EM027744-01 (en-us)

05 May 2017

General Service Information

New Fluid Specification for Hydraulic Mining Shovels (HMS)

Replaces Service Magazine media number BI644709

Model: All Hydraulic Mining Shovels 6015 - 6090 FS

ISSUE
New fluid specifications are available. Operation and Maintenance Manuals (OMM) will
continually be updated. This instruction applies for all Hydraulic Mining Shovels.

ACTION
The new fluid specification attached to this General Service Information (GSI) needs to be
observed with immediate effect.

©2017 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate
All Rights Reserved and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Caterpillar Global Mining HMS GmbH

GSI-EM027744-01-New Fluid Specification.docx
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Fluid Specifications HMS

6015 - 6090
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The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the service that
is given to the product. Obtain the complete and most current information before you start any job.

Published by: Caterpillar Global Mining HMS GmbH

© Copyright Caterpillar Global Mining HMS GmbH 2017. The reproduction, distribution and utilization of this
manual / file as well as the communication of its content to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Printed in Germany

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Contents

CONTENTS..................................................................................................................................................... 3

OIL FOR COMBUSTION ENGINES (CAT) .................................................................................................... 4

OIL FOR COMBUSTION ENGINES (CUMMINS) .......................................................................................... 5

FLUID / OIL FOR HYDRAULIC SYSTEM ...................................................................................................... 6

SPECIFICATION FOR GEARBOX OIL USED IN CATERPILLAR HYDRAULIC MINING SHOVELS ........ 7

SPECIFICATION FOR GREASE USED IN CATERPILLAR HYDRAULIC MINING SHOVELS, GREASE

FOR BEARINGS, SLEW RINGS AND TRACK SYSTEM (CENTRAL LUBRICATION SYSTEM).............11

GREASE FOR IDLERS, TRACK ROLLERS AND SUPPORT ROLLERS (LIFETIME LUBRICATION)....16

COOLANT FOR USE ON ALL COMBUSTION ENGINES .......................................................................... 17

NOTES .......................................................................................................................................................... 18

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Oil for combustion engines (Cat)

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Oil for combustion engines (Cummins)

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Fluid / oil for hydraulic system

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Specification for Gearbox Oil used in Caterpillar Hydraulic Mining

Shovels
SCOPE:
This specification defines the minimum requirements for gearbox oil used in Caterpillar Hydraulic Mining
Shovels (HMS).
Information contained within this document outlines the minimum lubricant characteristics to satisfy the pump
drive gearbox, final drive gearbox and swing drive gearbox.
The material furnished in accordance with the requirements of this specification must be dispensable through
the distribution lines of the gearboxes and cooling circuits at the lowest anticipated operating temperature.
This specification covers lubricants that may be applied in service at temperatures ranging from -40°C (-40 °F)
to the highest ambient temperature conditions. The particular grade or consistency selected must perform
within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS:
Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined
with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed
film and boundary conditions.
Various grades or viscosities of oils may be required to provide proper lubrication and application properties
over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate
for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or
exceed the minimum performance requirements listed in the “MINIMUM PERFORMANCE REQUIREMENTS”
section.
Viscosity, a fluid’s resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to
produce a lubricating film between two interfacing surfaces. All lubricating fluids possess a natural viscosity
that may be altered (enhanced) by additives such as resins or polymers. Some “viscosity enhancers” are shear
sensitive, which could result in insufficient protection of the lubricated components under high load, elevated
temperatures and/or high shear conditions. The viscosity of the fluids utilized shall be sufficient under operating
conditions for the product to meet or exceed the performance requirements listed in the “MINIMUM
PERFORMANCE REQUIREMENTS” section.
All oils that are used on hydraulic mining shovel applications should be checked for compatibility with
components of the gearboxes and connected systems. This should include lubricants that utilize dilutent to
improve dispensability. Please confirm compatibility with components, e.g. gaskets, o-rings, oil seal lip
materials (NBR, FKM), vent valves, bearing cages, swing drive brakes, coatings, primer, corrosion protection
and operating supplies like thread locker.
Whenever a lubricant change is desired/required, it is highly recommended that the gearboxes are fully flushed
prior to the shovel returning to service. Further, it is recognized that some level of lubricant will remain in the
gearboxes and the cooling system of the pump drive gearbox. To ensure proper lubrication confirm that the
lubricants are compatible or consider flushing the system. Failure to do so can result in a compromised system
and ultimately compromised component lubrication.
For geographic regions with extreme temperature variations, where the use of a single viscosity grade of oil is
not possible, it is critical that temperature is monitored closely and lubricant change occur at the appropriate
time. Failure to do so will result in reduced lubricant functionality, ultimately reducing the life and performance
of the components including potential loss of function.
If polyglycol/ester gear oils are used, fluid life might be impacted due to moisture absorption.
Recommended cleanliness level for oil as dispensed into gearboxes is (-/21/17) or cleaner according to ISO
4406.

