MAJOR CODE: 60

NO.: AH12518g
PARTS & SERVICE NEWS DATE: March 28, 2019
Page 1 of 8

SUBJECT: Hydraulic fluids / Oil Analysis & Condition Monitoring Manual

PURPOSE: Revision/ Updated OACM attached

APPLICATION: PC3000/6; PC4000/6; PC5500/6; PC7000/6; PC8000/6

FAILURE CODE: 6000Z9

DESCRIPTION:

1. Appropriate Hydraulic fluids

1.1 Hydraulic fluids, based on mineral oil (DIN 51524)
1.1.1 Hydraulic fluids for operation in moderate and hot climates
1.1.2 Hydraulic fluids for operation in cold and arctic climates
1.2 Biologically degradable, synthetic ester-based hydraulic fluids (ISO15380)

2. Conversion to biologically degradable hydraulic fluids

3. Disposal of Wastes

4. Oil Analysis and Oil Change Intervals

5. Hydraulic fluid power system – Classification level of contamination by

solid particles

Appendix:

Oil Analysis & Condition Monitoring Manual (OACM-GB-4)

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Page 2 of 8

1. Appropriate Hydraulic fluids

1.1 Hydraulic fluids, based on mineral oil with zinc additives
Hydraulic fluids, based on ash less (heavy metal free) additives

  Ex works our excavators are filled with hydraulic oil with zinc
additives.
Designations:
HLP; HLPD; HVLP
These oils meet all requirements of the DIN 51524 (P. 2 / 3).

 DO NOT mix zinc containing hydraulic oils with zinc free (ash
: less) hydraulic oils. The mixing of these fluids must be avoided
even if the mixing ratio is very low.
 DO NOT mix Mineral Hydraulic fluids with Synthetic Hydraulic
fluids.
 Mixing of the above fluids, will reduce anti wear properties and
oxidation stability of the fluid. Quick plugging of the oil filters
in the hydraulic system can occur.

1.1.1 Hydraulic fluids for operation in moderate and hot climates:

Point of Lubricant Ambient Viscosity

Quality Grades
Lubrication Temperature (°C) Grades
Hydraulic Hydraulic oil - 20 to + 11 22 DIN 51524
System HLP or HLPD - 14 to + 21 32 Part 2:
- 6 to + 31 46 HLP; HLPD
0 to + 40 68
+ 5 to + 48 100

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HLP fluids in accordance with DIN 51524 Part 2 (Viscosity Index = 100)
Fluids with corrosion, oxidation and proven wear protection additives.
HLP fluids are suitable for most fields of application and components provided
the temperature and viscosity provisions are observed.

HLPD fluids in accordance with DIN 51524 Part 2 (Viscosity Index = 100)
HLP fluids with additional deterging and disperging additives. Some of these
fluids are able to absorb significant quantities of water. This may have negative
implications for the wear protection and aging properties of the fluid.
If HLPD fluids are used, contamination does not settle. It rather remains
suspended and needs to be filtered out. For this reason, problems with the
standard size of filters can occur.
HLPD fluids may contain additives that in long run are incompatible with plastics,
elastomers and non-ferrous metals. Furthermore, these additives may lead to the
premature clogging of hydraulic filters.

HVLP fluids in accordance with DIN 51524 Part 3 (Viscosity Index >140)
HLP fluids with additional improved viscosity temperature behavior. HVLP fluids
should be used only if required by the temperature range.

Recommended hydraulic oils

  Komatsu Germany recommends using Komatsu Genuine Hydraulic

Oil in the hydraulic system as it is formulated especially for Komatsu
using the latest tribological technology. It is designed to maintain the
reliability and durability of Komatsu machines, ensuring extended
fluid lifetimes and improved anti-wear characteristics of metallic
hydraulic components.

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General information to selecting hydraulic oils

The minimum requirement from Komatsu Germany is that the hydraulic oil must conform
to DIN 51524 Part 2 (HLP) or part 3 (HVLP) and fulfill the viscosity requirements for the
prevailing ambient temperature at the site of operation. We state that:
– Mixing of zinc containing with zinc-free (ash less) hydraulic oils is not allowed,
even in small amounts.
– Mixing of mineral based hydraulic oils with synthetic based hydraulic oils is not allowed.

It is essential that the customer queries the hydraulic oil producer to the compatibility and
miscibility of hydraulic oils before changing or employing them in the hydraulic system of
the excavator.
All recommendations for miscibility and compatibility are entirely the responsibility of the
lubricant manufacturer and for the implementation of those recommendations, entirely the
responsibility of the customer using the guidelines given above by Komatsu Germany.
Komatsu Germany will not accept liability for any damage to the hydraulic components
resulting from the incorrect mixing of hydraulic fluids.

1.1.2 Hydraulic fluids for operation in cold and arctic climates

Ambient
Point of Quality
Manufacturer Lubricant Temperature
Lubrication Grades
(°C)
Hydraulic
System Shell Tellus S4 VX 32 - 50 to + 35
(pre heated) DIN 51524
Part 3: HVLP
ESSOTRANS EXTRA - 45 to + 28

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1.2 Biologically degradable, synthetic ester-based hydraulic fluids

As a result of industrial development water, soil and air are exposed to multiple
contaminating influences. One factor of pollution is the hydraulic fluids used in
machinery and equipment. KMG started a series of test runs with their machines
filled with biologically degradable synthetic ester based hydraulic oils, after having
conducted a market research for availability.
On the basis of the experience gathered, only the synthetic ester based hydraulic
oils (HEES) instead of mineral oils HLP ISO VG 46 are released for use.

Features of synthetic ester-based oils:

 high lubrication characteristics
 high non-aging properties
 high compatibility with plastics and paints
 use of paper type filters
 high thermal stability
 good compatible with Viton (FPM) seals
 excellent thermal characteristics, also for deep temperatures
 good corrosion protection

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2. Conversion to synthetic ester based hydraulic fluids

For the conversion according to VDMA 24568/24569, the remaining mineral oil
portion must not exceed 2 %.
In case the remaining mineral oil portion exceeds 2 %:
 The mixture can’t be called biodegradable and environment friendly.
 The disposal has to be clarified with waste-disposal companies.

  For reaching a mineral-oil portion of less than 2 %, the

hydraulic system has to be flushed several times depending
on machine design and oil volume (please check by oil
analysis) .
 Determine the Part No. of all cylinders which is punch marked
on the cylinder barrel close the retainer flange.
 Transmit these ET.-No. to the Service Department 8151 for the
investigation of the compatibility the Bio - Oil with the seals.
Only change oil after the release of our Service Dept. 8151.

The conversion has to be carried out as follows:

 Start engine and carry out all movements to increase the oil temperature, until
the operating temperature is reached
 retract all cylinders
 drain reservoir of mineral oil
 open all hoses / lines for draining (also at the traveling motors)
 thereafter close all connections
 refill reservoir with ester based oil, bleed all pumps carefully
 extend all cylinders slowly up to the end position
 drain return-oil
 replace the filters
 refill reservoir with ester-based oil
 move all cylinders in both directions sometimes to the end position for bleeding
and also move the travel chains slowly for bleeding the travel motors
 check the hydraulic fluid by oil analysis
 exchange oil filters after 20 - 50 operation hours again
 check oil filters again after 200 operation hours

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3. Disposal of Wastes
Hydraulic fluids based on mineral oil and related hydrocarbons are hazardous for
environment.
The individual manufacturers of hydraulic fluids provide specifications on
environmentally compatible handling and storage.
After draining oil, e.g. regular oil change interval, mineral oils and ester-based oils
have to be stored separately for cheaper and easier disposal. In case of mixed
storage, the waste-disposal company has to be contacted for the required oil
condition and the mixture ratio.
Please ensure that spilt or sputtered fluids are absorbed with appropriate binding
agents or by technical means and cannot reach water bodies, the ground or
sewerage.
Comply with the national legal provisions concerning the disposal of the
corresponding hydraulic fluid.

