COMPONENT CODE 08

PARTS & SERVICE REF NO. AA02083J

DATE March 23, 2015
NEWS (C)
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This Parts & Service News supersedes the previous issuance, AA02083I, dated March 9, 2015. AA02083I should be discarded.

SUBJECT: APPROVED SYNTHETIC OILS AND GUIDELINES FOR USE IN G.E.

GDY85, GDY106 AND GDY108 ELECTRIC WHEEL MOTORS
PURPOSE: Inform the field of approved wheel motor oils and filtering requirements.
APPLICATION: Komatsu Electric Drive Dump Trucks:
930E: 32604-32816, A30019, A30026-A30120;
930E-2: A30012, A30098, A30100, A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304-A30461;
930E-3SE: A30171-A30389;
930E-4: A30462 & Up;
930E-4AT: A30504 & Up;
930E-4SE: A30587 & Up;
960E-1: A30001, A30003 & Up
960E-2: A30027 & Up;
FAILURE CODE: 0830Z9
DESCRIPTION:

RECOMMENDED OILS FOR WHEEL MOTORS LISTED BELOW

General Electric has approved only the following oils for use in their GDY85, GDY106 AND GDY108
wheel motors:
•Mobil - Mobilgear SHC 680
•Mobil - SHC Gear 680 OH
•Shell - Shell Omala S4 Wheel ISO 680
•Valvoline - Syngard G-680
•Cognis - Emgard 680 EP
•Anderol Inc. - Anderol 5680
•Conoco Phillips - Syncon Premium EP Gear Oil 680
•Chevron - Chevron Synthetic EP ISO 680
•Texaco - Texaco Synthetic EP ISO 680
•CalTex - CalTex Synthetic EP ISO 680
•Total - Dynatrans 680 GEA
•BP Enersyn EP-XF 680
•Castrol Alphasyn EP 680
•Bel-Ray Synthetic Gear Oil 680
•Fuchs Renolin Unisyn CLP NA
•Petro Canada - Enduratex Synthetic OHV 680

An approval process must be initiated with G.E. if an alternative brand of oil is desired for use. Terms of
the approval process will be provided if needed.

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FILTERING REQUIREMENTS

Filtering Intervals
Wheel motor gear oil must be filtered (or changed) after the first 500 hours of operation, and then sam-
pled and analyzed every 500 hours of operation thereafter. (Regular interval filtering is no substitute for
spectrographic oil analysis. Wheel motor gear oil must be analyzed every 500 hours of operation.)

Due to the use of synthetic oil, replacement or filtration of the oil on a time based interval is not required.
The oil should be replaced or filtered based on the oil sample tests of viscosity, element levels and parti-
cle size and count.

Filtering synthetic oil for reuse is recommended, and can significantly extend the life of the oil. A 10
micron filter must be used for filtering the oil. Due to their additive formulation, approved oils may last
up to a year, or possibly longer. However, the additive package in synthetic oils will degrade over time.
Therefore, these additives must be monitored and replenished when content falls below manufacturer’s
specifications. After a year, the synthetic oil must be analyzed by the oil manufacturer if continued use is
desired.

Particle Size Analysis

When filtering synthetic oil for reuse, the oil must be monitored to determine when filtering is necessary.
The process of monitoring the oil for this purpose is particle size analysis. The test consists of passing a
beam of light through the oil as it passes through a clear tube. A computer analyzes the quantity and size
of particles contained in the oil.

Particles that are smaller than 5 microns in size are not large enough to cause any gear or bearing failures.
Particles over 25 microns can damage bearings and must be filtered from the oil.

General Electric recommends that the oil be tested for the size and number of particles in the lubricant.
This is an extremely important measurement of the condition of the oil.

GE recommends that a cleanliness code of 18/13 be used for motorized wheels. Oil qualified for
reuse must be filtered to 10 microns absolute.

Particle Count Max.

Rating Particle Size
Per Millimeter

18 2,500 5-15 microns

13 80 15-25 microns

greater than 25
- 0
microns

If particle analysis yields a result of greater than 18 for the top number or greater than 13 for the lower
number the motorized wheel oil should be filtered to 10 microns absolute. On occasion, the results of the
filtering process must be verified to ensure the filtering process is effective. Should the results be unac-
ceptable, check the filter type, condition, and particle size prior to re-filtering.

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Oil Viscosity
Viscosity of filtered oil must be monitored during each oil analysis to ensure proper lubrication. Viscosi-
ties below the condemning limit indicates entry of contamination that will affect the oil film and lubricat-
ing quality. The condemning limit for 680 oil, is 53cSt when tested at 100° C (212° F), and 588cSt at 40°
C (104° F). This value can be used along with element tracking (ie. phosphorus, iron, and zinc) to verify
correct oil viscosity. Ensure the appropriate viscosity value is being maintained for the approved oil you
are using. If the viscosity of the oil is below the acceptable limit, the oil should be rechecked. If the sec-
ond test fails, dispose of the oil. Fill the wheel motor with new, GE approved oil. The contaminated oil
should be properly disposed of according to local regulations.

If the viscosity of the oil is below the condemning limits, the oil may be contaminated with hydraulic
oil. Ensure all joints are properly sealed before filling the wheel motor with fresh oil. If hydraulic oil
continues to contaminate the wheel motor, serious damage to internal components may result.
Wheel motor gear oil contaminated with hydraulic oil CANNOT be filtered and/or reused. If wheel
motor gear oil contaminated with hydraulic oil is mixed with clean oil during the filtering process, the
entire lot must be discarded.

SPECTROGRAPHIC OIL ANALYSIS

As stated earlier, spectrographic oil sampling analysis must be done every 500 hours of operation. The
sample must be taken within a half an hour of truck shut down and within an hour of actual truck opera-
tion. Oil samples that are not taken under this stipulation will not convey an accurate measurement of
wheel motor condition.

When taking an oil sample, it is important to position one of the magnetic plugs in the six o’clock posi-
tion on the wheel. Oil samples should be taken from this plugged hole using a flexible tube that is 18
inches (457 mm) in length. The tube must be inserted downward exactly 12 inches (305 mm) toward the
bottom of the torque tube.

When a sample is extracted from the wheel motor and placed in a clear bottle, the appearance, as well as
odor of the oil should be inspected. Note any burning smells or other odors typical of fatigued or contam-
inated oil. Check the oil for cloudiness, large particles, and filming. Any of these conditions indicate a
problem.

When water is found in oil, a second sampling should be performed. (Often times the source of the water
is a contaminated oil drum.) If water is found after the second sampling, the oil must be changed. Ensure
the replacement oil is free of water before adding.

Refer to Parts and Service News Bulletin, AA02084, Wheel Motor Inspection Guidelines, for additional
information on oil analysis element content and other inspection guidelines.

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FLUSHING

The transmission of the wheel motor must be flushed using the same oil that is used in normal operation.
The use of solvents or low viscosity oils are not acceptable.

After flushing to remove contamination from the wheel motor, the transmission should be filled with new
or filtered oil. An oil sample should be taken for analysis after 100 hours of operation. If results of the oil
analysis are within the acceptance range, the wheel motor may return to the 500 hour interval for oil anal-
ysis. If the results of the analysis are not within the acceptance range, immediately contact your area GE
or Komatsu customer support manager. Large quantities of loose material in the oil may be an indication
of imminent wheel motor failure.

AA02083J