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18 OPERATIONAL MATERIALS
In order to ensure reliable and durable operation of the dump truck, it is necessary to use the operational
materials in accordance with current manual, the operating documentation for the engine, traction drive, sys-
tems and additional equipment installed on the dump truck.
PPUH Polmark Kielce Sp. z o.o. recommends to use original operational materials in accordance with
table 21.1
Table 21.1 – Operational materials

Рекомендованные смазочные
Тип смазочного материала
материалы ОАО «БЕЛАЗ»

Motor oil SCANIA Titan Cargo MAXX SAE 5W/30

Coolant G-ProfiAntifreeze Green 40 (ДВС Cummins, ЯМЗ)

G-Profi MDB
Oil for hydromechanical transmission
RENOFLUID TF 1500

Transmission oil G-Profi Trans 80W-90

G-Profi Hydraulic Tropic HVLP 68

G-Profi Hydraulic Summer HVLP 46

Hydraulic oil
G-Profi Hydraulic Winter HVLP 32

G-Profi Hydraulic Severe HVLP 32

ATTENTION: THE USE OF OPERATIONAL MATERIALS NOT CORRESPONDING TO THE REQUIREMENTS

GIVEN IN THE OPERATIONAL DOCUMENTATION CAN REDUCE THE LIFETIME OF DUMP TRUCK UNITS AND SYS-
TEMS AND/OR CAN LEAD TO THEIR MALFUNCTION.

The malfunction of units and systems caused by the use of NOT CORRESPONDING to technical char-
acteristics operational materials is not covered by the warranty. Responsibility for the use of such operational
materials is for the Company operating the equipment.
18.1 General requirements
Dump truck units and systems should be filled and lubricated in accordance with the requirements of the
current manual, operation documentation for the engine, traction drive, other components and systems in-
stalled on the dump truck.
In order to guarantee optimum operating conditions for the components, the materials specified in the
current Operation Manual should be used. When changing the brand, wash the units.
The grade of the operational material should correspond to the climatic season of the operation of the
dump truck.
To check the refilling level, place the dump truck on a flat horizontal surface, apply the parking brake
system and install wheel chocks under the wheels.
If the level does not correspond, it is necessary to bring it to the required level by addition or drainage.
When refilling or replacing, dust, dirt, water and other foreign materials are not allowed into the systems
and units.
ATTENTION! AVOID DIRECT CONTACT OF HOT COOLING LIQUID AND OIL WITH SKIN - IT CAN CAUSE A
STRONG BURN.

18.2 Operational materials, drainage and refilling

18.2.1 Fuel
Fuel for the engine should be applied in accordance with the recommendations set out in the engine Op-
eration Manual.

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18.2.2 The engine lubrication system.

PPUH Polmark Kielce Sp. z o.o. recommends to use Titan Cargo MAXX SAE 5W/30 oil (Scania engine)
or oils specified in the engine Operation Manual as the main motor oil.
Drainage of oil from the engine lubrication system.
To ensure that the oil is completely drained and contaminants are removed, it is necessary to warm up
the engine before oil is drained till it reaches the operating temperature of the coolant. Shut down the engine,
unscrew the plug in the oil pan. Clean the surface around the filter heads and remove them using the special
wrench for oil filters. Clean the surface on the engine for the gasket on the filter head.
Refilling the engine lubrication system with oil.
Install new oil filters on the engine. Use only filters recommended for this very engine. Before installation,
fill them with clean oil and apply a thin layer of lubricating oil to the surface of the sealing gasket. Insufficient lubri -
cation during the filling of the filter with oil immediately after starting the engine can cause damage to it.
Excessive tightening of the filter can lead to thread deformation or to seal damage. After contact of the
filter gasket with the surface, perform the filter retightening by three-quarter-turn (or perform the filter retighten-
ing according to the manufacturer’s instructions).
Clean from dirt and check the condition of the thread of the oil drain plug, the sealing ring and the seal-
ing surface. Install the oil drain plug and tighten it. Choose suitable oil for the climatic conditions and fill the en-
gine lubrication system with clean oil to the required level. Start the engine and let it idle. Ensure that there are
no oil leaks at the filters installation points and the oil drain plug.
Stop the engine, wait approximately 15 minutes to allow the oil to drain into the oil pan. Check the oil
level again, pour some if necessary, so that its level reaches the upper mark on the oil dipstick.

