. We present to your attention a complete review of this unique mining dump truck. It’s worth noting right away that the BelAZ-75710 is not just a showpiece, as you might think at first. And not the only “record-breaking truck” of its kind, a sort of “advertising showcase” for the Belarusian Automobile Plant. Of course, the Zhodino enterprise has not needed advertising for a long time. This is a production model!

The first copy of the largest truck on the planet, soon after its appearance in public (in the fall of 2013, at the 65th birthday of the BelAZ plant), already went to work at the Chernigovets coal mine, in the city of Berezovsky, in the Kuzbass. Following it, several more of these unique cars were built, also delivered to the Kemerovo region.

Features of this model

BelAZ-75600 became the plant's debut in the use of an electromechanical AC transmission based on modular electronic units for converting the ballast system, an electronic system for monitoring and diagnosing the operation of systems, using a telemetric rear view system.

The dump truck is equipped with a diesel power unit with a capacity of 2610 kW (3500 hp), which meets Tier II environmental standards; AC transmission, tires size 55/80R6З. The BelAZ-75600 is distinguished by high traction and dynamic characteristics, allowing it to reach speeds of up to 64 km/h.

In 2006, the BelAZ-75600 truck was put into operation at the Bachatsky coal mine in the Kemerovo region. Subsequently, other cars of this model were added to it.

The Bachatsky coal mine is one of the largest in Kuzbass. Its annual production exceeds 8.7 million tons of coal. From here fuel is supplied to the energy and metallurgical industries of the Russian Federation and many countries around the world.

BelAZ-75600 has long been the largest mining dump truck at this coal mine - load capacity 320 tons, total weight 560 tons. Such vehicles, each with four drivers, were operated here around the clock, with maintenance breaks every 250 hours.

During a 12-hour shift, a BelAZ dump truck travels approximately 150 km, transports 5–7 thousand tons of rock and burns 2–2.5 tons of diesel fuel. In total, each car covers about 100 thousand kilometers per year, and its service life before being written off is 600 thousand kilometers.

Practical application and operating points

The main reason for the appearance of this super-heavy dump truck was not the gigantomania of its creators or their desire for records, but an ordinary economic calculation. Because, in the end, one such 450-tonne truck provides significant savings in operation, compared to two or three mining dump trucks of lower carrying capacity. Despite its almost “manual” assembly and expensive maintenance. BelAZ-75710 provides not only a record carrying capacity, but also the lowest cost of transporting one ton of rock in the world.

Whatever the commercial vehicle: small, large or extra-large, the most important issues for its potential buyers were and remain the service life of this equipment and the fuel consumption that it demonstrates. The working life of mining dump trucks is small: on average, they operate in full mode for about 5-6 years. And the heavy-duty 450-ton BelAZ-75710 is no exception to this rule.

As for fuel consumption, it is, at a maximum, about 470 liters of diesel fuel per hour (for a fully loaded BelAZ-75710 vehicle). For a dump truck traveling empty, this figure is several times less. The expense is huge. But it is still much more profitable compared to the simultaneous use of 2-3 trucks of lower carrying capacity.

BelAZ-75710 at the test site.

The BelAZ-75710 has two diesel engines; each of them works in tandem with its own generator; All systems responsible for ensuring the operation of the motors are independent for each of them. In this regard, some argue that without a load the BelAZ-75710 moves using only one motor to save fuel, and both motors come into operation together only when transporting cargo.

Actually this is not true. Of course, such a scheme for the operation of the giant’s engines is theoretically possible, but in practice it has not yet been implemented. Bye. Because the design bureau of the Belarusian Automobile Plant has such plans. After all, this will really help save a large amount of diesel fuel, further increasing the economic return from operating a super-heavy dump truck.

These plans are already close to implementation, and soon an empty BelAZ-75710 will move on one diesel engine, and a loaded one will be connected to a second one. Moreover, to ensure uniform wear, the left and right engines at idle will be turned on alternately. In the meantime, fuel economy is ensured by another new engineering solution - the use of two differentials simultaneously - inter-axle and inter-side differential.

