Case Study 4 | Final Drive Oil Filtration

Dump Truck Final Drive Oil Cleanliness Results

This case study outlines the results achieved by a coal mining operation using the Lubemaster OS600 oil filtration system to clean oil from the final drives of a dump truck.

All oil samples were prepared using the industry standard 3μm Millipore method. Microscopic photographs were processed at X200 magnification. Calibration on the print was conducted at actual size, where 1ml equals 1μm.

Initial Oil Condition Before Filtration

The first filtergram image was taken shortly after filtration commenced. The sample displayed the dark appearance typical of unfiltered final drive oil.

Microscopic examination revealed a high concentration of large contamination particles measuring up to 30μm.

The contamination included:

  • Dust particles
  • Seal material
  • Metallic wear particles

The dark particles visible in the sample were primarily dust and seal material. The lighter particles represented metallic wear debris.

The overall dark appearance of the sample indicated a high level of particle contamination throughout the oil.

Oil Condition After 12 Hours of Filtration

After 12 hours of filtration with the Lubemaster OS600, a second microscopic examination was completed.

The analysis confirmed that the oil cleanliness level had improved significantly. Results showed the oil cleanliness was well below the limits specified by GE for oil re-use in final drives.

The filtered oil achieved cleanliness levels equivalent to ISO 4406 at 18/13. Particles smaller than 10μm were considered not significant for this application.

Used oil in early stage of filtration
Figure 1. Used oil in the early stages of filtration, showing high levels of wear particle and dirt contamination.
Oil after 6 hours filtering
Figure 2. The same oil after 6 hours filtering.
Oil after 12 hours filtering
Figure 3. The same oil sample after 12 hours of filtration, shown in reflected light mode. The image demonstrates that almost all dirt contamination has been removed, with only three particles remaining visible. Only one metal wear particle can be seen, measuring less than 1μm in size..
Oil sample with external lighting
Figure 4. The same oil sample shown in transmitted light mode, with light passing through the slide from below. This view highlights the absence of large contamination particles, which would normally appear as dark spots. The remaining particles visible are all less than 1μm in size.
Sludge after filtration of the oil
Figure 5. Filtergram showing sludge removed from inside the centrifuge rotor after operation, magnified X200. The sample was taken from 0.01 grams of sludge. Numerous large contamination particles were observed, ranging up to 250μm in size. Most visible particles in the image measure approximately 50μm. The sludge originated from a heavy deposit inside the centrifuge rotor measuring approximately 3mm in thickness.

Benefits of Final Drive Oil Filtration

Effective final drive oil filtration helps mining operations maintain cleaner oil and reduce contamination-related wear.

Key benefits include:

  • Removes dust and abrasive contamination
  • Reduces metallic wear particles
  • Improves oil cleanliness levels
  • Extends oil service life
  • Supports equipment reliability
  • Reduces maintenance costs
  • Minimizes unnecessary oil replacement

High-Efficiency Oil Filtration for Mining Equipment

The Lubemaster OS600 is designed for high-efficiency oil filtration in mining, industrial and heavy equipment applications.

By removing particulate contamination and wear debris, the system helps improve lubrication performance and maintain cleaner operating conditions in final drives, hydraulic systems and industrial machinery.