18.2.3 The engine cooling system

For the engine cooling system, it is recommended to use special low-freezing cooling fluids G-Profi An-
tifreeze Green 40 (Cummins engine) or fluids in accordance with the engine Operation Manual.
The scheduled replacement of coolants in accordance with the engine Operation Manual.
WARNING: COOLING FLUIDS ARE TOXIC AND, WHEN THE SANITARY REQUIREMENTS ARE VIOLATED,
CAN CAUSE POISONING!

To drain the coolant quickly and completely from the system, it is necessary to remove the plug from the
expansion tank and open the taps.
ATTENTION: UNSCREW THE PLUG ON THE EXPANSION TANK VERY CAREFULLY AND ONLY AFTER THE
COOLANT TEMPERATURE IS REDUCED, AS THE VAPOUR IN THE EXPANSION TANK COULD BE UNDER THE
PRESSURE.

Drain taps to remove coolant from the cooling system are located:
– on the engine (see the engine Operation Manual);
– on the cooling system pipes;
– on the fuel heater;
– on the engine start-up preheater and preheating pipes.
In cooling systems, it is possible to install plugs instead of taps.
After draining the fluid, put the plugs in place and leave the taps open. To completely drain the coolant
from the cab heater radiator, open the valve on the pressure pipeline.
Due to the design features of the engine, a complete draining from the upper part of the thermostats
casings and, accordingly, water pipes connecting the thermostats to the radiator is not ensured. To completely
remove the coolant from the thermostats boxes, it is necessary to disconnect the water pipes from them and
remove or drain fluid through the holes by disassembling the thermostat boxes over the socket.
Before refilling of new coolant, close all taps, assemble the thermostat box, reinstall the piping back and
fill the coolant.
Do not pour the fluid into the heated engine. This may damage the engine cast parts. Before filling it is
necessary to let the engine to cool down to the temperature not exceeding 50 0C.
In the engine cooling system after its start-up and subsequent shutdown, the coolant level should be at
the level of the lower end of the restricting pipe in the filler neck.

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When refilling (after leaks, evaporation) it is necessary to ensure that the coolant of the appropriate
brand and concentration is poured.

18.2.4 Hydromechanical transmission

For hydromechanical transmissions, it is recommended to apply oils:
- G-Profi MDB;
- G-Profi MDB PLUS.
during the warranty and post warranty period.
This oil is intended for use in the hydromechanical transmissions, as well as in the integrated systems of
the hydromechanical transmissions and multidisc oil cooled brakes of mining, special and road-building equip-
ment.
When the recommended G-Profi MDB and G-Profi MDB PLUS oils are not available, it is allowed to use
ATF qualifying oils in the hydromechanical transmissions of the KRONOS equipment, the level of performance
characteristics should be at least of Dexron IID grade, having kinematic viscosity of 7,1 – 8,5 mm2/с at 100º С.
When choosing oil, it is also necessary to take into account the ambient temperature. Prior to starting
the engine of the dump truck when an ambient temperature is below -30 °C, it is necessary to use oils in the
HMT with a pour point not higher than -50 °C or to preheat the oil.
The first oil change in the hydraulic system of the hydromechanical transmission should be performed at
the end of the dump truck run-in. Oil change on dump trucks is to be performed in 1500 motor hours operation.
Drain oil into special tanks from hydromechanical transmission through drain plugs located in the lower
part of the crankcase or pan.
Drainage of the oil should be performed immediately after the end of the dump truck operation, when the
oil is still warm. If the dump truck stayed without operation, warm up the oil in the hydromechanical transmis-
sion up to plus 40-50 °C.
Prior to changing the oil, it is necessary to wash the filtering elements in the oil filters, as well as to re-
place all the filtering elements of oil cleaning fine filters.
Perform washing operation of the filtering elements in the oil filters in the following order:
- unscrew the covers located in the lower part of the crankcase, remove the filtering element packs;
- remove dirt from the filter flanges in the area of the sealing ring;
- disassemble and wash the filtering elements in diesel fuel and blow it with compressed air, rinse the
covers;
- assemble and install filtering elements and screw the covers in;
If necessary, install new packages of filtering elements, replace the sealing rings.
Change the oil in the following order:
- before filling the oil thoroughly clean the plug from dirt;
- pour fresh oil into the hydromechanical transmission to the middle line on the sight glass, then add 10
liters more;
- start the engine and heat the oil in the hydromechanical transmission up to plus 40-50 °C;
- check the oil level by turning the indicator cover and having opened the sight glass. With steady-state
idling speed of the engine crankshaft, the oil level should be in the middle of the sight glass. If the oil level is
higher than normal one (the oil completely covers the sight glass) or lower (the sight glass is free from oil), so it
is necessary to stop the engine and drain or add the required amount of oil. It should be remembered that 2
liters of oil changes the oil level by approximately 10 mm. If during the test the oil level is correct, then stop the
engine and close the sight glass with the cover.
If there is an external oil indicator in the hydromechanical transmission, check and, if necessary, adjust
its position in the following sequence:
- place the dump truck on a flat horizontal site;

