Final Drive Excavators

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Service Magazine
2007/07/16
Media Number -SEPD0897-00 Publication Date -2007/07/16 Date Updated -2007/07/16
i02797155
Managing the Life Cycles of Excavator Final Drives {4050}

SMCS - 4050
Excavator:
z All
Service Magazine SEPD0891, 04 June 2007, "Managing the Life Cycles of Excavator Final Drives". Disregard this
article. See the replacement article that follows.
Several sources of information are currently available with guidelines for the wear analysis of the final drives in
Excavators. Certain information could be easily misunderstood. Information that is misunderstood can cause
unnecessary repairs. A comprehensive study of the final drives in Excavators was performed in order to provide one
safe source of information. The result of the study is reflected in the following information. The following guidelines
provide an explanation of the wear analysis and the contamination that occurs in final drives. The guidelines provide a
plan of action in order to address abnormal conditions. Unnecessary action that is performed beyond the guidelines is
not recommended.
Certain compartments can routinely generate widely varying amounts of debris accumulation. The following variables
affect wear in a compartment: geographic locations, climate, type of lubricant, maintenance practices and operating
techniques. The variables create a broad range of data from the oil analysis. These guidelines were developed in order
to better understand the results of the oil analysis by the S·O·S interpreter and the Caterpillar dealership. The correct
understanding of the results of the oil analysis will improve the management of the machine. The correct understanding
will also decrease the operating costs for the customer.
Differences Between Final Drive Operation And Application

The final drives in Excavators move the machine between locations. The final drives in other Caterpillar machines
move the machine and heavy material between locations.
In a typical application, Excavators operate for many hours with very little movement of the tracks. When an Excavator
moves, the travel speed is much slower than other Caterpillar machines with final drives. Also, the seals in the final
drives on Excavators are located close to the ground. The final drives on other Caterpillar machines are located higher
from the ground. The seals in the final drives that are located close to the ground provide an increased opportunity for
packed dirt or packed mud. Machine movement can force dirt or mud beyond the seals and into the final drive. The
wear characteristics of the final drives in Excavators are unique because of the differences in the operation and the
application.
Contamination In Final Drives

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The presence of dirt, mud, or water in a final drive is detected by oil analysis. An oil analysis with elevated values of Si
and Al indicate dirt contamination. The Si value will always exceed the Al value. The oil analysis will also detect water
contamination. An oil sample with large amounts of water will have a milky brown appearance. A test that uses a hot
plate can detect small amounts of water. The Karl Fischer method of a titration can also be used in order to detect a
small amount of water.
Dirt will initially produce wear on gears, shafts, and carriers. The initial wear will be identified by elevated Fe readings.
Eventually, this wear could extend to the rolling element bearings in the final drive. Wear on the bearings is identified
by elevated Cr values.
Guidelines For The Analysis Of Final Drive Oil

Special guidelines have been developed in order to address the unique characteristics of the final drives in Excavators.
Oil Sampling
The Operation and Maintenance Manual recommends an interval of 250 service hours for oil sampling. The sampling
interval should be decreased to an interval of every 125 service hours, if the machine has a history of contamination in
the final drive or if the operating conditions promote contamination. An oil sample should also be analyzed within 125
service hours, if the final drive has been repaired or if the final drive has been cleaned in order to remove
contamination. The analysis of an oil sample may also be preferable at an interval of 50 service hours if the Cr value is
abnormal.
Wear Element Analysis
Wear element analysis is used in order to detect small wear particles in the oil and contamination from dirt. Table 1 is a
guideline for the wear element analysis. Most Caterpillar tables for wear element analysis are only valid for the
recommended oil drain. Table 1 is valid for the final drives in Excavators regardless of the service hours of the fluid.
Table 1
Wear Element Analysis (1)

