Mining lubrication challenges

COLLABORATING
WITH PAMA TO HELP
MAXIMISE OUTPUT
EXTENDING EXCAVATOR HYDRAULIC-FLUID
DRAIN INTERVALS TO 6,000 HOURS
Shell Lubricants

Lakeview Images/Shutterstock.com

LOCATION
Opencast coal mine in Indonesia
APPLICATION
Excavator hydraulic systems
CHALLENGE
Reduce excavator lubricant and
maintenance costs
SOLUTION
Trial a longer-life semi-synthetic lubricant
Shell Tellus S3 M 68

PT Pamapersada Nusantara (PAMA) is a leading Indonesian mining contractor

with more than 10 opencast coal mines. The company operates a large fleet of Hitachi
excavators. In co-operation with Shell, PAMA decided to target reducing its excavator
hydraulic system maintenance costs while improving performance and maintaining high
levels of equipment protection. The plan was to extend the hydraulic-fluid-drain interval
from the 4,000 hours recommended by the equipment manufacturer to 6,000 hours.
The solution proposed for extending the fluid-drain interval was to
trial Shell Tellus S3 M hydraulic fluid. The trial included training for
PAMAs maintenance staff, revising operating procedures, sampling
and laboratory analysis. The aim was to demonstrate that the target
of 6,000 hours could be routinely achieved.
Analysis of hydraulic fluid samples from nine Hitachi EX2500-6 excavators on one site
showed that Shell Tellus S3 M was suitable for the extended fluid-drain interval.
By replacing the existing hydraulic oil with Shell Tellus S3 M for a trial period, PAMA has
reported total annual savings equivalent to US$44,5311 for the nine excavators. PAMA
has the opportunity to unlock additional value, as it can apply the same method to the
Hitachi EX2500-6 excavators used in its other mining sites.

OUTCOME
Shell Tellus S3 M 68 was proven to extend the excavators
fluiddrain interval from 4,000 to 6,000 hours and met all
expected performance criteria, which resulted in total reported
savings of US$44,5311 per year.

1
The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site-to-site and from time-to-time, depending on, for example,
the application, the operating conditions, the current products being used, the condition of the equipment and the maintenance practices.

HYF00175

SHELL TELLUS S3 M

PREMIUM ZINC-FREE INDUSTRIAL HYDRAULIC FLUID

DESIGNED TO PROTECT
n

DESIGNED FOR LONG OIL LIFE

Up to 76% less wear than the maximum allowed in the

industry-standard hydraulic pump tests

Up to five times longer oil life than the industry

minimum

Maximum wear allowed

Shell Tellus S3 M hydraulic pump wear test results

Shell Tellus S3 M

Shell Tellus S3 M
Shell Tellus S3 M 46

Maximum wear allowed

Up to 91% less wear

Up to 76% less wear

Eaton
Vickers
35VQ25
V104C11

Equipment
Equipment
manufacturer limits1
manufacturer limits1

Up to 84% less wear

Up to 39% less wear

Eaton
Denison
2
35VQ25
T6H
Shell Tellus
M2 hydraulic
pump wear
results
Shell S3
Tellus
S3 M hydraulic
pumptest
wear
test results
0

Vickers Vickers
V104C1V104C1

20
20

Shell Tellus
M 46
Shell S3
Tellus
S3 M 46

MaximumMaximum
wear allowed
wear allowed

40
60
40Upless
Up to 91%
wearless60
to 91%
wear
Lower is better
Lower is better

80
80

Up to five times longer life

Up to five times longer life

IndustryIndustrystandard limits2
standard limits2

100
100

500
1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000
500
1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Equipment
Equipment
manufacturer
limits1 limits1
manufacturer

Higher is better
Higher is better

Relative oil life (hours) (ASTM D943 TOST life test)

Relative oil life
(ASTM
D943
Up(hours)
to five times
longer
life TOST life test)

Hydraulic pump wear

(% of less
maximum
limit allowed)
Up (%
to 84%
wearless
Hydraulic pump wear
ofUp
maximum
limit
allowed)
to 84%
wear

Up to five times longer life

Industry-Industry1
1
Eaton Eaton
ISO 11158 HM; DIN 51524-2 (HLP oils) 2 Eaton I-286-S,
M-2950-S
GM LH-04-2-002 2ASTM D6158; ISO 11158 HM; DIN 51524-2 HLP
1 limits2
21Eaton brochure
standardstandard
694 (formerly I-286-S and M-2950-S) 2Parker Hannifin (formerly Denison Hydraulics) HF0, HF1 and HF2
GM LH-04-2-00
2
limits2ASTM D6158, ISO 11158 HM; DIN 51524-2 HLP
35VQ2535VQ25