- make sure that the oil level in the hydromechanical transmission with the steady-state idling speed of
the engine crankshaft and oil temperature of 40-50 °C coincides with the middle line of the sight glass on the
HMT housing;
- check the oil level by the remote indicator, if it is below or above the centerline of the sight glass, then
unscrew the bolts and move the pointer upwards or downwards and tighten the bolts.
18.2.5 Driving axle
It is recommended to use transmission oil G-Profi Trans 80W 90 in driving axles.

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When the recommended oil G-Profi Trans 80W-90 oil is not available, it is allowed to use the other SAE
75W-90, 80W-90, 85W-90 transmission oils which meet the following technical requirements:
- kinematic viscosity at 100 ºС is within 13.5 - 15.5 mm2/s;
- performance characteristics - API GL-5;
- flashpoint is at least of 210 ºС.
The oil should pass the test on the mining dump truck under operating conditions.
Perform the first replacement of the working fluid at the end of the dump truck run-in, the subsequent re -
placements should be performed in 3000 motor-hours, but at least once a year.
Drainage of the oil from the driving axle and the wheel drive should be performed after preheating the oil
up to a temperature of 30-50 °C. It is recommended to drain the oil after the work shift.
Prior to proceeding directly to draining the oil from the wheel drive, the wheel should be set so that the
drain hole is located approximately on the horizontal axis of the wheel. Unscrew the drain plug and screw the
fitting with the hose attached to it into the hole. Turn the wheel with drain hole downwards, direct the end of the
hose into a container with a height of not more than 30 cm and drain the oil.
To drain the oil from the driving axle housing, place a container under the housing and unscrew the
drain plug. After draining the oil, thoroughly clean the magnets of the drain plug from metal particles (wear
products) and screw the plug into the housing.
The oil level in the rear axle with the combined lubrication system of the main and wheel gears should
be over the lower edge of check plug hole located on the driving axle housing.
18.2.6 Suspension cylinders
As a working fluid, shock absorber fluid ЛУКОЙЛ-АЖ is used, substitutes are: shock absorber fluid
МГП-12 and ГРЖ-12. Damping fluid does not require the scheduled replacement. Its replacement is required
only when repairing suspension cylinders.
The use of working fluid depending on the ambient temperature is given in table 21.2.

