Hitachi Construction Machinery (Australia)

PRODUCT SUPPORT BULLETIN

PRODUCT : Hitachi

REFERENCE: 711-2003-005

ISSUE DATE: 17-November-2003

SUBJECT: Hitachi Oil Sampling Guidelines

APPLICABLE MODELS: ALL HCA Distributed Products

OUTLINE:
On the attached pages you will find the oil sampling guidelines that are to be
applied to all HCA distributed products.

These guidelines are supplied to Probe who judge all sample results based on
the attached sampling levels

These levels have been derived from either the OEM’s oil sampling limits or
they are the result of analysis done on Probes sample database and as such
are subject to review.

The last page provides a detailed description of the action that is to be taken
as a result of the sample judgement done by Probe.

An accurate indication of the compartment condition can only be achieved

with regular sampling. This regular sampling provides a trend so newly
sampled levels can be compared to previous sample results and a more
accurate assessment of the oils condition can be arrived at.

Oil sampling is a troubleshooting tool only and should not be used as the sole
basis for determining that a repair is required.

Peter Woodley
Product Group Manager - Service
 Hitachi Oil Sampling Guidelines
Hydraulic/ Transmission/ Drives
Compartment Equipment Material Normal Level Monitor Trend Take Action
Hydraulic EX/LX Iron 0-20ppm 20-45ppm 46~
Levels for 500 Hr Copper 0-175ppm 176-200ppm 201~
Sampling Intervals Lead 0-20ppm 21-40ppm 41~
Silicon 0-5ppm 6-15ppm 16~
Water (%/Vol) ~ ~ 0.2% / vol
Visc@40oC cst Within +/-10% from first tested value ~ Over +/- 10% of first tested Value
Colour 0-6 ~ 6~
T.A.N. mgKOH/g With +/- 0.5 Of First Tested Value ~ Over +/- 0.5 Of First Tested Value
T.B.N. mgKOH/g With +/- 0.5 Of First Tested Value ~ Over +/- 0.5 Of First Tested Value
Millipore 0.8 Micron per 100mg 0-20 21-30 30~
Foaming (Rush Kit Only) 0 0-50 51~

Pump Drive EX Iron 0-300ppm 301-750ppm 751~

Levels for 500 Hr Copper 0-30ppm 31-60ppm 61~
Sampling Intervals Silicon 0-45ppm 46-74ppm 75~

Swing Drive EX Iron 0-100ppm 101-400ppm 401~

Levels for 500 Hr Copper 0-30ppm 31-60ppm 61~
Sampling Intervals Silicon 0-45ppm 46-74ppm 75~

Final Drives EX Iron 0-1500 1501 - 2000 2001~(See Note 2)

Levels for 500 Hr Copper Testing for this is not Required
Sampling Intervals Silicon 0-500 501~ (See Note 2)
PQ Index 0-750 751~ (See Note 2)
Water (%/Vol) 0-0.35 0.5 ~

Axles LX Iron 0-300ppm 301-600ppm 600~

Levels for 500 Hr Copper 0-100ppm 101-250ppm 250~
Sampling Intervals Silicon 0-30ppm 31-60ppm 61~

TransmissionNOTE 1 LX Iron 0-150ppm 151-300ppm 301~

Copper 0-225ppm 226-400ppm 401~
Levels for 500 Hr Silicon 0-30ppm 31-40ppm 41~
Sampling Intervals Aluminium 0-15ppm 16-30ppm 31~

Issue Date 17/11/2003

 Hitachi Oil Sampling Guidelines
Engines
Compartment Equipment Material Normal Level Monitor Trend Take Action
Engine Cummins Iron 0-70ppm 71-150ppm 150~
MTU Copper 0-30ppm 31-60ppm 61~
Silicon 0-15ppm 16-20ppm 21~
Lead 0-30ppm 31-50ppm 51~
Chromium 0-5ppm 6-12ppm 13~
Aluminium 0-15ppm 16-30ppm 31~
CUMMINS Fuel Dilution 0-3.5 % 3.6-4.4% 4.5%~
MTU Fuel Dilution 0-1.0% 1 -1.4% 1.5%~

Engine Iron 0-70ppm 71-100ppm 101~

MHI EX1200-5 Copper 0-30ppm 31-50ppm 51~
EX1900-5 Silicon 0-15ppm 16-20ppm 21~
EX3600-5 Lead 0-30ppm 31-60ppm 61~
Chromium 0-7ppm 8-19ppm 20~
Aluminium 0-20ppm 21-40ppm 41~
Fuel Dilution 0-3.0 % 3.0-5.0% 5.1%~

Engine Iron 0-75ppm 75-120ppm 120~

Deere Copper 0-30ppm 31-50ppm 51~
Silicon 0-13ppm 14-19ppm 20~
Lead 0-30ppm 31-50ppm 51~
Chromium 0-5ppm 5-15ppm 15~
Aluminium 0-15ppm 15-25ppm 25~
Fuel Dilution 0-2.0 % 2.0-2.9% 3.0%~

Issue Date 17/11/2003

 Hitachi Oil Sampling Guidelines
Notes
Note 1- Lead Value for loader transmissions is to ignored. The Source of lead is from the clutch pack disks.
Note 2- A final Drive sample can only become Take Action if the all three Noted (Iron, Silicon, PQ Index) items are above
the Take Action Levels. If only one or two of the three items are above the Take action Levels and the remaining items are below
the set levels then the sample will only be a Monitor trend

Exception to the Above Levels:-

Should any sample for any of the above contaminates being Tested have a rise of over 50% from the previous sample from that
compartment then that sample shall be deemed critical.

Corrective Action
Normal:- This Category indicates that the machine condition is normal and no action is required. Normal oil sa
are maintained.

Monitor Trend:- Supplementary oil sampling of new oil is required at 250 Hrs to reassess oil condition in this category.
(Except In the Case of Final Drives where Supplementary Sampling is not required / Continue to Resample at the Normal Intervals )
If the result of the Re-sampling is:-
A) Normal:- Resume normal sampling Periods
B) Monitor Trend:- The next oil sample should be performed at 250Hrs from the last sample to reassess oil condition
C) Take Action:- Follow Take Action Instructions

Take Action:- This Category indicates that potential for failure and that a serious problem MAY Exist. Supplementary oil
sampling of new oil is required at 50hrs ( Or immediately for unchanged oil) to reassess oil in this category.
If the result of the Resampling is:-
A) Normal:- Return to normal sampling periods
B) Monitor Trend:- Follow the instruction in Monitor Trend instruction (B)
C) Take Action:- In The Case of Hitachi Stated Values:- Submit the sample results to Hitachi within one week of resampled
date. Hitachi will instruct of the appropriate action within one week of receiving results.
In The Case of HCA Stated Values:- Submit the Sample Results to HOPS immediately and Instructions on the
Appropriate action will be sent within one week of receiving results.

Issue Date 17/11/2003