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MINIMUM PERFORMANCE REQUIREMENTS:

PROPERTY REFERENCE REQUIREMENTS

Ambient Temperature -40°C to 20°C -10°C to 55°C

(See note 1) -40°F to 68°F 14°F to 131°F
ASTM D 2422,
AGMA grade 3EP AGMA grade 5EP
Viscosity Grade ISO 12925-1,
ISO VG 100 ISO VG 220
CHARACTERISTICS

DIN ISO 3448

ASTM D 445, max.: 110 max.: 242
GENERAL

Viscosity [cST @ 40°C, 107°F]

DIN ISO 3104 min.: 90 min.: 198
ASTM D 445, -42°C -13°C
Pour Point [°C, °F]
DIN ISO 3104 -43.6°F 8.6°F
ASTM D2270,
Viscosity Index 90 90
DIN ISO 2909
ASTM D5182,
FZG Scuffing fail stage A/8.3/90 12 12
DIN ISO 14635-1
DIN 51819-3,
FE 8 wear test, D7,5/100-80.
ASTM D 2783, 10 10
Roller wear [mg]
FAG “4-step-test” step 1
DIN 51819-3,
FE 8 wear test, D75/80-80,
ASTM D 2783, 10 10
duration 800h, roller wear [mg]
FAG “4-step-test” step 2
LOAD CARRYING CAPABILITY

FAG wear test, duration 700h FAG “4-step-test” step 3 pass pass
WEAR /

Timken O.K. Load [lb] ASTM D 2782 65 65

4-Ball EP test - weld load [kg] ASTM D 2783 200 250

4-Ball EP test wear [mm] ASTM D 4172 0,45 0,45

Micro pitting resistance FVA 54/I–IV (FVA 54/7) 10 10

Ortlinghaus brake friction test ON contact:

9-2-10 (reference material 5021- Ortlinghaus-Werke GmbH
>0.12 >0.12
54) Kenkhauser Strasse 125
>0.08 >0.08
Static friction [1] 42929 Wermelskirchen,
Dynamic friction [1] Germany

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MINIMUM PERFORMANCE REQUIREMENTS (continued):

PROPERTY REFERENCE REQUIREMENTS

Copper strip corrosion 130, ASTM D 130,

1b 1b
3h@100°C, 212°F DIN ISO 2160

Rust Test -synthetic seawater ASTM D665,

Pass Pass
[24h] DIN ISO 7120
CORROSION

Oxidation for lubricating oils

ASTM D 2893B, <6 <6
viscosity change [%]
DIN ISO 4263-4 0,1 0,1
predicipation number [ml]
contact:
Ortlinghaus brake material Ortlinghaus-Werke GmbH
compatibility Kenkhauser Strasse 125 pass pass
42929 Wermelskirchen,
Germany
Foam Test, Tendency/Stability, ASTM D 892
[ml] / [ml] * For sequence 2 mix oil with 2%
0/0 0/0
Sequence 1 of any CLP 220 or 100 mineral
30/0 30/0
Sequence 2 oil DIN 51517-3
Rubber property – Effect of
Liquids
Material: 72 NBR 902,
PROPERTIES
PHYSICAL

temperature 100°C, 212 °F,

-2 ≤ x ≤ 5 -2 ≤ x ≤ 5
duration 1006h.
-5 ≤ x ≤ 5 -5 ≤ x ≤ 5
Change in volume [%] ASTM D 471
-50 ≤ x ≤ 20 -50 ≤ x ≤ 20
Change in Shore A hardeness
[%] -60 ≤ x ≤ 20 -60 ≤ x ≤ 20
Change in tensile strength [%]
Change in elongation at break
[%]
Water Separability of Fluids ASTM D 1401
30 30
Maximum [min] DIN ISO 6614

Notes:
1. Ambient Temperature – The ambient temperature shall be the temperature at the point of lubricant
application. Temperature ranges are general, and the customer/owner should consult with the lubricant
supplier to determine the appropriate usable temperature range for the specific lubricant.

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LUBRICANTS:
The selection and utilization of lubrication products other than the Caterpillar recommended products is the
sole responsibility of the equipment operator/owner. Further, Caterpillar does not assume any liability
expressed or implied for any degradation in equipment performance, up to and including damage to the
equipment. As Caterpillar is not able to predict all specific operational variables including but not limited to
climate, application, performance and regional/local regulatory requirements it is recommended that the
equipment operator/owner consult with and obtain a written guarantee from the lube supplier for the use of the
lubricant. In the event damage occurs to the Caterpillar manufactured equipment within the warranty claim
period, Caterpillar reserves the right to request all pertinent information for the performance of independent
Quality Control of the lubricant.This may include but not limited to lubricant samples, certificates that contain
specific technical / chemical data pertaining to: viscosity, weld point, scar, etc. Safety datasheets of the
selected oils to be adhered.
The use of lubricants not meeting the minimum criteria contained within this specification will invalidate
Caterpillar product warranty obligation.