Table 18.2 – The use of working fluid depending on the ambient temperature

Lubricant brand Temperature range of using the lubricants

Shock absorber fluid ЛУКОЙЛ-АЖ Above minus 50°С

Shock absorber fluid МГП-12 Above minus 40°С

Shock absorber fluid ГРЖ-12 Above minus 50°С

Shock absorber fluid Shell Tellus T15 Above minus 50°С

Shock absorber fluid Esso Univis HVI 13 Above minus 50 оС

For charging the suspension cylinders and hydropneumatic accumulators of the braking brake system
and steering control, use commercial gaseous nitrogen (State Standard (ГОСТ) 9293 “Gaseous and Liquid Ni-
trogen”).
Commercial gaseous nitrogen is delivered in steel seamless cylinders under the pressure of
(15.0±0.5) MPa. The cylinders are coloured black. At the top of the cylinder there is a yellow marking “NITRO-
GEN” and brown annular marking band.
Fill the suspension cylinders with oil and charge with nitrogen in accordance with the “Suspension” sec-
tion of current Operation Manual.
18.2.7 United hydraulic system
The following hydraulic oils are recommended for the hydraulic system:
– G-Profi Hydraulic Severe HVLP 32;
– G-Profi Hydraulic Winter HVLP 32;
– G-Profi Hydraulic Summer HVLP 46;
– G-Profi Hydraulic Tropic HVLP 68.
Recommended brands of oils and their admissible analogues, depending on the climatic conditions of
operation are given in Table 21.3.
G-Profi Hydraulic oils are produced on the basis of high-quality mineral and synthetic base oils using
highly effective additive packages that ensure reliable operation of the hydraulic system of the dump truck.
In the case of absence of recommended oils, other hydraulic fluids approved by Bosch Rexroth
RDE 90245 are applied.
Level of the working fluid in the tank shall be no higher than upper mark and no lower than bottom mark
of the inspection hole.
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Before leaving for the ride when an outdoor temperature is negative, the working fluid in the tank should
be heated. To warm up the working fluid, start up the engine and work without loading the pump until the oil
temperature in the tank is at least of the recommended values listed in table 21.3.
In the case of working fluid overheating (t p> 95ºC), it is necessary, after eliminating the cause of over-
heating, to perform an extraordinary replacement of the working fluid, since during prolonged operation of the
hydraulic system with high temperatures, accelerated oxidation of the working fluid and loss of its performance
characteristics occur.
The first replacement of the working fluid is to be performed after the end of the run-in, the subsequent
replacement – after 4000 – 5000 motor hours, but not later than the seasonal maintenance.
Perform the replacement of the working fluid when the load body is completely lowered. Before draining,
warm up the working fluid up to the operating temperature, after stopping the engine, discharge the oil spaces
of the pneumatic hydroaccumulators by unscrewing the locking needles on the brake valve.
Table 18.3 – Recommended oil brands depending on the operation conditions

Cli- Temperature scale

Viscosity
matic Oil brand
type ISO -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90
zone

G-Profi *
Hydraulic
Tropical

Tropic HVLP 68
VG68
Shell Tellus S2
VX 68

*
Moderate

G-Profi
Summer

Hydraulic
VG46 Summer
HVLP 46

*
G-Profi Hy-
draulic
Winter HVLP 32
Moderate
winter

VG32
*
G-Profi
Hydraulic
Severe HVLP 32

*
Cold

Mobil Univis
VG15 HVI 13

- Admissible temperature limits of atmosphere air

- Admissible temperature limits of working fluids (viscosity from 1500 to 10 mm2/c (cSt))
- Temperature limits when the heating of working fluids is required
*

To drain the working fluid from the tank, remove the drain valve cap and unscrew the valve by 3 – 4
turnovers, preliminarily having installed a reservoir under the oil tank.
Flush the hydraulic tank before refilling. The inner surface of the tank should be clean, without resinous
deposits. Unscrew the magnetic drain plugs from the tank and remove metal particles.
Fill the hydraulic fluid into the oil tank only through the tank drain filter. Since the filter resistance can
reach 0.4 MPa, the tank should be refilled under pressure using a special refilling device. To connect the refill-
ing device to the tank there is a special refilling valve.
ATTENTION! IT IS NECESSARY TO REMEMBER THAT THE CONTAMINATION OF THE WORKING FLUID
AND ILL-TIMED REPLACEMENT OF THE HYDRAULIC SYSTEM FILTERS IS THE MAIN REASON OF PREMATURE

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MALFUNCTION OF HYDRAULIC UNITS AS WELL AS MALFUNCTION OF UNITS IN THE STEERING, BRAKE SYS -
TEMS AND DUMPING MECHANISM.
For the hydraulic system, it is necessary to apply a working fluid of purity class of not lower than 12 ac -
cording the State Standard 17216 or 22/18/15 ISO 4406. When refilling the tank with working fluid and when
pouring it, it is necessary to exclude impurities and water from entering the internal space of the tank.

18.2.8 Grease lubricants

Automatic centralized lubrication system.
For an automatic centralized lubrication system, it is recommended to use multifunctional lithium (lithium
complex) lubricants containing extreme pressure additives (EP); corresponding NLGI 0, 1, 2, depending on the
ambient air temperature, designed for lubrication of friction type and frictionless bearings under high loads.
The use of class 0 grease at high ambient temperatures can cause in leakage of grease from friction
units and, as a result, their damage from dry friction. The use of grease of 3 or 2 classes of penetration at low
temperatures can lead to the blocking of lubricant in the output hoses.
Recommended greases: Mobilgrease XHP 220, Mobilith SHC 220, Shell Gadus S2 V220, Gazpromneft
Grease LX EP, Gazpromneft Grease Synth LX EP, Fuchs Renolit LX-EP, MS-1400 NORD, MS-1000,
BECHEM High-Lub LT EP and other similar greases. It is recommended to apply grease G-Profi Grease CLS
when the ambient temperature is of minus 50°С – plus 10°С.
In the case of absence of recommended greases, it is allowed to use another grease, taking into ac-
count the requirements in accordance with table 21.4.
Table 18.4 – Requirements to the grease for automatic centralized lubrication system