4. Oil Analysis and Oil Change Intervals

Air, water, temperature effects and solid particle contamination change the usage
properties of hydraulic fluids, contributing to their age.
To preserve the usage properties and ensure a long service life for fluid and
components, the monitoring of fluid condition and a filtration adapted to the
application requirements are indispensable.
After commissioning the shovel and after oil change we recommend making a
reference oil sample analysis and then continuing in 1000 working hour’s steps.
The hydraulic fluid shout be tested by the fluid supplier or by recognized,
accredited test labs.

The minimum data to be tested for analyses are:

– Viscosity at 40 °C and 100 °C (in acc. with ISO 3104)
– Acid number (AN, ASTM D 664 / neutralization number NZ DIN 51558)
– Reserve alkalinity or base number (BN, ISO 3771)
– Water content (Karl-Fischer method, EN ISO 12937)
– Particle measurement (ISO 4406) or mass of the filter membrane (EN 12662)
– Element analysis (RFA, ICP, specify test method)
– Comparison with new product and available trend analyses
– Assessment / evaluation for further use.
- PQ-Index
- Color index (DIN ISO 2049)
- Foaming behavior (in acc. with ASTM D 2272)

The oil-change intervals have to be observed in accordance with the Lubrication

and Maintenance Manual of the shovel.
The hydraulic oil change intervals can be extended, when an oil sample analysis
shows a positive result. However, it is recommended to change the hydraulic oil
and the suction strainers after 6000 operating hours at the latest.

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5. Hydraulic fluid power system – Classification level of contamination by

solid particles
In hydraulic fluid power systems, power is transmitted and controlled through a
liquid under pressure within an enclosed circuit. Hydraulic fluids contain all a
certain amount of solid particle contaminants.
The International Standard ISO 4406/1999 specifies the code to be used in
defining the quantity of solid particles in fluids used in hydraulic fluid power
systems.

There are two possibilities for particle counter analysis:

1. Determination of code using automatic particle counter analysis

The hydraulic system in our excavators correspond to the
Code number 21/18/14
(The number of particles ≥4µm / ≥6µm / ≥14µm will be valued.)

2. Determination of code using microscope sizing

The hydraulic system in our excavators correspond to the
Code number -/18/15
(The number of particles ≥5 µm / ≥15µm will be valued.)

Cleanliness classes according to ISO 4406/1999

Number of particles per milliliter Cleanliness code

More Than Up To

40,000 80,000 23

20,000 40,000 22

10,000 20,000 21 ≥ 4µm

5,000 10,000 20

2,500 5,000 19

1,300 2,500 18 ≥ 6µm

640 1,300 17

320 640 16

160 320 15

80 160 14 ≥ 14µm

Appendix

AH12518g
 OACM-GB-4

Oil Analysis & Condition Monitoring

HYDRAULIC
MINING
SHOVEL
 COPYRIGHT

This material is property of Komatsu Mining Germany GmbH and is not to be reproduced, used, or
disclosed except in accordance with the written authorization of Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.
INTRODUCTION

1 INTRODUCTION

Oil Analysis & Condition Monitoring

GENERAL INTRODUCTION

1.1 GENERAL

1.1.1 GENERAL SAFETY

WARNING
SAFETY HAS TOP PRIORITY!
Taking insufficient safety precautions may lead to serious injury or death.
Read and ensure you fully understand the detailed safety precautions in Chapter 2 of the Operation and
Maintenance Manual. A copy should always be found in the operator's cab.

– All activities must be executed by skilled and authorized personnel only.

– Brief operating personnel before beginning and appoint a person to supervise the activities.
– In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down proce-
dures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
– Ensure that the area is adequately secured.
– The machine must be secured against inadvertent starting by:
– locking the principal control elements and removing the ignition key and/or
– attaching a warning tag to the main switch or control levers.
– setting the maintenance safety switch to the 0 position and securing it with a padlock
– Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
– Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the
Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.
– A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
– Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.

1.1.2 SAFETY CONSIDERATIONS WHEN HANDLING LUBRICANTS

– Check lube temperature prior to sampling. If greater than 48°C (120°F), wear appropriate thermal insulating
gloves to protect hands.
– Wear protective eyewear at all times when performing oil sampling or analysis.
– Wear latex type gloves to protect hands when handling lubricants, reagents, and solvents. Confirm chemical
compaitibility between lubricants, reagents, solvents and the glove material.
– Wash any lubricants that contacts the skin immediately with high quality industrial hand cleaner and plenty of
water.
– Should any lubricant, reagents or solvents get into the eye, refer to the instructions in the appropriate material
safety data sheet (MSDS - widely available online) and seek medical care.
– Should any lubricants be ingested, refer to the instructions in the appropriate material safety data sheet
(MSDS) and seek medical care.
– Dispose of lubricants, reagents and solvents properly.
– Never perform tests near open flame, or in a poorly ventilated area.
– Do not smoke when sampling or testing.

1 -2 Oil Analysis & Condition Monitoring - Introduction

INTRODUCTION GENERAL

1.1.3 FOREWORD
Lubricating and hydraulic oils are subjected to extremes of physical stress, temperature and pressure. They can
rapidly lose their effectiveness if particles of dirt and wear metals contaminate the system, if the ingress of water
causes corrosion, or if general degradation and the depletion of additives negatively influence the quality of the oil
over time.
The aim of this procedure is to monitor the condition of the fluid in the various systems by analysing the various
properties and materials. By regularly sampling and analyzing the fluids, a baseline of normal wear can be estab-
lished which can help indicate when abnormal wear or contamination is occurring.

Oil Analysis & Condition Monitoring - Introduction 1 -3

CONTENTS INTRODUCTION

1.2 CONTENTS
1 INTRODUCTION........................................................................................ 1-1
1.1 GENERAL .......................................................................................................................................... 1-2
1.1.1 GENERAL SAFETY ............................................................................................................... 1-2
1.1.2 SAFETY CONSIDERATIONS WHEN HANDLING LUBRICANTS ........................................ 1-2
1.1.3 FOREWORD.......................................................................................................................... 1-3
1.2 CONTENTS ........................................................................................................................................ 1-4

2 HYDRAULIC OIL ANALYSIS ..................................................................... 2-7

2.1 KNOWING WHEN TO PERFORM AN ANALYSIS............................................................................ 2-8
2.2 TESTING METHODS ......................................................................................................................... 2-8
2.2.1 TRACE PARTICAL CONTAMINATION OF WEAR METALS ................................................ 2-8
2.2.2 MAGNETIC ABRASION......................................................................................................... 2-8
2.2.3 VISCOSITY ............................................................................................................................ 2-9
2.2.4 COLOUR OF THE OIL........................................................................................................... 2-9
2.2.5 VISUAL HAZINESS (WATER CONTENT)............................................................................. 2-9
2.2.6 ACIDITY ................................................................................................................................. 2-9
2.2.7 FOAMING ............................................................................................................................ 2-10
2.2.8 CLEANLINESS CLASS........................................................................................................ 2-10
2.3 TAKING A SAMPLE FROM THE HYDRAULIC SYSTEM............................................................... 2-13
2.3.1 POTENTIAL SOURCES OF INTERFERENCE (ERROR) ................................................... 2-13