DESIGNED
HIGH
EFFICIENCY
0
20 FOR
40
60
80
0
20
40
60
n

80

100 0

100

1,000
500

1,500
1,000

2,000
1,500

2,500
2,000

3,000
2,500

Up to 71%
Upfaster
to 71% faster

IndustryIndustry
limit
limit1
20

20

40

60

40

60

80

80

100

5,000
4,500

5,000

MaximumMaximum
time allowed
time allowed

4,500
4,000

MaximumMaximum
time allowed
time allowed

4,000
3,500

2
1
2
ISO 11158
HM;
DIN 51524-2
oils) (HLP
Eaton
M-2950-S
ISO
11158
HM; DIN(HLP
51524-2
oils)I-286-S,
Eaton
I-286-S, M-2950-S

Shell Tellus
M S3 M
Shell S3
Tellus
(typical)(typical)

3,500
3,000

Up to 72% better
filterability
Higher isHigher
better
is better
in Relative
the demanding
standard
wet
procedure and
oil life (hours)
(ASTM
TOST
test)test
Relative
oil lifeindustry
(hours) D943
(ASTM
D943life
TOST
life test)
excellent
resistance
to
breakdown
in
the
presence
of water
GM LH-04-2-00
ASTM D6158,
ISO
11158ISO
HM;
DIN 51524-2
GM LH-04-2-00
ASTM
D6158,
11158
HM; DINHLP
51524-2 HLP
for more efficient operation

Up to 71% faster
release
Lower air
is better
Lower is better
for Hydraulic
efficientpump
andwear
precise
hydraulic
power
transmission
(% of maximum
limit
allowed)
Hydraulic pump wear (% of maximum limit allowed)

500
0

Dry

Dry

Wet

Wet

Up to 72%
Upfaster
to 72% faster
Up to 48%
Upfaster
to 48% faster

1
Test limitTest
limit1

100

Lower is better
Lower is better

Air release
time (% time
of limit)
(ASTM
method)method)
Air release
(% of
limit) D3427
(ASTM D3427

20

20

40

40

60

60

80

80

100

100

Lower is better
Lower is better

1 HM; DIN 51524-2 HLP ISO 46

ISO 11158
ISO 11158 HM; DIN 51524-2 HLP ISO 46

FiltrationFiltration
time (% time
of limit)
(Denison
TP-02 100)
(% of
limit) (Denison
TP-02 100)
1
Parker Hannifin
Hydraulics)
HF0 and HF2
Parker(formerly
HannifinDenison
(formerly
Denison Hydraulics)
HF0 and HF2

SPECIFICATIONS AND APPROVALS

Shell Tellus S3 M fluids are approved by Parker Hannifin HF-0, HF-1 and HF-2; Eaton Vickers Brochure 694; and MAG (Cincinnati Machine)
P-68, P-70 and P-69. They meet or exceed the requirements of ISO 11158 (HM fluids); DIN 51524-2 (HLP oils); ASTM 6158
(HM mineral oils); and Swedish Standard SS 15 54 34 M.

HOW SHELL LUBRICANTS WORK

INDUSTRIAL LUBRICANTS

1 GEAR OILS

Shell Omala S2 G, S4 GX, S4 Wheel

2 HYDRAULIC OILS

1 4 5 8

Shell Tellus S2 M, S2 V, S3 M, S4 ME

Dragline

3 COMPRESSOR OILS

Crusher and conveyors

1 2 4 5 6 7 8

Shell Corena S2 P, S3 R, S4 P, S4 R

1 4

Shovel and excavators Haul trucks

4 GREASES

2 5 6 7 8
1 4

Mill

Shell Malleus GL, Shell Gadus S4 OG

Shell Tactic EMV

Ore processing
1 2 3 4

Underground shafts
1 2 4

Crusher and
conveyors
1 4

VEHICLE LUBRICANTS

5 AXLE AND GEAR OILS

Shell Spirax S2 A, S2 ALS, S3 AX, S6 AXME

6 TRANSMISSION FLUIDS

1 4

Mill

Ore processing
1 2 3 4

Shell Spirax S4 CX, S6 CXME

Excavation and machinery

7 VEHICLE GREASES

2 3 4 5 6 7 8

Shell Gadus S3 V 460 D2

8 HEAVY-DUTY DIESEL ENGINE OILS

Shell Rimula R3 MV, R4 MV

www.shell.com

Coal bed

Elevators

Shell Lubricants refers to the various Shell companies engaged in the lubricants business
The information contained in this leaflet is correct as at 10 May 2013.
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