Worn Iron Analysis

Worn Iron Analysis
The Cat® Rental Store Business Tip

Close examination of worn ground-engaging tools can reveal problems and point to improvements. 

Sometimes considered "sacrificial iron," ground-engaging tools (GET) sustain the majority of wear in order to protect the larger, more expensive parts such as buckets, motor grader moldboards and dozer blades. By examining that wear, contractors may discover ways to help extend the life of their GET, prevent premature replacement, as well as save money.

How Wear Works
Speed + downward pressure = wear. If the GET are wearing prematurely, speed and pressure should be considered

Missing Components
GET that have been allowed to wear excessively and fall off are no longer protecting the structural base edge. Missing GET mean the machine must work harder to dig, requiring more fuel and longer cycle times. Operating a bare bucket edge will also negatively affect production. Bucket edges that have worn thin often curl, making it more difficult to enter the pile.

Excessive GET wear also affects the adapter. When the adapter wears, the bucket tip is loosened and pushes up when loading, so the tip wears through the back and both the tip and adapter must be replaced.

Bucket Wear
Bucket wear occurs mostly from the bottom up, due to the pressure from the bucket, and the flow of material. GET that wear away and are no longer protecting the structural components (thin, cracking wear plates) should be replaced before the base edge begins to wear. Once the base edge, a structural component, starts to wear down, the wear plate may not attach correctly, thus failing to protect the bucket. Furthermore, the bucket is structurally weakened and welds can crack, especially at the corners. Worn base edges must be replaced, a costly measure that will require significant downtime.

The corners of a bucket see the greatest amount of wear for two reasons: The corner causes a change in directional flow of material, exerting more pressure for more wear. Secondly, operators generally favor one side or another when loading, exerting additional stress on the corner of choice. By rotating the bucket tips from the center to the corners, contractors can extend the life of the tips. Similarly, bucket teeth and edges can be flipped for extended wear.

Grader Blades
Motor grader blade edges should be changed before they wear into the moldboard. Contractors should be using the largest edge appropriate to the intended application to prolong edge life. Hardened washers last longer to keep the edge properly secured. Like bucket teeth, grader bits should also be rotated for even wear.

Operating Techniques
Proper operating techniques can extend the life of the components and prevent premature GET replacement. A slight change in loading technique can mean a lot of savings in terms of GET life as well as an increase in productivity.

Generally, the proper angle at which a bucket should enter a pile, or a ripper pulls through the ground creates the smallest footprint possible for the least amount of drag. By making a "clean" cut into a pile or into the ground, the operator can minimize fuel use and maximize efficiency.
Bucket tips that are worn through from the bottom may indicate that the operator has been loading uphill, rather than keeping the base edge parallel to the ground. Loading uphill accelerates wear on the underside of the bucket, as the material flows beneath the bucket
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A dozer operator is causing premature wear and unnecessary machine stress if he or she leaves the ripper shank to trail behind the machine. The tip should be positioned so that material flows down the centerline of the tip, which slows the rate of wear.

A motor grader operator who has been laying the blade back too far will have an edge worn to a greater angle. This practice creates a larger footprint, accelerates wear on the edge and consumes more fuel. Additionally, grader bits can chip away prematurely if the blade is rolled too far back.
Equipment dealers or rental equipment providers such as The Cat Rental Store can help instruct operators in using the most efficient techniques for maximum productivity and longer GET life.