3 EVALUATING THE HYDRAULIC OIL SAMPLE ...................................... 3-15

3.1 LIMITS .............................................................................................................................................. 3-16
3.1.1 GENERAL ............................................................................................................................ 3-16
3.1.2 EXPLANATION OF THE RATING OF EACH VALUE ......................................................... 3-16
3.1.3 EXPLANATION OF THE TOTAL RATING........................................................................... 3-16
3.2 HYDRAULIC OIL.............................................................................................................................. 3-17
3.2.1 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000 LITERS........................ 3-17
3.2.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000 LITERS.................... 3-18
3.3 CHECK SHEETS TO FILL OUT FOR EVALUATION...................................................................... 3-19
3.3.1 EXAMPLE OF A COMPLETED SHEET ON A VG100 QUALITY OIL ................................. 3-19
3.3.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000 LITERS....................... 3-20
3.3.3 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000 LITERS................... 3-21

4 GEAR OIL ANALYSIS.............................................................................. 4-23

4.1 GEARBOXES ON THE EXCAVATOR............................................................................................. 4-24
4.2 TAKING AN OIL SAMPLE ............................................................................................................... 4-25
4.3 SPENT OIL ANALYSIS.................................................................................................................... 4-28
4.3.1 VISUAL APPEARANCE....................................................................................................... 4-28
4.3.2 COLOUR OF THE OIL......................................................................................................... 4-28
4.3.3 VISCOSITY .......................................................................................................................... 4-28
4.3.4 ACIDITY ............................................................................................................................... 4-29
4.3.5 VISUAL HAZINESS (WATER CONTENT)........................................................................... 4-29
4.3.6 TRACE PARTICAL CONTAMINATION OF WEAR METALS .............................................. 4-29
4.3.7 MAGNETIC ABRASION....................................................................................................... 4-29

1 -4 Oil Analysis & Condition Monitoring - Introduction

INTRODUCTION CONTENTS

5 EVALUATING THE GEAR OIL SAMPLE................................................. 5-31

5.1 LIMITS .............................................................................................................................................. 5-32
5.1.1 GENERAL ............................................................................................................................ 5-32
5.2 LIMIT TABLES ................................................................................................................................. 5-33
5.2.1 TRAVEL GEAR (60-155 LITRES), CLP 220........................................................................ 5-33
5.2.2 TRAVEL GEAR(200-400 LITRES), CLP 220....................................................................... 5-34
5.2.3 POWER TAKE-OFF (PTO) GEAR, CLP 150....................................................................... 5-35
5.2.4 SWING GEAR, CLP 220...................................................................................................... 5-36

Oil Analysis & Condition Monitoring - Introduction 1 -5

CONTENTS INTRODUCTION

1 -6 Oil Analysis & Condition Monitoring - Introduction

HYDRAULIC OIL ANALYSIS

2 HYDRAULIC OIL
ANALYSIS

Oil Analysis & Condition Monitoring - Hydraulic oil Analysis 2 -7

KNOWING WHEN TO PERFORM AN ANALYSIS HYDRAULIC OIL ANALYSIS

2.1 KNOWING WHEN TO PERFORM AN ANALYSIS

The influences of air, water, temperature and internal friction all contribute to the aging of an oil. The viscosity of
the oil can positively influence the aging as does the addition of chemical compounds such as corrosion inhibitors,
anti-foaming agents or antioxidants. These, and other additives, protect the equipment from wear, corrosion and
excess friction. It is therefore important that they do not deplete, particularly during long-term usage.

A change in the condition of the oil can be noticed by:-

– A visual darkening of the oil

– Increased viscosity
– Visual haziness
– Foaming
Knowing when and if to change the oil depends on the results of a number of tests conducted on an oil sample.
This sample should be extracted into a clear and clean U/V (ultra-violet) proof plastic container (see page 2-13).
The oil should be extracted from a point in the circuit continually flushed with oil.

2.2 TESTING METHODS

2.2.1 TRACE PARTICAL CONTAMINATION OF WEAR METALS

As the contamination of hydraulic oil by wear metals exactly reflects the condition of the unit, analysing the amount
and type of contaminant can indicate the rate of wear and also show if any contamination is excessive.
The metallic particle elements that are tested for are iron, chrome, lead, copper, aluminium and silicon.

REMARKS: Please note that monitoring elements in KMG units during routine monitoring other than the ones
listed is not necessary.

Values Method of Testing What is tested

Element analysis:- Amount of wear. Chemical condition of

ICP-OES
Fe, Cr, Pb, Cu, Al, Si or more the degraded oil

2.2.2 MAGNETIC ABRASION

Magnetic metals enter the oil circulation when wear on the componants due to abrasion, fatigue, severe sliding or
adhesion has occured or when the system has been contaminated. Screening for magnetic particles in conjunction
with metallic trace particle analysis is worthwhile as it will identify magnetic particles larger than 5µm.

Values Method of Testing What is tested

Magnetic metals abrasion PQ-Index Amount of magnetic metals present.

2 -8 Oil Analysis & Condition Monitoring - Hydraulic oil Analysis

HYDRAULIC OIL ANALYSIS TESTING METHODS

2.2.3 VISCOSITY
The resistance to flow of oil determines its viscosity. Oil becomes more viscous with usage. This thickness can be
measured. If purely mineral oil is used, measuring the kinematic viscosity at 40°C is enough.
Differentiating between synthetic and mineral oil can easily be determined using the viscosity index. For this, it is
important to measure the kinematic viscosity at two different temperatures; 100°C and 40°C

Values Method of Testing What is tested

Kinematic viscosity at 40°C ISO 3104 The flow and lubricating abilities of the oil

Kinematic viscosity at 100°C ISO 3104 The flow and lubricating abilities of the oil

Viscosity Index (VI) ISO 2909 Pure mineral oil <105

2.2.4 COLOUR OF THE OIL

The colour of the oil will darken with usage and can give an indication as to possible contamination and degrada-
tion.

Values Method of Testing What is tested

Colour number ISO 2049 Value for oxidisation (trend)

2.2.5 VISUAL HAZINESS (WATER CONTENT)

If the oil is hazy or opaque, this will usually signify the presence of water. The limit of water contamination is 0.1%.
Anything greater will reduce the oils ability to lubricate, its ability to prevent corrosion and will reduce the effective-
ness of the additives.

Values Method of Testing What is tested

Water content Karl-Fischer or FT-IR Presence of condensate or leakage

2.2.6 ACIDITY
The AN (Acid Number or neutralisation number) can be ascertained using acid base titration. The AN, together
with the fresh oil values, can demonstrate age-based acid production and also additive degradation. In hydraulic
units filled with mineral oil, the significance is limited as all expected changes are minimal.

Values Method of Testing What is tested

Acidity ASTM D 664 Reference number for oxidisation

Oil Analysis & Condition Monitoring - Hydraulic oil Analysis 2 -9

TESTING METHODS HYDRAULIC OIL ANALYSIS

2.2.7 FOAMING
Increased foaming can lead to extreme malfunctions and is often the cause of accelerated degradation of the
hydraulic oil. Foaming is caused by such factors as air and other contamination (through leakages etc), old age or
the mixing of oils. Anti-foaming agents lose their effectiveness as the oil degrades which itself is an indicator of
degraded oil quality.

