U1l3s Basic Contamin Cont

Lesson 3: Contamination Control
Lesson 3: Contamination Control
Introduction:
This lesson covers the effect of contamination, methods of measuring

contaminants, and ways to lessen the impact of contamination on
machine enclosed fluid systems.
Objectives:
Upon completion of this lesson, the student will be able to:

1. Identify four sources of contamination.
2. Identify two types of contamination.
3. State the effects of contamination in a hydraulic system.
4. Identify seven methods of contamination prevention.
5. Identify the ISO rating from the amount and size of particles per
mL.
References:
Fluid Contamination--the silent thief (Video) PERV4632

NOTES
Unit 1 2 Caterpillar Service Industry
Lesson 3
Overview
• Contamination Control Overview

• Cleanliness Targets
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First, an overview of Contamination Control:

The need for contamination control.
Contamination definition.
Effects of contamination.
Contamination prevention.
Cleanliness targets for hydraulic systems:

Measuring contamination.
ISO Code limits for various fluid systems.
Lesson 3
Why Contamination Control?

• Customers are demanding .
– More power
– Greater breakout forces
– Faster cycle times
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The need for contamination control is driven by the desire to meet customer needs.
Customers are expecting more from Caterpillar equipment. As costs go up and business
gets more competitive, Caterpillar equipment must give top performance to keep the
customer as productive as possible.
Lesson 3

• Industry trends
– Electro-hydraulics
– Higher system pressures
– Tighter clearances
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In order to do this, the industry is going toward more advanced machine systems, those that
include electro-hydraulics, higher system pressures, and tighter clearances. These advanced
machine systems allow Caterpillar to build more sophisticated and higher production
machines.
Lesson 3

• Result – Today’s fluid systems are more
sensitive to contamination
– Hydraulics
– Transmissions / Final drives
– Fuel systems
– Engines
Contamination 1 5
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The result of using these sophisticated machine systems is higher sensitivity to

contamination. These systems are running at higher pressures and have tighter tolerances
which require a need for cleaner systems.
Systems running at a lower psi of 3450 kPa (500 psi) to 4830 kPa (700 psi) have larger
clearances. In the 5500 kPa (800 psi) to 69,000 kPa (10,000 psi) range, like hydraulic
cylinders, the tighter spool clearances are more sensitive. With injectors that operate at
179,000 Kpa
(26,000 psi) , tolerances are very tight. There is no room for contamination or related wear.
Lesson 3

• Contaminated fluid systems:
– Shorten component and fluid life
– Reduce productivity
– Can lead to catastrophic failure and costly
downtime and repairs
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What does contamination do to these systems? Contaminants shorten component and fluid
life. They also reduce productivity by reducing system efficiency. In hydraulic systems, for
example, system efficiency can drop up to 20 percent before the operator detects a problem.
That is a loss of one day per week!
If not dealt with, contamination eventually can lead to catastrophic failure. A contamination
problem that spreads throughout the system can lead to a repair that takes days or weeks to
complete.
Lesson 3

• Tests prove clean oil improves life
– Increased bearing life
– No contamination-related failures from
6,000 to 11,000 hours
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In tests conducted by Caterpillar, engineers overwhelmingly concluded that monitoring the

oil and maintaining cleanliness standards significantly improved bearing life.
At one large mine site, 793C off-highway trucks were routinely experiencing final drive
failure at 6,000 hours, mostly because of bearing problems. By implementing new
contamination control procedures at every 500 hour service interval (that filtered drive
train oil through a kidney loop filter cart), the final drive life has improved to as much as
25,000 plus hours with no contamination-related failures. Bearing failures, which plagued
the mine in the past, are no longer a limiting factor. Contamination control procedures
helped the mine get the life they desired out of their final drive.
This documented study is only an example of the benefits of monitoring and maintaining
oil cleanliness.
Lesson 3
What Is Contamination?
• Anything in a fluid that doesn’t belong
• The #1 enemy of fluid systems
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What is contamination?
Contamination can be considered anything in a fluid that does not belong.

Particulate contaminants are the most common and controllable. They include such
things as dirt, metals, weld spatter, paint flakes, rag fibers, and sealing materials.
These can be built in, introduced through maintenance or generated internally.
Heat, water and air are also contaminants. These elements combine to break down
the oil's chemical composition, forming oxidation and acids.
Fluids used in Caterpillar machines are highly effective unless they contain
damaging amounts of contamination.
Contamination is the #1 enemy to fluid systems. Fluids must be kept clean, cool,
and closed.
Lesson 3
Contamination Sources
• Built -in
Built-in
• New fluids
• Introduced contamination
– Cylinder wiper seals
– Reservoir vent ports
– Poor maintenance
• Generated internally
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Contamination can be introduced in a number of ways. One possibility is at the

factory. When machines are being assembled, contaminants can be left in critical
systems. Caterpillar has contamination control programs in all of their plants to
address this issue.
New fluid is a common source of contamination. It may be clean when it leaves the
refinery, but often gets contaminated to unacceptable levels during transportation,
transfer and storage. By the time the fluid is used at the machine, it may contain
higher levels of contamination than our operating levels allow.
Contaminants can be introduced into the machine, that is, contaminants are brought
into the machine systems by some means, whether through leaky seals or poor
maintenance practices. Machine operation is a source, especially if some of the
systems are not properly maintained. A rule of thumb is that, if fluid is leaking out,
contamination is getting in. If it is from poor preparation procedures, improper
flushing, dirty rags, etc., maintenance and service of the equipment is a prime
opportunity for contamination.
Finally, contamination can be generated from within the machine’s systems. Wear
debris or failing parts will send debris through the machine systems.
Lesson 3
Two Types of Contamination
40 Microns & Larger Under 40 Microns
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There are two types of contamination that require different strategies and
understanding to reduce their damaging effects. The easiest and quickest way to see
results is to remove the dirt seen with the naked eye. This would be contaminants
that are greater than 40 microns in size.
Contaminants that cannot be seen with the naked eye, cause the greatest amount of
damage. As clearances get smaller, a greater percentage of particles exist that are
equal in size to the designed clearances. These small particles are harder to filter
and cause damage in tight clearance areas.
Lesson 3
Small Particle Contamination

