Filtration Guideline

The following document should be viewed as a guideline for the

dimensioning and installation of CJC® filtration systems on Komatsu
930E off-highway haul trucks and indicate what results to expect.
The document is based on previous installations on identical or
similar applications.

Implementing CJC® filtration systems on critical oil systems of

mining machinery will extend oil and component life, consequently
increasing equipment availability, thus lowering the overall
operating costs.

The following are the oil systems, which would be suitable for CJC®
filtration.

• System capacity: 1325 L / 350 U.S. Gal

• Typical oil type: ISO VG 32

Located on the left-hand side of the truck, the cylindrical hydraulic

tank holds 947 L / 250 U.S. Gal and supplies oil to the hoist,
steering, and brake system. Due to the multiple areas of potential
ingress, it is not uncommon to encounter ISO codes highly above
the contamination limit recommended by the OEM.

Location of
hydraulic tank

• Filter type: HD HDU 27/27

• Pump (flow): PV4-38 (260 l/h / 1.14 GPM)
• CJC® insert: B 27/27

For the hydraulic system, it is recommended to install an onboard

solution, which continuously will filtrate the oil when the truck is in
operation. With continuous filtration, it will be possible to maintain
the cleanliness of the oil, despite the continuous ingress of
CJC® HD HDU
contaminants from the numerous points of potential ingress. 27/27

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It is recommended to install the CJC® filter on the right-hand side of the cab deck, as depicted in the images
below. With the available space, it should be possible easily to access the CJC® filter from all sides during
maintenance.

Recommended area for installing CJC® Image of similar installation on hydraulic Image of similar installation on hydraulic
filter for hydraulic system. system (1) system (2)

The depicted results are derived from an installation on a Komatsu 830E holding 946 L / 250 U.S. Gal, however,
similar results should be expected for a Komatsu 930E.

The table below describes the main figures of five (05) oil samples taken from the hydraulic system of a Komatsu
830E, operating at an iron ore mine in South America. During the reported period of five (05) months, the
hydraulic oil was not drained and replaced. The documented improvements in contamination level should,
therefore, fully be ascribed to the installation of the CJC® onboard filter.

As seen from the table below, the contamination level, after installing the CJC® onboard filter, was reduced
significantly. The contamination level had within 2 months reduced from an ISO code 23/21/15 to an ISO code
17/15/11, which is equivalent to a 97% reduction in particle count.

Since components in high-pressure hydraulic systems have a particularly low tolerance for contamination, the
reduction in particle count will have a significant effect on component life, which in theory, could be extended
by a factor of 5.

Fe 4μm 7μm 14μm

Status Sample date (ppm) PQI ISO 4406 (part/ml) (part/ml) (part/ml)
Abnormal 14/08/2021 6 12 23/20/15 40015 5869 184
Abnormal 21/09/2021 6 11 23/20/14 42026 7497 137
Abnormal 16/10/2021 4 7 23/21/15 53617 16748 256

CJC® onboard filter installed beginning of December 2021

Normal 09/12/2021 2 0 19/16/14 2781 444 83

Normal 31/01/2022 2 1 17/15/11 1108 245 20

Test results from installing an HD HDU 27/27 on the hydraulic system of a Komatsu 830E

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• System capacity (each): 95 L / 25 U.S. Gal
• Typical oil type: ISO VG 680

The Komatsu 930E is an electric drive mining truck, meaning that

each rear wheel is connected to an electrical motor (wheel motor),
which is powered by a generator. Each of these wheel motors has
an independent oil system to lubricate the gears inside. Due to the
extreme working conditions, high contamination levels are
common, and it is therefore often a necessity to replace the oil
frequently.

Location of
wheel motors

• Filter type: MFU 27/108

• Pump (flow): GP 26-8 (≤ 850 l/h / 3,7 GPM)
• CJC® insert: GFi 27/27

Since the oil systems for the wheel motor transmissions only can be
accessed from the outer sides of the wheels, it is not possible to
install a permanent onboard solution. Oil filtration must therefore
take place during the scheduled PMs, where the truck is not in
motion.
The CJC® Mobile Flushing Unit (MFU) is designed for flushing oil CJC® mobile
systems operating in rough environments, such as found on earth flushing unit
moving equipment on mine sites. The flushing speed depends on (MFU)
the oil temperature/viscosity and is automatically regulated by the
buit-in frequency converter. A built-in CJC® Oil Contamination
Monitor makes it possible to monitor the oil cleanliness of the
systems during flushing.

The CJC® MFU can be connected to the wheel motor by attaching

the included hoses for suction and return directly to the wheels as
depicted in the images.

Return

CJC® MFU connected to Close-up of CJC®

wheel motor of a MFU connected to
Komatsu 930E wheel motor of a
Suction
Komatsu 930E

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The depicted results are derived from flushing a wheel motor on a Komatsu 930E with a CJC® MFU. The oil
contamination level during the flushing was monitored using the built-in CJC® Oil Contamination Monitor.

Before flushing, the oil was highly contaminated, and the particle count was measured to be 24/21/15.
During 90 minutes of flushing, the oil was circulated 4,5 times and the contamination level was decreased from an
ISO code 24/21/15 to an ISO code 17/15/10, which is equivalent to a 98,7% reduction in particle count.

The result is prolonged life of components and oil as well as a decreased need for maintenance. This all leads to less
scheduled and unscheduled downtime, increasing equipment availability and decreasing the operating costs.

Oil samples from wheel motor before
flushing (left) and after flushing (right)
with CJC® MFU
Particle count reading (ISO 4406) from
wheel motor before flushing (above)
and after flushing (below) with CJC®
MFU. Particle count was measured
using the built-in CJC® Oil
Contamination Monitor.

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• System capacity: 4542 L / 1200 U.S. Gal
• Typical oil type: Diesel fuel

The fuel tank is located on the right-hand side of the truck and
holds 4542 L / 1200 U.S. Gal. of diesel fuel. The importance of clean
diesel fuel is widely accepted, as there is a direct correlation
between running on contaminated diesel fuel and experiencing
injector wear and incomplete combustion. Moreover, running on
contaminated diesel fuel will often result in contaminants
accumulating in the bottom of the tank, contaminating any clean
diesel filled on the truck. Figure 1 -
Location of
fuel tank

• Filter type: HD HDU 15/25

• Pump (flow): PVMD2-38 (260 l/h / 1.14 GPM)
• CJC® insert: DFi 15/25

To avoid excessive injector wear, it is recommended that all the

diesel fuel entering the combustion chamber, previously has passed
through a CJC® filtration medium. Due to the fuel tank volume and Figure 2 - CJC®
the hourly fuel consumption of the truck, it is recommended that HD HDU 15/25
the primary CJC® filtration for diesel fuel is implemented before
being filled on the trucks.

Please contact your local CJC® representative, to learn how

implementing CJC® filtration on fuel storage tanks can ensure that
only diesel fuel fulfilling the OEM recommendations of cleanliness is
being filled on your mining machinery.

In combination with CJC® filtration on the storage tanks, it is

recommended to install a CJC® filter on the truck, connected to the
fuel tank. The CJC® filter will act as a polishing filter as it will remove
any accumulated contaminants and condensation from the bottom
of the fuel tank and ensure that the cleanliness of diesel fuel and
the fuel tank itself is maintained.

It is recommended to install the CJC® filter on the lower platform on

the front of the truck as illustrated below. With the available space,
it should be possible easily to access the CJC® filter from all sides
during maintenance.

Figure 4 - Recommended
area for installing CJC® Figure 3 - Image of
polishing filter for fuel similar installation
tank. on fuel tank.

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