SPECIFICATION REVISIONS:

Date Chapter Changes

Note:
A Selection List of recommended Gearbox Oils can be found in the Operation and Maintenance Manual of the
CGMHMS machine or in the Special Publication SEBU6250.

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Specification for Grease used in Caterpillar Hydraulic Mining Shovels,

grease for bearings, slew rings and track system (Central lubrication
system)
SCOPE:
This specification defines the minimum requirements for Grease used in Caterpillar Hydraulic Mining Shovels
(HMS).
Information contained within this document outlines the minimum lubricant characteristics to satisfy the slew
bearing rolling element requirements. As a result, it is the defining application within the hydraulic mining
shovel, however this product can be successfully utilized on the rest of the shovel with the automatic lubrication
system including the gear portion of the slew bearing and all points on the attachment and undercarriages that
are connected to the centralized lubrication system.
The material furnished in accordance with the requirements of this specification must be dispensable through
the distribution lines of a centralized lubrication system to the most remote application points, at the lowest
anticipated operating temperature. It must not plate or plug components of the centralized lubrication system
such as distributors, injectors, or dispensing points. Further, as lubrication system operation is sensitive to
viscosity, it is very important that dispensing is visually confirmed at the most remote points of the lube system.
This specification covers lubricants that may be applied in service at temperatures ranging from -45°C (-49°F)
to the highest ambient temperature conditions. The particular grade or consistency selected must perform
within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS:
Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined
with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed
film and boundary conditions.
Lubricants supplied in accordance with this specification must have excellent adhesive and cohesive qualities
throughout the specified usable operating temperature range. The lubricant must not chip or throw off, and
must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between
applications of the lubricant under all operating conditions.
Various grades or consistencies of grease may be required to provide proper lubrication and application
properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be
appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant
to meet or exceed the minimum performance requirements listed in the “MINIMUM PERFORMANCE
REQUIREMENTS” section.
Viscosity, a fluid’s resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to
produce a lubricating film between two interfacing surfaces. All lubricating fluids possess a natural viscosity
that may be altered (enhanced) by additives such as resins or polymers. Some “viscosity enhancers” are shear
sensitive, which could result in insufficient protection of the lubricated components under high load, elevated
temperatures and/or high shear conditions. The viscosity of the fluids utilized shall be sufficient under operating
conditions for the product to meet or exceed the performance requirements listed in the “MINIMUM
PERFORMANCE REQUIREMENTS” section.
Lubricants supplied in accordance with this specification must have good thermal stability (should not flow out
or harden) when temperatures increase during operation. Further they should exhibit good reversibility with a
significant number of thermal cycles.
Lubricants supplied in accordance this specification must have excellent water washout or leaching
characteristics. Further the lubricant will also have excellent rust preventive qualities. The adhesive nature of
the lubricant must meet or exceed the performance requirements listed in the “MINIMUM PERFORMANCE
REQUIREMENTS” section.
All greases that are used on hydraulic mining shovel applications should be checked for compatibility with the
centralized lubrication system. This should include lubricants that utilize diluent to improve dispensability.

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Please confirm compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent
valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-13.
For extended use in low temperature areas, lubricants supplied under this specification should be capable of
slumping in containers that are exposed to -45°C (-49°F) and should be pumpable through lube lines without
the aid of heat tracing.
Whenever a lubricant change is desired/required, it is highly recommended that the lube system is fully purged
prior to the shovel returning to service. Further, it is recognized that some level of lubricant will remain in the
system even after purging. To ensure proper lubrication and centralized lubrication system function confirm
that the lubricants are compatible. Failure to do so can result in a compromised lubrication system and
ultimately compromised component lubrication. Please note that both, the thickener and additives must be
compatible with the new lubricant.
For geographic regions with extreme temperature variations, where the use of a single grade of grease is not
possible, it is critical that temperature is monitored closely and lubricant change occur at the appropriate time.
Failure to do so will result in reduced lubricant functionality, ultimately reducing the life and performance of the
components including potential loss of function.
(Note: In the event a purge of the system is not completed, it may take up to 240 machine operating hours for
the new grease to reach the extreme points of lubrication.)

Compounding:
a. Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy
duty ball, roller, and plain bearing lubrication.
b. Base fluid is to be mineral or synthetics which are compatible with mineral base.
c. Thickener types are to be of the following types: Aluminum, Lithium, Calcium, or Calcium Sulfonate.
Please note for optimum performance Calcium Sulfonate is the preferred thickener.