Element No Action Required Monitor Action Required
Cu 0-15 16-20 >20
Fe 0-300 301-450 >450
Cr 0-7 8-12 >12
Al 0-35 36-60 >60
Pb 0-2 3-4 >4
Si 0-150 151-250 >250
Sn 0-2 3-4 >4
(1) Values are listed in parts per million (ppm).
Particle Count Analysis
An optical instrument for particle count analysis is used in the S·O·S laboratories in order to measure the larger
particles in an oil sample. The instrument for particle count analysis measures particles from approximately 4 microns
to 50 microns in size. Wear element analysis can only measure particles up to approximately 10 microns in size. The
instrument for a particle count analysis should be capable of detecting dirt contamination and wear material in an oil
sample from a final drive. Particle count analysis has not been an effective tool for managing the final drives in
Excavators. The following two reasons describe the difficulty in the measurement of the particles:
z Satisfactory final drives with low levels of wear and no significant contamination will produce a reading of 23/22
in the ISO code system. The 23/22 value is near the top of the measurable range on most of the instruments for a
particle count analysis. If the particle counts increase, the instrument cannot measure the increase and the reading
is high off of the scale. The code for the ISO system will report a High Base Line (HBL) if a condition that is off
of the scale occurs.
z Approximately 50% of the samples for the final drives in Excavators produce a measurable value on the particle
count. The samples that do not produce a particle count have three problems: too much water in the sample, too
dark of a sample and too many particles in the sample
Samples that have too many particles will report a reading of High Base Line (HBL). The reading will be off of the
scale.
The data from a particle count analysis cannot be effectively used in order to manage the final drives in Excavators
because of the problems that were previously listed. The values from the ISO system that are listed in this document
should be used for reference purposes only.
Interpretation Of Oil Sample Results
Interpretation of the results for oil samples from final drives is performed in order to determine if the wear has become
abnormal. The main indicator of abnormal wear is the level of Cr. Elevated levels of Cr indicate wear of the rolling
element bearings. Excessive wear of the bearings will result in the failure of the final drive.
The two most important tests for the oil sample from final drives are wear element analysis and visual inspection.
Visual inspection of the oil sample can indicate a serious problem of water contamination. Oil samples with a milky
brown appearance probably contain an excessive amount of water. A quick test on a hot plate in a laboratory will
confirm the excessive water. Oil samples with excessive water cannot be run on any other lab tests. The sample should
be given a Red Alert status. At a minimum, the final drive oil should be drained and the compartment should be flushed
in order to remove the water. The final drive should be sampled again within the next 125 service hours. Final drives
that continually contain excessive water may require new seals.
Visual inspection may also reveal visible metal particles in the oil. The results of the oil sample cannot be obtained by a
particle count analysis. If oil samples are analyzed on a particle count analysis, the results will be off of the scale high.
Oil samples with visible metal can be run on the wear element analysis. The results from a wear element analysis will
determine the extent of the wear.
If the oil sample can be tested for wear element analysis, the following guidelines should be used for interpretation of
the results. The guidelines are based on the information in Table 1.
1. Refer to Table 2. Perform the following action if the values from the wear element analysis of your oil sample
equal the values in the table. Make sure that the final drive compartment is flushed at the next scheduled service
interval. The sample should be given a Green Alert or a Yellow Alert status. Flush the final drive with diesel
fuel, kerosene, or hydraulic oil. If it is feasible, a loop circuit on a portable filter cart could be used in order to
clean the compartment. Evaluate another oil sample after 125 service hours.
Table 2
Results
Element Value (1)