The BelAZ-75710 model has all the conditions for sale, further modernization and development. Cyclically recurring crises in the global economy have contributed to the emergence of a persistent desire among producers to reduce the costs of extraction and transportation of minerals. The giant dump truck from Belarus is precisely suited to meet these aspirations when it comes to industrial mining of coal and ore in open pits. Therefore, the BelAZ-75710 corresponds to modern economic realities.

Engine and transmission of the BelAZ-75600 dump truck

The BelAZ-75600 truck is equipped with a Cummins QSK 78-C four-stroke 18-cylinder V-shaped diesel engine with gas turbine supercharging. Its working volume is 77.6 liters and its power is 261O kW / 3500 hp. s., at a speed of 19OO rpm. The maximum torque of the Cummins QSK 78-C engine reaches 13771 N*m, at 1500 rpm. Cylinder diameter – 170 mm. The piston stroke is 190 mm. The fuel tank holds 4360 liters of diesel fuel. Specific fuel consumption – 196 g/kW*h.

The power plant of this dump truck is electronically controlled and has a switchable impeller. The cooling system impeller drive is a friction electrohydraulic clutch. Management is carried out automatically. This design provides the BelAZ-75600 with high power and fuel efficiency. The motors are equipped with pneumatic starting, three-stage dry air filters with clogging indicators and automatic dust removal.

Exhaust gases are released through the body and through mufflers. The engine lubrication system is circulating, under pressure, with a “wet” sump. The cooling system is liquid, with forced circulation, dual-circuit. The oil is cooled by a water-oil heat exchanger. The preheating system is liquid. The engine starting system is pneumatic starter.

The air pressure in the starting system is 0.8-1.0 MPa. The voltage in the electrical system is 24 Volts.

The transmission of the BelAZ-75600 truck is electromechanical, manufactured by , which includes a traction generator YJ177B, from and two traction electric motors 1TBZOZO-2GAOZ, from; double-row planetary gearboxes of differential-type electric motor wheels, control devices, control devices and a microprocessor control system. The motor-wheel gearbox is double-row, planetary. The gear ratio is Z9, Z2.

Also, in other modifications of BelAZ dump trucks of the 7530 series, DC traction motors DK-724 can be used; EDP-800; EK-735A; traction generators SGTM-1400; GST-1600 – all domestically produced.

Modifications

There are two more modifications in the BelAZ-75600 line, which differ in engines and payload capacity. Below is a brief overview of each:

Model 75601. The truck is capable of transporting up to 360 tons of cargo, equipped with an MTU 20V400 power unit. Power – 2.8 thousand kW, Kato rotary type generator. The engine is connected to the wheels through a combination of an electric motor and a double-row planetary gearbox. The systems are integrated into the rear wheels, equipped with 59/80 R63 tires. The total weight of the dump truck reaches 610 thousand kg, the cargo volume is 218 cubic meters. The maximum acceleration of the car is 64 km/h.
Option 75602. The largest dump truck from the series under consideration can transport a load weighing 360 tons, it is equipped with a diesel engine 1 TB330-2GA03, which allows it to transport increased weight. The developers, in addition, managed to reduce fuel consumption to 198 g/kW per hour.

Suspension and chassis; steering and brakes; hydraulics BelAZ-75600

The frame of the heavy dump truck of this model is welded, made of high-strength low-alloy steel. The longitudinal spars are box-shaped, of variable height, connected to each other by cross members. In areas of greatest load, cast elements are used for reinforcement.

The BelAZ-75600 uses a dependent suspension with pneumohydraulic cylinders (two each on the front axle and on the driven rear axle), with trailing arms, central hinges and transverse rods. Hydraulic shock absorbers are built into the pneumatic-hydraulic cylinders (oil and nitrogen), with a cylinder piston stroke of: front 200 mm, rear – 170 mm.

The steering is hydraulic volumetric, equipped with an emergency circuit. In cases of failure of the main system, or engine stops, pneumohydraulic accumulators are connected to operation. The available energy reserve in them will be enough to perform several maneuvers.