Values Method of Testing What is tested

Foaming behaviour Seq. 1 AST M D 892 disposition to foaming

2.2.8 CLEANLINESS CLASS

The cleanliness class is used to define the level of contamination of solid particles within the sample. The amount
of particles of differing sizes (4, 6, 14 µm) allowed within a millilitre is specified

Values Method of Testing What is tested

Cleanliness class ISO 4406 Particle count

Number of particles per milliliter Cleanliness code

More Than Up To

40,000 80,000 23

20,000 40,000 22

10,000 20,000 21

5,000 10,000 20

2,500 5,000 19

1,300 2,500 18

640 1,300 17

320 640 16

160 320 15

80 160 14

40 80 13

20 40 12

10 20 11

5 10 10

2,5 5 9

1.3 2.5 8

0.64 1.3 7

2 - 10 Oil Analysis & Condition Monitoring - Hydraulic oil Analysis

HYDRAULIC OIL ANALYSIS TESTING METHODS

According to the table, the cleanliness code of 21/18/14 can be decoded as:-

– A particle of 4 µm can be found 10,000 to 20,000 times in 1 mlillilitre. (Cleanliness code 21)
– A particle of 6 µm can be found 1,300 to 2,500 times in 1 millilitre. (Cleanliness code 18)
– A particle of 14 µm can be found 80 to 160 times in 1 millilitre. (Cleanliness code 14)

Oil Analysis & Condition Monitoring - Hydraulic oil Analysis 2 - 11

TESTING METHODS HYDRAULIC OIL ANALYSIS

Fig. 2-1

2 - 12 Oil Analysis & Condition Monitoring - Hydraulic oil Analysis

HYDRAULIC OIL ANALYSIS TAKING A SAMPLE FROM THE HYDRAULIC SYSTEM

2.3 TAKING A SAMPLE FROM THE

HYDRAULIC SYSTEM
WARNING
HIGH PRESSURE FLUID!
The hydraulic system is always under internal pressure and can lead to serious injury when accessed.
All relevant safety aspects are to be considered on pressurized systems.

Legend for Fig. 2-1

(1) Minimess connection

(2) Stand pipe on hydraulic oil tank

(3) Hydraulic oil tank

(4) Tube to collect sample

(5) Quick connect coupling

(6) Plastic UV proof bottle

All samples should be taken from circulating systems, ideally when the pumps are kept at a high idling speed,
or failing that, immediately upon shutdown while the hydraulic fluid is within 5°C (9°F) of normal system
operating temperature.

Systems not up to temperature may provide non-representative samples of system dirt and water content, and
such samples should either be avoided or so indicated on the analysis report.

It should be taken using a minimess connection (1) in the return oil line (stand pipe - 2) to the hydraulic oil tank (3)
before the filter.

Extract the oil sample using an adapted tube (4) with quick connect coupling (5) into a clear and clean plastic bot-
tle (6).

REMARKS: Ultra-violet rays from direct sunlight can change the properties of the sample. Ensure that the plastic
bottle is 100% UV (ultra-violet) proof (see Fig. 2-1).

The first oil coming from the sampling point should be discarded, since it can be very dirty and does not repre-
sent the system. As a general rule, a volume of oil equivalent to one to two times the volume of oil contained in
the sampling line and valve should be drained before the sample is taken.

2.3.1 POTENTIAL SOURCES OF INTERFERENCE (ERROR)

– Failure to ensure that the sample is drawn from the same point each time due to variable distance into the tank
or sump or due to the drop tube coiling up, in or out.
– Failure to ensure that the machine is sampled during operation, or the same time period after shutdown, each
time.
– Scraping side wall deposits into the drop tube when entering tank or sump.
– Picking up bottom sediment or water.
– Contaminating the sample during handling.
– In circulating systems, failure to obtain live samples downstream of ingestion points.
– Contamination of plastic tubing
– Contamination from the vacuum pump.

Oil Analysis & Condition Monitoring - Hydraulic oil Analysis 2 - 13

TAKING A SAMPLE FROM THE HYDRAULIC SYSTEM HYDRAULIC OIL ANALYSIS

2 - 14 Oil Analysis & Condition Monitoring - Hydraulic oil Analysis

EVALUATING THE Hydraulic OIL SAMPLE

3 EVALUATING THE
HYDRAULIC OIL SAMPLE

Oil Analysis & Condition Monitoring - Evaluation 3 - 15

Limits EVALUATING THE Hydraulic OIL SAMPLE

3.1 LIMITS

3.1.1 GENERAL
The limits in the following tables are set for KMG recommended hydraulic oil that has been in operation under nor-
mal working conditions for between 2000 and 6000 hours.

NOTICE
It is recommended that the oil be changed after 6000 operating hours regardless of an oil analysis or
planned refills.

A traffic light system is used to evaluate each individual limit.

3.1.2 EXPLANATION OF THE RATING OF EACH VALUE

GREEN Value is normal

YELLOW Value is slightly increased but non-critical. Corrective action such as decreasing the inter-
vals between sample analysis may be necessary.

RED Value is clearly increased. An oil change is necessary and/or other corrective measures

The total rating is comprised of individual ratings compiled to the following rules.

Individual Ratings Total Rating

All values "green" 

One value "yellow", all others "green" 
More than one value "yellow", all others "green" ?
All values "yellow" ?
At least one value "red" !*
More than one value "red" exceeds double the "red" limits. ! **

*) If just one value is red, the results of the complete analysis can be verified by an immediate reanalysis.

**) It is recommended the Komatsu Mining technical service is contacted immediately.

3.1.3 EXPLANATION OF THE TOTAL RATING

 All values are normal. No indication of a reduction in the lifetime of the components

? Some values are slightly increased but non-critical. Corrective actions such as decreasing the
intervals between sample analysis may be necessary. Without corrective action, a reduction in
the lifetime of the components is possible.

! Value is clearly increased. An oil change is necessary. Further corrective actions may also be
necessary. A reduction in the lifetime of the components is expected.

3 - 16 Oil Analysis & Condition Monitoring - Evaluation

EVALUATING THE Hydraulic OIL SAMPLE HYDRAULIC OIL

3.2 HYDRAULIC OIL

3.2.1 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000

LITERS.

Quality Reference value Method Unit GREEN YELLOW RED

Fe <5 5 - 13 >13

Cr <2 2-5 >5

Cu <7 7 - 15 >15
ICP-OES mg/kg
ALL Pb <3 3-9 >10

Al <2 2-9 >9

Si <4 4 - 10 >10

Magnetic metal abrasion PQ-Index - <31 31 - 39 >39

Kinematic Visc. @ 40°C mm²/s 20.5 - 23.5 <20.5; >23.5 <19.8; >24.4
ISO 3104
VG22 Kinematic Visc. @100°C (cSt) 3.9 - 4.5 <3.9; >4.5 <3.8; >4.7

Viscosity index ISO 2909 - 82 - 104 <82; >104 <79; >110

Kinematic Visc. @ 40°C mm²/s 29.8 - 34.2 <29.8; >34.2 <28.8; >35.1
ISO 3104
VG32 Kinematic Visc. @ 100°C (cSt) 5 - 5.8 <5; >5.8 <4.8; >6

Viscosity index ISO 2909 - 91 - 111 <91; >111 <85; >116

Kinematic Visc. @ 40°C mm²/s 42.8 - 49.2 <42.8; >49.2 <41.4; >50.6
ISO 3104
VG46 Kinematic Visc. @ 100°C (cSt) 6.3 - 7.3 <6.3; >7.3 <6.1; >7.5

Viscosity index ISO 2909 - 94 - 109 <94; >109 <91; >111

Kinematic Visc. @ 40°C mm²/s 63.2 - 72.8 <63.2; >72.8 <61.2; >74.7
ISO 3104
VG68 Kinematic Visc. @ 100°C (cSt) 7.9 - 9.1 <7.9; >9.1 <7.6; >9.3

Viscosity index ISO 2909 - 89 - 100 <89; >100 <85; >101

Kinematic Visc. @ 40°C mm²/s 93 - 106 <93; >106 <90; >110

ISO 3104
VG100 Kinematic Visc. @ 100°C (cSt) 10.5 - 11.7 <10.7; > 11.7 <10; >12.5

Viscosity index ISO 2909 - 93 - 105 <93; >105 <90; >110

Colour code number ISO 2049 - <4 5-6 >6

<1000mg/ <1200 mg/kg >1200 mg/

Karl-Fischer mg/kg or
Water content kg (<0.1 (<0.12 weight kg (>0.12
or FT-IR weight %
weight %) %) weight %)
ALL
Acidity (AN)* ASTM D 664 mgK OH/g <0.3 0.3 - 0.5 >0.5

Cleanliness class ISO 4406 ISO Code 21/18/14 >21/18/14 >22/19/15

Foaming behaviour seq, 1 ASTM D 892 ml/ml 150/0 200/0 - 400/0 >400/10

*) Increase in comparison with fresh oil.