Fe 301-450
Si 151-250
Cr 0-7
equal the values in the table. Make sure that the oil is drained and that the final drive compartment is flushed at
the earliest convenience. The sample should be given a Yellow Alert status. Evaluate another oil sample after
125 service hours. Continue operation if the oil sample that was obtained at 125 service hours is normal.
Continue with a normal sampling interval and a normal oil drain interval.
Table 3
Results
Element Value (1)
Fe 301-450
Si 151-250
Cr 8-12
equal the values in the table. Drain the oil from the final drive compartment. Schedule service for the final drive
within the next 50 hours. Flush the final drive compartment in order to remove the contamination and the wear
metals. The sample should be given a Yellow Alert status. Evaluate another oil sample after 125 service hours.
Continue operation with a normal sampling interval and a normal oil drain interval, if the oil sample from the
125 service hour interval is normal.
Table 4
Results
Element Value (1)
Fe >450
Si >250
Cr 8-12
equal the values in the table. The oil should be drained immediately from the final drive compartment. Flush the
final drive compartment in order to remove contamination and wear metals. The sample should be given a Red
Alert status. Evaluate another oil sample within 50 service hours. If the final drive continues to produce levels of
Cr that exceed 12 ppm, inspect the final drive for abnormal gear and bearing wear. Make the necessary repairs.
Table 5
Results
Element Value (1)
Fe >450
Si >250
Cr >12
equal the values in the table. This applies to either the Fe value or the Cr value. Make sure that the final drive is
immediately inspected. The sample should be given a Red Alert status. Relatively low levels of Si indicate that
the entry of dirt is not causing the abnormal wear. A component failure could be occurring.
Table 6
Results
Element Value (1)
Fe >450
Si 0-250
Cr >12
The emphasis is caution for the interpretation of these guidelines. Excavator final drives can safely operate with
relatively high levels of dirt and Fe wear particles in the oil. The gear wear is usually minimal because the final drives
operate at low speeds. If the level of Cr increases above 12 ppm, the bearings could be experiencing abnormal wear.
Action should be taken in order to find the cause of the wear when this condition occurs.
Oil Sample Results From The Final Drives In New Excavators
Many dealerships perform a predelivery inspection of oil samples from the final drives of a new machine. Sampling
generally occurs within the first 30 service hours of operation. The analysis of the wear elements should be in the range
of no action required. Refer to Table 1.
Grease and other compounds may be used during the initial assembly or the rebuild of final drives. One of the most
common materials that is used is anti-seize compound. Anti-seize compound is applied to bearing races, dowel pins,
and other components with a tight fit in order to make disassembly easier. Residual anti-seize compound mixes with
the oil during the early hours of operation. Oil samples from the first oil change will indicate some of the elements from
the anti-seize compound.
The chemical composition of the anti-seize compound commonly contains copper, aluminum, molybdenum, and other
elements. The amount and the type of element will vary depending on the manufacturer. Certain particles from the anti-
seize compound will appear in the oil sample from the final drive compartment. The oil sample will appear to have a
gold shine or a silver shine when light is reflected from the suspended particles. The particles may continue to be
observed in the next couple of oil changes. The particles will eventually disappear. The visual particles can occur in the
following final drives: new, rebuilt and remanufactured
Particle count analysis will be difficult with the presence of the anti-seize compound. Approximately 20% of the initial
oil samples will not produce data from a particle count analysis. The data may be high off of the scale, or the oil sample
may be too dark for a measurement. If a particle count is obtained, the value for the ISO code may have an approximate
range of 22/19 to 23/21. Use the ISO code values in this document for reference purposes only. Refer to "Particle
Count Analysis" section of this article.
Copyright 1993 - 2007 Caterpillar Inc. Thu Jul 5 17:36:26 EDT 2007
All Rights Reserved.
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Media Search - SEPD0897 - 2007/07/16 Page 1 of 6

Product: NO EQUIPMENT SELECTED

Managing the Life Cycles of Excavator Final Drives {4050}

Differences Between Final Drive Operation And Application

Contamination In Final Drives

Guidelines For The Analysis Of Final Drive Oil

Wear Element Analysis

Wear Element Analysis (1)

Particle Count Analysis

Interpretation Of Oil Sample Results

Element Value (1)

Oil Sample Results From The Final Drives In New Excavators

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