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MINIMUM PERFORMANCE REQUIREMENTS:

PROPERTY REFERENCE REQUIREMENTS

Ambient
-45°C to -12°C -20°C to 38°C 0°C to 55°C
Temperature
-49°F to -10°F -4°F to 100°F 32°F to 131°F
(See note 1)

NLGI Consistency 1,0,00 (see Note

ASTM D-217 2,1 2
GENERAL CHAR.

# #2)
Dropping Point
°C(°F) ASTM D-2265 177(350) 177(350) 177(350)
Minimum
Viscosity of Base 60cST@40°C, 150cST@40°C, 220cST@40°C,
ASTM D-445
Fluid Minimum 104°F 104°F 104°F

Timken O.K.
LOAD CARRYING CAPABILITY

Load-lbs (kgf) ASTM D-2509 55(25) 55(25) 55(25)

Minimum

Four Ball EP
Load wear index
ASTM D-2596 65 65 65
(LWI)kg
Minimum

Load Weld kg
ASTM D-2596 400 400 400
Minimum

Four Ball Wear

Wear Scar mm
WEAR

Maximum
ASTM D-2266 0.6 0.6 0.6
40KG for 1 hour
@75°C (167°F)
@1200RPM

Corrosion Present
Sea Water
ASTM D-5969 Pass Pass Pass
24 Hrs @ 52°C
RUST AND CORROSION

(125°F)

Copper Strip
Corrosion
ASTM D-4048 2e 2e 2e
24 Hrs @ 100°C
(212°F)

Rust Test ASTM D-1743 Pass Pass Pass

Roll Stability Test

Maximum change ASTM D-1831 15% 15% 15%
in 2 hours

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MINIMUM PERFORMANCE REQUIREMENTS (continued):

PROPERTY REFERENCE REQUIREMENTS

Resistance Of Lubricating
ADHESIVE CAPABILITY

ASTM D-4049 40% 40% 40%

Grease To Water Spray Off Max

Water Washout Test

Loss @38°C (100°F) 3% 3% 3%
Maximum
ASTM D-1264
Loss @80°C (175°F)
5% 5%
Maximum 5%

To vent from 1800psi (127 kgf/cm²) to less

than or equal to 600 psi (42 kgf/cm²) within
The Lubrication Engineers
Pumpability, Lincoln Ventmeter 30 seconds at the lowest anticipated
Manual (United States Steel)
ambient temperature (Testing temperature
not less than -25°C/-13°F).

Lubricating Solids
(Molybdenum Disulfide,
Less than or equal to 5%
Graphite, Etc.)
% by Weight

Lubricating Solids
(Molybdenum Disulfide,
8 Microns
Graphite, Etc.)
Particle Size, (Microns, max.)

NOTES:
1. Ambient Temperature – The ambient temperature shall be the temperature at the point of lubricant
application. Temperature ranges are general, and the customer/owner should consult with the
lubricant supplier to determine the appropriate usable temperature range for the specific lubricant.
2. Low Temperature Grease – For extended use in low temperature (-12°C to -46°C/ +10°F to -50F°)
areas, this product should be capable of slumping in containers and should be pumpable through
lube lines without the aid of heat tracing. This product should meet the Mobility and Pump-ability
criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it
is desirable that the thickener and additive system be compatible with the additional grades that are
suitable for the other ambient temperatures.

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LUBRICANTS:
The selection and utilization of lubrication products other than the Caterpillar recommended products is the
sole responsibility of the equipment operator/owner. Further, Caterpillar does not assume any liability
expressed or implied for any degradation in equipment performance, up to and including damage to the
equipment. As Caterpillar is not able to predict all specific operational variables including but not limited to
climate, application, performance and regional/local regulatory requirements it is recommended that the
equipment operator/owner consult with and obtain a written guarantee from the lube supplier for the use of the
lubricant. In the event damage occurs to the Caterpillar manufactured equipment within the warranty claim
period, Caterpillar reserves the right to request all pertinent information for the performance of independent
Quality Control of the lubricant. This may include but not limited to lubricant samples, certificates that contain
specific technical / chemical data pertaining to: viscosity, weld point, scar, moly size and percent content per
batch to validate properties.

The use of lubricants not meeting the minimum criteria contained within this specification will invalidate
Caterpillar product warranty obligation.

SPECIFICATION REVISIONS:
Date Chapter Changes

Note:
A Selection List of recommended Greases can be found in the Operation and Maintenance Manual of the
CGMHMS machine or in the Special Publication SEBU6250.

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Grease for idlers, track rollers and support rollers (Lifetime lubrication)

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Coolant for use on all combustion engines

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Notes

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© Copyright The reproduction, distribution and utilization of this manual / file as well as the
Caterpillar Global Mining communication of its content to others without express authorization is prohibited.
HMS GmbH Offenders will be held liable for the payment of damages. All rights reserved in the event
2017 of the grant of a patent, utility model or design.
Printed in Germany