Oil Analysis & Condition Monitoring - Evaluation 3 - 17

HYDRAULIC OIL EVALUATING THE Hydraulic OIL SAMPLE

3.2.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000

LITERS.

Quality Reference value Method Unit Green Yellow RED

Fe <4 4-9 >9

Cr <2 2-4 >4

Cu <5 7 - 10 >10
ICP-OES mg/kg
ALL Pb <3 3-6 >6

Al <2 2-6 >6

Si <4 4-7 >7

Magnetic metal abrasion PQ-Index - <30 30 - 39 >39

Kinematic Visc. @ 40°C mm²/s 20.5 - 23.5 <20.5; >23.5 <19.8; >24.4
ISO 3104
VG22 Kinematic Visc. @100°C (cSt) 3.9 - 4.5 <3.9; >4.5 <3.8; >4.7

Viscosity index PQ-Index - 82 - 104 <82; >104 <79; >110

Kinematic Visc. @ 40°C mm²/s 29.8 - 34.2 <29.8; >34.2 <28.8; >35.1
ISO 3104
VG32 Kinematic Visc. @ 100°C (cSt) 5 - 5.8 <5; >5.8 <4.8; >6

Viscosity index PQ-Index - 91 - 111 <91; >111 <85; >116

Kinematic Visc. @ 40°C mm²/s 42.8 - 49.2 <42.8; >49.2 <41.4; >50.6
ISO 3104
VG46 Kinematic Visc. @ 100°C (cSt) 6.3 - 7.3 <6.3; >7.3 <6.1; >7.5

Viscosity index PQ-Index - 94 - 109 <94; >109 <91; >111

Kinematic Visc. @ 40°C mm²/s 63.2 - 72.8 <63.2; >72.8 <61.2; >74.7
ISO 3104
VG68 Kinematic Visc. @ 100°C (cSt) 7.9 - 9.1 <7.9; >9.1 <7.6; >9.3

Viscosity index PQ-Index - 89 - 100 <89; >100 <85; >101

Kinematic Visc. @ 40°C mm²/s 93 - 106 <93; >106 <90; >110

ISO 3104
VG100 Kinematic Visc. @ 100°C (cSt) 10.5 - 11.7 <10.5; > 11.7 <10; >12.5

Viscosity index ISO 2909 - 93 - 105 <93; >105 <90; >110

Colour code number ISO 2049 - <4.5 5-6 >6

<1000mg/ <1200 mg/kg >1200 mg/

Karl-Fischer mg/kg or
Water content kg (<0.1 (<0.12 weight kg (>0.12
or FT-IR weight %
weight %) %) weight %)

ALL ASTM D
Acidity (AN)* mgK OH/g <0.3 0.3 - 0.5 >0.5
664

Cleanliness class ISO 4406 ISO Code 21/18/14 >21/18/14 >22/19/15

ASTM D
Foaming behaviour seq, 1 ml/ml 150/0 200/0 - 400/0 >400/10
892

*) Increase in comparison with fresh oil.

3 - 18 Oil Analysis & Condition Monitoring - Evaluation

 CHECK SHEETS TO FILL OUT FOR EVALUATION

3.3 CHECK SHEETS TO FILL OUT FOR EVALUATION

3.3.1 EXAMPLE OF A COMPLETED SHEET ON A VG100 QUALITY OIL

Conf. Total
Quality Reference value Method Unit GREEN YELLOW RED
Value Rating

Fe <5 5 - 13 >13 4 
Cr <2 2-5 >5 2 ?
Cu <7 7 - 15 >15 8 ?
ICP-OES mg/kg
ALL Pb <3 3-9 >10 11 !
Al <2 2-9 >9 4 ?
Si <4 4 - 10 >10 5 ?
Magnetic metal abrasion PQ-Index - <31 31 - 39 >39 29 
Kinematic Visc. @ 40°C 20.5 - 23.5 <20.5; >23.5 <19.8; >24.4
ISO 3104 mm²/s (cSt)
VG22 Kinematic Visc. @ 100°C 3.9 - 4.5 <3.9; >4.5 <3.8; >4.7

Viscosity index ISO 2909 82 - 104 <82; >104 <79; >110

Kinematic Visc. @ 40°C 29.8 - 34.2 <29.8; >34.2 <28.8; >35.1

ISO 3104 mm²/s (cSt)
VG32 Kinematic Visc. @ 100°C 5 - 5.8 <5; >5.8 <4.8; >6

Viscosity index ISO 2909 91 - 111 <91; >111 <85; >116

Kinematic Visc. @ 40°C 42.8 - 49.2 <42.8; >49.2 <41.4; >50.6

ISO 3104 mm²/s (cSt)
VG46 Kinematic Visc. @ 100°C 6.3 - 7.3 <6.3; >7.3 <6.1; >7.5

Viscosity index ISO 2909 94 - 109 <94; >109 <91; >111

Kinematic Visc. @ 40°C 63.2 - 72.8 <63.2; >72.8 <61.2; >74.7

ISO 3104 mm²/s (cSt)
VG68 Kinematic Visc. @100°C 7.9 - 9.1 <7.9; >9.1 <7.6; >9.3

Viscosity index ISO 2909 89 - 100 <89; >100 <85; >101

Kinematic Visc. @ 40°C 93 - 106 <93; >106 <90; >110 99 

ISO 3104 mm²/s (cSt)
VG100 Kinematic Visc. @ 100°C 10.5 - 11.7 <10.7; > 11.7 <10; >12.5 11.2 
Viscosity index ISO 2909 93 - 105 <93; >105 <90; >110 101 
Colour code number ISO 2049 <4 5-6 >6 7 !
Karl-Fischer mg/kg or <1000mg/kg <1200 mg/kg >1200 mg/kg
Water content
or FT-IR weight % (<0.1 weight %) (<0.12 weight %) (>0.12 weight %)
991 

Acidity (AN)* ASTM D 664 mgK OH/g <0.3 0.3 - 0.5 >0.5 0.4 ?
ALL

21/18/
Cleanliness class ISO 4406 ISO Code 21/18/14 >21/18/14 >22/19/15 
14
Foaming
behaviour seq, 1
ASTM D 892 ml/ml 150/0 200/0 - 400/0 >400/10 150/0 

*) Increase in comparison with fresh oil.

Oil Analysis & Condition Monitoring - Check Sheet - 19

 CHECK SHEETS TO FILL OUT FOR EVALUATION

3.3.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000

LITERS

Conf. Total
Quality Reference value Method Unit GREEN YELLOW RED
Value Rating

Fe <5 5 - 13 >13

Cr <2 2-5 >5

Cu <7 7 - 15 >15
ICP-OES mg/kg
ALL Pb <3 3-9 >10

Al <2 2-9 >9

Si <4 4 - 10 >10

Magnetic metal abrasion PQ-Index - <31 31 - 39 >39

Kinematic Visc. @ 40°C 20.5 - 23.5 <20.5; >23.5 <19.8; >24.4

ISO 3104 mm²/s (cSt)
VG22 Kinematic Visc. @ 100°C 3.9 - 4.5 <3.9; >4.5 <3.8; >4.7

Viscosity index ISO 2909 82 - 104 <82; >104 <79; >110

Kinematic Visc. @ 40°C 29.8 - 34.2 <29.8; >34.2 <28.8; >35.1

ISO 3104 mm²/s (cSt)
VG32 Kinematic Visc. @ 100°C 5 - 5.8 <5; >5.8 <4.8; >6

Viscosity index ISO 2909 91 - 111 <91; >111 <85; >116

Kinematic Visc. @ 40°C 42.8 - 49.2 <42.8; >49.2 <41.4; >50.6

ISO 3104 mm²/s (cSt)
VG46 Kinematic Visc. @ 100°C 6.3 - 7.3 <6.3; >7.3 <6.1; >7.5