Measure
Index Value Test method
unit

Stiffener agent - Lithium, lithium complex -

Base oil - Mineral, synthetic -
Viscosity class according to NGLI - 0, 1, 2 DIN ISO 2137
Corrosion protection - 0-0 DIN 51802 IP 220
Water proof - 1-90 DIN 51807-1
Additives - Extreme pressure -
Weld point, at least N 2500 ASTM 2596 IP 239
Diameter of the wear spot mm 0.6 ASTM 2266
Approval of the Manufacturer of the
Content of solid additives automatic centralized lubrication
(graphite, molybdenum disulfide) - -
system is required

When replacing the applied lubricant by lubricant with another stiffener agent or made on the basis of a
different base oil (mineral, synthetic), the friction units should be cleaned of the old lubricant and refilled with
new one. Pump the lubrication system until fresh grease appears from all ends of the pipelines disconnected
from the friction units.
Refilling the tank of the lubrication system is possible in several ways:
– using a quick-fill nipple, which is installed instead of a plug into one of the unused pressure ports on
the pump casing (preferred);
– through the refilling nipple installed in the pump casing with the help of a grease lubricant pumper with
a pneumatic, hydraulic, electric actuator or by means of manual pumper;
– through the neck on top of the tank (not recommended).
If there are air bubbles in the grease, it is necessary to loosen the attachment of the pump element and
start an additional lubrication cycle until the bubbles disappear.
ATTENTION:
WHEN REFILLING THE PUMP TANK WITH GREASE THROUGH THE NECK (TOP), DEENERGIZE
THE POWER SOURCE.
THE GREASE SHOULD NOT CONTAIN IMPURITIES AND SHOULD NOT CHANGE ITS CONSIS-
TENCE.

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WHEN THE TANK IS OVERFILLED, THERE IS A HAZARD OF ITS DAMAGE, THEREFORE NEVER
EXCEED THE MAXIMUM GREASE LEVEL WHICH IS INDICATED ON THE TANK.

Recommended greases for the cardan shaft:

– for hinges – №158М ТУ 38.301-40-25; АЗМОЛ №158 ТУ У.00152365.118; ИТМОЛ-150Н
ТУ BY 10029077.005; Shell Retinax LX2 (Gadus S2 V220C 2, Gadus S3 V220C 2), Fuchs Renolit LX PEP 2;
– for a spline joint - Литол-24 ГОСТ 21150, ЦИАТИМ-201 ГОСТ 6267, Shell Retinax LX2 (Gadus S3
V220C 2), Fuchs Renolit LX PEP.

The list of grease lubricants and recommendations for their use, depending on the ambient air tempera-
ture for lubricating friction units that are not lubricated by an automatic centralized lubrication system, are given
in Table 21.5.
Table 18.5 – The use of greases depending on the ambient air temperature

State Standard, Technical Temperature range of

Grease brand Specification (ГОСТ, ТУ) grease using

Grease № 158М ТУ 38.301-40-25 Above minus 30 ОС

Grease Литол-24 ГОСТ 21150 Above minus 40 ОС

Grease Лита ТУ 38.101808 Above minus 50 ОС

Grease МС-1000 ТУ 0254-003-45540231 Above minus 40 ОС

Grease МС 1400 (NORD) ТУ 0254-028-45540231 Above minus 50 ОС

18.2.9 Commercial Ethyl Alcohol

For filling the anti-freezer of the pneumatic system and washing the parts of the electrical machines and
equipment, use commercial rectified ethyl alcohol to the State Standard (ГОСТ) 18300.

WARNING: THE RECOMMENDED ALCOHOL IS PRODUCED FROM NON-FOOD VEGETABLE RAW MATE-
RIAL. AS REGARDS THE SEVERITY OF THE HUMAN HEALTH IMPACT, IT IS RELATED TO THE FORTH CLASS OF
DANGER TO THE STATE STANDARD (ГОСТ) 12.1.007.

18.3 Sampling, sampling conditions, equipment and devices for sampling

Sampling, sampling conditions, equipment and devices for sampling
Monitoring changes in the performance properties of lubricants is intended to evaluate the current tech-
nical state of units and assemblies of equipment and to identify possible hidden faults in real time on a part-
time basis.
Sampling is organized by the PPUH Polmark Kielce Sp. z o.o.
The frequency of sampling is determined individually and depends on the operating conditions of the
equipment and may vary for different enterprises in the industry.

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