Hydraulics are combined for the brake system, tipping and steering mechanisms. Its operation is ensured by a two-section axial piston oil pump of variable displacement, with a pressure regulator. The body lift cylinders of the BelAZ-75600 are telescopic, two-stage (one of the stages is double-acting).

The total volume of oil filled into the hydraulic system of the BelAZ-75600 is 600 liters. Its pressure in the operating circuit is 165 atmospheres.

Each of the wheels of the BelAZ-75600 weighs eight tons and costs about a million rubles. To install tires, a dump truck requires a special loader-manipulator. The tires are pneumatic, tubeless, of radial design, with a landing diameter of 63″. The tread pattern of the dump truck tires is quarry. Designation – 56/80R63; 59/80R63. The internal pressure is 0.6 MPa. The rim designation is: 41.00-63/5.0; 44.00-63/5.0.

The brake system of a mining dump truck includes working, parking, auxiliary and spare mechanisms. The service brakes installed on the shafts of the traction motors of the front and rear wheels are dry, disc with four brake mechanisms (on the front wheels), double-disc (on the rear wheels), and with automatic clearance adjustment. Drive – hydraulic, separate for front and rear wheels.

The parking brake is of a permanently closed type, with two brake mechanisms per side, of a permanently closed type, having hydraulic control and a spring drive. As an auxiliary braking system, electrodynamic braking is used by traction electric motors in generator mode (with forced cooling of the braking resistors). The backup brake system applies the parking brake and the service brake circuit.

The brake system of the BelAZ-75600 dump truck complies with current international standards and safety requirements ISO 3450. Braking resistors have a power of 3760 kW.

Technical parameters of BelAZ-75600 in numbers

Overall dimensions: length – 15.3 m; width – 9.7 m; height – 7.67 m.
Turning radius – 17.2 m.
Overall turning diameter – 38 m.
The steering angle of the steering wheels is 39 degrees.
Wheelbase width – 6.8 m.
Weight characteristics: dump truck weight without load is 240 tons.
Load capacity – 320 tons.
The total weight of the vehicle is 560 tons.
Percentage distribution of dump truck weight along the axles: without load / with load - front 49% / 33%; rear 51% / 61%.
The geometric volume of the body is 139 or 162.8 cubic meters.
Body volume “with a header” is 199 or 218 cubic meters.
Refueling capacities: fuel tank – 4375 liters; engine cooling system – 860 liters; engine lubrication system – 340 liters; hydraulic system - 1410 liters; motor-wheel gearboxes – 300 liters (two 150 liters each); front suspension cylinders - 130.8 liters (two 65.4 liters each); rear suspension cylinders – 127.6 liters (two 63.8 liters each)

Technical information

The BelAZ-75600, whose technical characteristics are simply unrealistic to compare with domestic trucks, is designed for transporting minerals, quarries and other bulk cargo off public roads.

Basic vehicle data:

Length/width/height (m) – 14.5/9.2/7.2.
Weight (kg), full/curb – 5,600/2,400.
Powertrain – Cummins QSK.
Generator – Kato (2,536 kilowatts).
Electric motors – Siemens (2 x 1,200 kW).
Body volume (cubic meters) – 140-200.
Maximum speed (km/h) – 65.
Turning radius (m) – 16.6.
Load capacity (kg) – 320 thousand.

Cabin and body of the BelAZ-75600 dump truck

The car is equipped with a double cabin with two doors. The driver's workplace of the BelAZ-75600 meets the standards of the ROPS safety system. The noise level in the cabin is no more than 80 decibels. The local vibration level per person is no more than 126 decibels (A), and the general vibration level is no more than 115 decibels (A). The steering column is adjustable. The driver's seat is air-sprung and equipped with various adjustments. The optional passenger seat does not have such options.

The driver's workplace of the BelAZ-75600 complies with the requirements of standards EN 474-1 and EN 474-6, which establish permissible levels of internal noise, vibration, concentration of harmful substances and air dust. This driver's workplace fully meets the requirements of the ROPS safety system.

The body of the BelAZ-75600 truck is welded, equipped with a protective visor, a locking system in the raised position, stone chippers and stone ejectors. The underbody is heated by diesel engine exhaust gases.