Viscosity index ISO 2909 94 - 109 <94; >109 <91; >111

Kinematic Visc. @ 40°C 63.2 - 72.8 <63.2; >72.8 <61.2; >74.7

ISO 3104 mm²/s (cSt)
VG68 Kinematic Visc. @100°C 7.9 - 9.1 <7.9; >9.1 <7.6; >9.3

Viscosity index ISO 2909 89 - 100 <89; >100 <85; >101

Kinematic Visc. @ 40°C 93 - 106 <93; >106 <90; >110

ISO 3104 mm²/s (cSt)
VG100 Kinematic Visc. @ 100°C 10.5 - 11.7 <10.7; > 11.7 <10; >12.5

Viscosity index ISO 2909 93 - 105 <93; >105 <90; >110

Colour code number ISO 2049 <4 5-6 >6

Karl-Fischer mg/kg or <1000mg/kg <1200 mg/kg >1200 mg/kg

Water content
or FT-IR weight % (<0.1 weight %) (<0.12 weight %) (>0.12 weight %)

ALL Acidity (AN)* ASTM D 664 mgK OH/g <0.3 0.3 - 0.5 >0.5

Cleanliness class ISO 4406 ISO Code 21/18/14 >21/18/14 >22/19/15

Foaming
ASTM D 892 ml/ml 150/0 200/0 - 400/0 >400/10
behaviour seq, 1

*) Increase in comparison with fresh oil.

- 20 Oil Analysis & Condition Monitoring - Check Sheet

 CHECK SHEETS TO FILL OUT FOR EVALUATION

3.3.3 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000

LITERS

Conf. Total
Quality Reference value Method Unit GREEN YELLOW RED
Value Rating

Fe 4 4-9 9

Cr <2 2-4 >4

Cu <5 7 - 10 >10
ICP-OES mg/kg
ALL Pb <3 3-6 >6

Al <2 2-6 >6

Si <4 4-7 >7

Magnetic metal abrasion PQ-Index - 30 30 - 39 >39

Kinematic Visc. @ 40°C 20.5 - 23.5 <20.5; >23.5 <19.8; >24.4

ISO 3104 mm²/s (cSt)
VG22 Kinematic Visc. @ 100°C 3.9 - 4.5 <3.9; >4.5 <3.8; >4.7

Viscosity index ISO 2909 82 - 104 <82; >104 <79; >110

Kinematic Visc. @ 40°C 29.8 - 34.2 <29.8; >34.2 <28.8; >35.1

ISO 3104 mm²/s (cSt)
VG32 Kinematic Visc. @ 100°C 5 - 5.8 <5; >5.8 <4.8; >6

Viscosity index ISO 2909 91 - 111 <91; >111 <85; >116

Kinematic Visc. @ 40°C 42.8 - 49.2 <42.8; >49.2 <41.4; >50.6

ISO 3104 mm²/s (cSt)
VG46 Kinematic Visc. @ 100°C 6.3 - 7.3 <6.3; >7.3 <6.1; >7.5

Viscosity index ISO 2909 94 - 109 <94; >109 <91; >111

Kinematic Visc. @ 40°C 63.2 - 72.8 <63.2; >72.8 <61.2; >74.7

ISO 3104 mm²/s (cSt)
VG68 Kinematic Visc. @100°C 7.9 - 9.1 <7.9; >9.1 <7.6; >9.3

Viscosity index ISO 2909 89 - 100 <89; >100 <85; >101

Kinematic Visc. @ 40°C 93 - 106 <93; >106 <90; >110

ISO 3104 mm²/s (cSt)
VG100 Kinematic Visc. @ 100°C 10.5 - 11.7 <10.5; > 11.7 <10; >12.5

Viscosity index ISO 2909 93 - 105 <93; >105 <90; >110

Colour code number ISO 2049 <4 5-6 >6

Karl-Fischer mg/kg or <1000mg/kg <1200 mg/kg >1200 mg/kg

Water content
or FT-IR weight % (<0.1 weight %) (<0.12 weight %) (>0.12 weight %)

ALL Acidity (AN)* ASTM D 664 mgK OH/g <0.3 0.3 - 0.5 >0.5

Cleanliness class ISO 4406 ISO Code 21/18/14 >21/18/14 >22/19/15

Foaming
ASTM D 892 ml/ml 150/0 200/0 - 400/0 >400/10
behaviour seq, 1

*) Increase in comparison with fresh oil.

Oil Analysis & Condition Monitoring - Check Sheet - 21

CHECK SHEETS TO FILL OUT FOR EVALUATION

- 22 Oil Analysis & Condition Monitoring - Check Sheet

GEAR OIL ANALYSIS

4 GEAR OIL ANALYSIS

Oil Analysis & Condition Monitoring - Gear Oil Analysis 4 - 23

Gearboxes on the Excavator GEAR OIL ANALYSIS

4.1 GEARBOXES ON THE EXCAVATOR

The following gearboxes on the excavator are to be checked for the condition of the used oils:-

1. Swing gears

2. Travel gears

3. Power take-off (PTO) gears

Fig. 4-2

4 - 24 Oil Analysis & Condition Monitoring - Gear Oil Analysis

GEAR OIL ANALYSIS Taking An Oil Sample

4.2 TAKING AN OIL SAMPLE

REMARKS: A sample of fresh oil should always be on hand in order to directly compare the results of a used oil
sample analysis.

All samples should be taken from circulating systems, ideally when the gear is at operating temperature, or
failing that, immediately upon shutdown while the gear oil is within 5°C (9°F) of normal system operating
temperature.

Systems not up to temperature may provide non-representative samples of system dirt and water content, and
such samples should either be avoided or so indicated on the analysis report.

REMARKS: Ultra-violet rays from direct sunlight can change the properties of the sample. Ensure that the plastic
bottle is 100% UV (ultra-violet) proof. Ensure that the bottle is tight-sealing.

The first oil coming from the sampling point should be discarded, since it can be very dirty and does not repre-
sent the system. As a general rule, a volume of oil equivalent to one to two times the volume of oil contained in
the sampling line and valve should be drained before the sample is taken.

The intervals for extracting an oil sample are set for every 1000 operating hours whereas the interval for checking
the oil level are every 50 operating hours. If an abnormality is discovered during an oil level check (oil level too low
indicating a leak or defective seal or too high indicating possible water contamination) proceed initially with visual
check of the system followed by an oil sample analysis.

REMARKS: A sample should also be taken directly after commissioning the machine.

4.2.0.1 FROM THE SWING GEAR

Fig. 4-3 shows the oil filler port on a swing gear.

Fig. 4-3

Oil Analysis & Condition Monitoring - Gear Oil Analysis 4 - 25

Taking An Oil Sample GEAR OIL ANALYSIS

4.2.0.2 FROM THE TRAVEL GEAR

Fig. 4-4 shows the dipstick port on a travel gear.

Fig. 4-4

4.2.0.3 FROM THE POWER TAKE-OFF (PTO) GEAR

Fig. 4-5 shows the dipstick port on a PTO gear.

Fig. 4-5

4 - 26 Oil Analysis & Condition Monitoring - Gear Oil Analysis

GEAR OIL ANALYSIS Taking An Oil Sample

The oil sample should be extracted using a quick connect coupling and an adapter tube attached to the oil drain
plug as shown. A sample of approx. 0.5 liters should be taken.

Ensure the sampling area is clean and free from water so that no contaminant may enter the gearbox and influ-
ence the sample.

Ensure the sampling equipment is clean and dry.

The sampling of the oil should be conducted by experienced personnel only.

Ensure the sample is properly labeled. Data should include:

– Gearbox type
– Oil brand
– Oil level
– Date of sample
– Gearbox (or machine) operating hours since last sample.
– Top-up oil volume
– Top-up oil brand.
– Name of person taking the sample

Oil Analysis & Condition Monitoring - Gear Oil Analysis 4 - 27

SPENT OIL ANALYSIS GEAR OIL ANALYSIS

4.3 SPENT OIL ANALYSIS

The influences of air, water, temperature and internal friction all contribute to the aging of an oil. The viscosity of
the oil can positively influence the aging as does the addition of chemical compounds such as corrosion inhibitors,
anti-foaming agents or antioxidants. These, and other additives, protect the equipment from wear, corrosion and
excess friction. It is therefore important that they do not deplete, particularly during long-term usage.

A change in the condition of the oil can be noticed by:-

– A visual darkening of the oil

– Increased viscosity
– Visual haziness
– Foaming
Knowing when and if to change the oil depends on the results of a number of tests conducted on an oil sample.

4.3.1 VISUAL APPEARANCE

If the oil is dark (and maybe has a ’burnt’ smell) and thick, this may indicate a spent oil. The oil has oxidised and
increased in viscosity. If it has a misty appearance, the presence of water may be involved.

4.3.2 COLOUR OF THE OIL

The colour of the oil will darken with usage and can give an indication as to possible contamination and degrada-
tion. This should be compared with the colour of the fresh oil.

Values Method of Testing What is tested

Colour number ISO 2049 Value for oxidisation (trend)

4.3.3 VISCOSITY

The resistance to flow of oil determines its viscosity. Oil can become more viscous with usage. This thickness can
be measured. If purely mineral oil is used, or when evaluating analytical results from gearboxes, measuring the
kinematic viscosity at 40°C is usually enough.
Differentiating between synthetic and mineral oil can easily be determined using the viscosity index. For this, it is
important to measure the kinematic viscosity at two different temperatures; 100°C and 40°C

Values Method of Testing What is tested

Kinematic viscosity at 40°C ISO 3104 The flow and lubricating abilities of the oil

Kinematic viscosity at 100°C ISO 3104 The flow and lubricating abilities of the oil

Viscosity Index (VI) ISO 2909 Pure mineral oil <105, synthetic is higher

4 - 28 Oil Analysis & Condition Monitoring - Gear Oil Analysis

GEAR OIL ANALYSIS SPENT OIL ANALYSIS

4.3.4 ACIDITY
The AN (Acid Number or neutralization number) can be ascertained using acid base titration. The AN, together
with the fresh oil values, can demonstrate age-based acid production and also additive degradation.

Values Method of Testing What is tested

Acidity ASTM D 664 Reference number for oxidisation

4.3.5 VISUAL HAZINESS (WATER CONTENT)

If the oil is hazy or opaque, this will usually signify the presence of water. The limit of water contamination is 0.1%.
Anything greater will reduce the oils ability to lubricate, its ability to prevent corrosion and will reduce the effective-
ness of the additives.

Values Method of Testing What is tested

Water content Karl-Fischer or FT-IR Presence of condensate or leakage

4.3.6 TRACE PARTICAL CONTAMINATION OF WEAR METALS

As the contamination of gear oil by wear metals exactly reflects the condition of the unit, analysing the amount and
type of contaminant can indicate the rate of wear and also show if any contamination is excessive.
.

Values Method of Testing What is tested

Element analysis:- Amount of wear. Chemical condition of

ICP-OES
FE, Cr, Sn, Al, Ni, Cu, Pb, Mo, the degraded oil

4.3.7 MAGNETIC ABRASION

Magnetic metals enter the oil circulation when wear on the componants due to abrasion, fatigue, severe sliding or
adhesion has occured or when the system has been contaminated. Screening for magnetic particles in conjunction
with metallic trace particle analysis is worthwhile as it will identify magnetic particles larger than 5µm.

Values Method of Testing What is tested

Magnetic metals abrasion PQ-Index Amount of magnetic metals present.

Oil Analysis & Condition Monitoring - Gear Oil Analysis 4 - 29

SPENT OIL ANALYSIS GEAR OIL ANALYSIS

4 - 30 Oil Analysis & Condition Monitoring - Gear Oil Analysis

EVALUATING THE GEAR OIL SAMPLE

5 EVALUATING THE GEAR

OIL SAMPLE

Oil Analysis & Condition Monitoring - Evaluating Gear Oils 5 - 31

Limits EVALUATING THE GEAR OIL SAMPLE

5.1 LIMITS

5.1.1 GENERAL
The limits in the following tables are set for KMG recommended gear oil that has been in operation under normal
working conditions for between 1000h and 3000h or has shown abnormal levels when an oil level check per dip-
stick is made.

NOTICE
These values are basic recommended values only. The local environment, machine usage times, compo-
nent temperature or fluid manufacturer etc., may mean that greatly different results are produced. It is
therefore useful to analyze each unit sample separately and evaluate the results according to these differ-
ences in circumstance. It is recommended to evaluate a trend rather than an individual reading.

5 - 32 Oil Analysis & Condition Monitoring - Evaluating Gear Oils

EVALUATING THE GEAR OIL SAMPLE LIMIT TABLES

5.2 LIMIT TABLES

5.2.1 TRAVEL GEAR (60-155 LITRES), CLP 220

Test Ref. value Unit OK Warning

Iron - Fe =/< 285 >285

Chromium - Cr =/< 7 >7

Tin - Sn =/< 7 >7

Aluminium - Al =/< 11 >11

Wear mg/kg
Nickel - Ni =/< 3 >3
metal (ppm)
Copper - Cu =/< 23 >23

Lead - Pb =/< 8 >8

Molybdenum - Mo =/< 8 >8

PQ Index =/< 184 >184

Silicon/ Dust =/<39 >39

mg/kg
Potassium - K Fresh oil + 25 Fresh oil + >25
Contam. (ppm)
Sodium - Na Fresh oil + 25 Fresh oil + >25

Water Wt % =/< 0.012 >0.12

mm²/s
Oil Kin. V. @ 40°C (cSt) 192 - 248 <192 & >248

Calcium - Ca Fresh oil +/- 20%

Magnesium - Mg Fresh oil +/- 20%

Boron - B Fresh oil +/- 20%

mg/kg
Additives Zinc - Zn Fresh oil +/- 20%
(ppm)
Phosphorus - P Fresh oil +/- 20%

barium - Ba Fresh oil +/- 20%

Sulfer - S Fresh oil +/- 20%

mgKOH
Acidity NZ (AN, TAN) -0.2 / +0.7
/g

Oil Analysis & Condition Monitoring - Evaluating Gear Oils 5 - 33

LIMIT TABLES EVALUATING THE GEAR OIL SAMPLE

5.2.2 TRAVEL GEAR(200-400 LITRES), CLP 220

Test Ref. value Unit OK Warning

Iron - Fe =/< 195 >195

Chromium - Cr =/< 7 >7

Tin - Sn =/< 7 >7

Aluminium - Al =/< 7 >14

Wear
Nickel - Ni mg/kg =/< 3 >3
metal
Copper - Cu =/< 18 >18

Lead - Pb =/< 8 >8

Molybdenum - Mo =/< 8 8

PQ Index =/< 144 >144

Silicon/ Dust =/< 32 >32

mg/kg
Potassium - K Fresh oil + 25 Fresh oil + > 25
Contam. (ppm)
Sodium - Na Fresh oil + 25 Fresh oil + > 25