Body lifting time is 31 seconds.
The body lowering time is 20 seconds.
The maximum pressure in the hydraulic system is 21 MPa.
Maximum performance of hydraulic pumps, at 1900 rpm – 948 dm3/min.
Filtration level – 10 microns.

In the BelAZ-75600 configuration

The standard basic version of the car of this model includes systems for monitoring diesel fuel, load and tire pressure, and a pre-heater for fuel and coolant. There is an automatic combined fire extinguishing system, there is a side and rear video view, a centralized lubrication system, a heating and air conditioning unit, an automatic lubrication system, a telemetric tire pressure monitoring system, a video review system and video monitoring of “dead spots,” underbody lining. All this is standard equipment.

As additional options, the Belarusian manufacturer offers potential buyers: installation of an “advanced” air conditioner, a radio, electrically heated mirrors, an alarm when approaching a high-voltage power line, an additional heater, and an air purification system in the cabin.

How such large trucks as BelAZ-75600 are made

At the BelAZ plant itself in the city of Zhodino, the final assembly of cars is almost never done. There it is carried out only for experimental and demonstration purposes. The factory produces parts, components and assemblies (not all).

They are loaded onto freight cars and sent directly to the consumer. Some parts, including a diesel engine from , are not delivered to the BelAZ plant at all, but are delivered immediately to the final assembly site, bypassing both the enterprise itself and the Republic of Belarus.

The final assembly of a truck of such a respectable “caliber” is carried out directly at the site of its future operation. An assembly and warranty team from the Belarusian Automobile Plant goes there, or the dump truck operator himself has an authorized service center at his place of work.

The history of the creation of the model and its closest analogue in terms of performance characteristics

Since in quarrying there are certain dimensional restrictions related, among other things, to the width of technological roads, the BelAZ-75710 needs, despite its gigantic size, to comply with them, and in terms of turning/turning radius be comparable with much more compact “brothers” .

This required engineers to create a new and very sophisticated control scheme. For such a giant, and even with a dual-pitch front tire, the usual option with front turning wheels will not work. There are only two other options: an articulated frame and swing axles. However, in the first case, the articulation unit would have to undergo terrible stress, and therefore the hinge would have to be enlarged to incredible sizes. Therefore, we adopted scheme No. 2.

The designers called the mechanism with rotary bridges an “upside down excavator.” Because in an excavator the chassis is stationary, but the body rotates; and in the giant BelAZ the body remains motionless, and the axles located under the frame rotate.

Visually: BelAZ-75710 and the Volga car.

This new system, like many other new things, is a “well forgotten old one.” Since back in the early 70s of the 20th century, specialists from the Belarusian Automobile Plant tried to develop a similar truck - with two rotary axles on eight tires. A special “experimental mobile stand” was built using the components of a 42-ton BelAZ, on which this control scheme was tested and honed.

In 1977, this technological solution was tested, with varying degrees of success, on a heavier experimental vehicle, the BelAZ-7520. This dump truck with a lifting capacity of 110 tons with swing axles turned out to be too high. Therefore, the control circuit with rotary bridges was shelved.

In 1990, the topic was revived and developed in a completely new way. The first predecessor of the BelAZ-75710 was the first actually operated commercial super-heavy truck on eight tires - the 280-ton BelAZ-75501. It held the record for carrying capacity among BelAZs until 2005, when the second predecessor of the BelAZ-75710 was released - the 320-ton BelAZ-75600, based on six wheels with tire size 55/80R63.

It should be noted that the carrying capacity of mining dump trucks directly depended and depends on the capabilities of the tire industry, and are growing with it. When it was able to offer even more reinforced tires of size 59/80R63, in 2010, the BelAZ-75600 was able to “take on board” not 320, but 360 tons.

And the supergiant BelAZ-75710 also “mounted” these tires. Just one such tire weighs five and a half tons! By the way, only the first dump trucks were equipped with Bridgestones. Subsequently, the production of these modern products was mastered at BelShin.

The closest analogue of the BelAZ-75501 among foreign competitors is the German heavy mining dump truck Liebherr T282-B (Liebherr). It has been produced since 2004 and has a lifting capacity of 363 tons.