Water Wt % =/< 0.12 >0.12

mm²/s
Oil Kin. V. @ 40°C (cSt) 192 - 248 <186 & >254

Calcium - Ca Fresh oil +/- 20%

Magnesium - Mg Fresh oil +/- 20%

Boron - B Fresh oil +/- 20%

mg/kg
Additives Zinc - Zn Fresh oil +/- 20%
(ppm)
Phosphorus - P Fresh oil +/- 20%

barium - Ba Fresh oil +/- 20%

Sulfer - S Fresh oil +/- 20%

mgKOH
Acidity NZ (AN, TAN) -0.2 / +0.7
/g

5 - 34 Oil Analysis & Condition Monitoring - Evaluating Gear Oils

EVALUATING THE GEAR OIL SAMPLE LIMIT TABLES

5.2.3 POWER TAKE-OFF (PTO) GEAR, CLP 150

Test Ref. value Unit Normal Warning

Iron - Fe =/< 155 >155

Chromium - Cr =/< 7 >7

Tin - Sn =/< 4 >4

Aluminium - Al =/< 9 >9

Wear
Nickel - Ni mg/kg =/< 3 >3
metal
Copper - Cu =/< 18 >18

Lead - Pb =/< 6 >6

Molybdenum - Mo =/< 4 4

PQ Index =/< 121 >121

Silicon/ Dust =/< 43 >43

mg/kg
Potassium - K Fresh oil + 30 Fresh oil + > 30
Contam. (ppm)
Sodium - Na Fresh oil + 30 Fresh oil + > 30

Water Wt % <0.12 >0.12

mm²/s
Oil Kin. V. @ 40°C (cSt) 130.5 - 169.5 <126.5 & >173.5

Calcium - Ca Fresh oil +/- 20%

Magnesium - Mg Fresh oil +/- 20%

Boron - B Fresh oil +/- 20%

mg/kg
Additives Zinc - Zn Fresh oil +/- 20%
(ppm)
Phosphorus - P Fresh oil +/- 20%

barium - Ba Fresh oil +/- 20%

Sulfer - S Fresh oil +/- 20%

mgKOH
Acidity NZ (AN, TAN) -0.2 / +0.7
/g

Oil Analysis & Condition Monitoring - Evaluating Gear Oils 5 - 35

LIMIT TABLES EVALUATING THE GEAR OIL SAMPLE

5.2.4 SWING GEAR, CLP 220

Test Ref. value Unit Normal Warning

Iron - Fe =/<141 >141

Chromium - Cr =/< 4 >4

Tin - Sn =/< 3 >3

Aluminium - Al =/< 9 >9

Wear mg/kg
Nickel - Ni =/< 3 >3
metal (ppm)
Copper - Cu =/<122 >22

Lead - Pb =/< 49 >9

Molybdenum - Mo =/< 6 >6

PQ Index =/< 116 >116

Silicon/ Dust =/< 48 >48

mg/kg
Potassium - K Fresh oil + 30 Fresh oil + >30
Contam. (ppm)
Sodium - Na Fresh oil + 30 Fresh oil + >30

Water Wt % =/> 0.12 >0.12

mm²/s
Oil Kin. V. @ 40°C (cSt) 192 - 248 <186 & >254

Calcium - Ca Fresh oil +/- 20%

Magnesium - Mg Fresh oil +/- 20%

Boron - B Fresh oil +/- 20%

mg/kg
Additives Zinc - Zn Fresh oil +/- 20%
(ppm)
Phosphorus - P Fresh oil +/- 20%

barium - Ba Fresh oil +/- 20%

Sulfer - S Fresh oil +/- 20%

mgKOH
Acidity NZ (AN, TAN) -0.2 / +0.7
/g

5 - 36 Oil Analysis & Condition Monitoring - Evaluating Gear Oils

1 INTRODUCTION........................................................................................ 1-1
1.1 GENERAL .......................................................................................................................................... 1-2
1.1.1 GENERAL SAFETY ............................................................................................................... 1-2
1.1.2 SAFETY CONSIDERATIONS WHEN HANDLING LUBRICANTS ........................................ 1-2
1.1.3 FOREWORD.......................................................................................................................... 1-3
1.2 CONTENTS ........................................................................................................................................ 1-4

2 HYDRAULIC OIL ANALYSIS ..................................................................... 2-7

2.1 KNOWING WHEN TO PERFORM AN ANALYSIS............................................................................ 2-8
2.2 TESTING METHODS ......................................................................................................................... 2-8
2.2.1 TRACE PARTICAL CONTAMINATION OF WEAR METALS ................................................ 2-8
2.2.2 MAGNETIC ABRASION ........................................................................................................ 2-8
2.2.3 VISCOSITY............................................................................................................................ 2-9
2.2.4 COLOUR OF THE OIL........................................................................................................... 2-9
2.2.5 VISUAL HAZINESS (WATER CONTENT) ............................................................................ 2-9
2.2.6 ACIDITY................................................................................................................................. 2-9
2.2.7 FOAMING ............................................................................................................................ 2-10
2.2.8 CLEANLINESS CLASS ....................................................................................................... 2-10
2.3 TAKING A SAMPLE FROM THE HYDRAULIC SYSTEM............................................................... 2-13
2.3.1 POTENTIAL SOURCES OF INTERFERENCE (ERROR) ................................................... 2-13

3 EVALUATING THE HYDRAULIC OIL SAMPLE ...................................... 3-15

3.1 LIMITS .............................................................................................................................................. 3-16
3.1.1 GENERAL ............................................................................................................................ 3-16
3.1.2 EXPLANATION OF THE RATING OF EACH VALUE ......................................................... 3-16
3.1.3 EXPLANATION OF THE TOTAL RATING .......................................................................... 3-16
3.2 HYDRAULIC OIL.............................................................................................................................. 3-17
3.2.1 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000 LITERS. ...................... 3-17
3.2.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000 LITERS. .................. 3-18
3.3 CHECK SHEETS TO FILL OUT FOR EVALUATION ..................................................................... 3-19
3.3.1 EXAMPLE OF A COMPLETED SHEET ON A VG100 QUALITY OIL ................................. 3-19
3.3.2 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 4000 TO 7000 LITERS ...................... 3-20
3.3.3 LIMIT VALUES FOR A HYDRAULIC SYSTEM OF 10000 TO 15000 LITERS .................. 3-21

4 GEAR OIL ANALYSIS.............................................................................. 4-23

4.1 GEARBOXES ON THE EXCAVATOR............................................................................................. 4-24
4.2 TAKING AN OIL SAMPLE............................................................................................................... 4-25
4.3 SPENT OIL ANALYSIS.................................................................................................................... 4-28
4.3.1 VISUAL APPEARANCE....................................................................................................... 4-28
4.3.2 COLOUR OF THE OIL......................................................................................................... 4-28
4.3.3 VISCOSITY.......................................................................................................................... 4-28
4.3.4 ACIDITY............................................................................................................................... 4-29
4.3.5 VISUAL HAZINESS (WATER CONTENT) .......................................................................... 4-29
4.3.6 TRACE PARTICAL CONTAMINATION OF WEAR METALS .............................................. 4-29
4.3.7 MAGNETIC ABRASION ...................................................................................................... 4-29

5 EVALUATING THE GEAR OIL SAMPLE................................................. 5-31

5.1 LIMITS .............................................................................................................................................. 5-32
5.1.1 GENERAL ............................................................................................................................ 5-32
5.2 LIMIT TABLES ................................................................................................................................. 5-33
5.2.1 TRAVEL GEAR (60-155 LITRES), CLP 220........................................................................ 5-33
5.2.2 TRAVEL GEAR(200-400 LITRES), CLP 220....................................................................... 5-34
5.2.3 POWER TAKE-OFF (PTO) GEAR, CLP 150....................................................................... 5-35
5.2.4 SWING GEAR, CLP 220...................................................................................................... 5-36