Even Particles Too Small to See are Harmful!
Human
Cat System Hair
Clearances Smallest Visible
to the Eye
2
30
40
MICRONS
80
(μm)
Contamination 1 11
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Cat fluid systems are designed for close tolerances and very high pressures. Some hydraulic
fluid system pressure spikes can reach a momentary high of 69,000 kPa (10,000 psi), while
some fuel system pressures can reach 179,000 kPa (26,000 psi).
Pressure plus contamination will reduce system life. Tighter system clearances and higher
system pressures will have a damaging effect on things such as pumps, motors, valves and
bearings.
The typical piece of human hair measures 80 microns.
5 to 30 micron clearances are built into Caterpillar hydraulic systems, but clearances in fuel
systems are as small as 2 microns, so the most damage is done by these minute particles.
They are able to fit in between moving parts and wear in locations where larger particles
would not fit.
Filters remove 40 micron and larger particles relatively quickly. Contamination that is close
in size to the clearance between parts will wear away parent material.
Lesson 3
What is a Micron?
1 Millionth of a Meter
100 microns (μm) - grain of table salt

80 microns (μm) - diameter of a
human hair
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1 millionth of a meter equals a micron. To get a better idea of how small that is,
compare it to a couple of items of relatively small size.
A grain of table salt is 100 microns. The diameter of a human hair is about 80
microns.
Lesson 3
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This slide shows the relative size of a micron. A micron is extremely small in
comparison to the diameter of a human hair. Also shown is how much smaller it is
than 1/1000th of an inch.
Particles this small can be very damaging to Caterpillar systems because they fit
between moving parts.
Lesson 3
Video
Fluid Contamination:
The Silent Thief
(10 minutes)
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The video will show the dirt that can not be seen traveling through a hydraulic
system. The purpose of showing this video is to help with the understanding of how
much damage unseen dirt can cause.
The Silent Thief is available in various languages as a video and as a CD.

Cat media numbers are as follows:
Video CD
English PEVN4632 PERV4632
French PFVN4632 PFRV4632
German PGVN4632 PGRV4632
Spanish PSVN4632 PSRV4632
Portuguese PPVN4632 PPRV4632
Lesson 3
Effects of Contamination
Hydraulic System experts attribute
75 to 85%
of all component failures to particle contamination in the
fluid and not a weakness in the system components.
-- Hydraulics & Pneumatics, June 1998

-- Equipment Today, August 1997
Contamination 1 15
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The effects of contamination often lead to component failure. In fact, it is estimated

by experts that 75- 85% of component failures are due to particle contamination.
This illustrates that most failures are not due to manufacturing or material flaws, but
contamination does magnify maufacturing and material shortcomings.
Lesson 3
Pump Manufacturer
ISO
C
22/19
Component Life
o
n
21/17
---- 2,500
t 20/15 -----
a
m 19/16
i
10,000
n
a
18/15
------------
t
i
17/14
25,000
o 16/13
n Clean New Oil
15/12
14/11
13/10
12/09
Component Life Over Time
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One pump manufacturer performed a study to investigate the effect of

contamination on pump life over time. The graph slope shows some interesting
information about contamination. The higher the ISO Code the shorter the life of
the pump will be. If oil is kept at 18/15 or below, component life is greatly
increased.
Lesson 3
Effects of Contamination
• Erratic steering
• Cylinder drift
• Slower performance
• Unreliable operation
• Lower productivity
• Machine downtime
• Higher operating costs
Contamination 1 17
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If fluid contamination levels are too high, eventually operators will notice erratic steering,
cylinder drift, slower performance and unreliable operation. Productivity will be lower,
machines will be down more often and bottom line, operating costs will be higher.
Lesson 3
Prevention
• Housekeeping
• Oil storage and transfer
• Change filters carefully
• Parts handling and storage
• Hose assembly and storage
• Care in maintenance and repair
• Adhere to proper maintenance intervals
• Particle counting
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Contamination prevention will include all aspects of operation, from housekeeping to parts
handling, to fluid analysis and particle counting.
Lesson 3
Housekeeping
• Sweep floors daily
• Clean up spills immediately
• Keep work benches uncluttered
and free of debris
• Limit use of floor storage
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General housekeeping will make a large difference on contamination control. If the shop
environment is clean and uncluttered, it will reduce the chances of contaminating
equipment being serviced.
As seen in these pictures, there are many sources for contamination in the shop.
Lesson 3
Housekeeping
Floor Dry Hand Pump
Parts
Parts Cleaner Packaging/Storage
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Here are some example sources of contamination in the service area of a shop.
Floor dry should not be used because of dust and particulates. A hand pump in a 50
gallon drum with no filter to keep contaminants from entering clean assemblies or
systems. No filtration on a parts cleaner to maintain solvent cleanliness. Also, a
cluttered parts cleaner is difficult to keep clean. Finally, improper parts packaging
and storage to maintain new and rebuilt parts cleanliness.
Lesson 3
Housekeeping
Contamination 1 21
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Contamination prevention starts in the shop. This is a workstation with

many of the ideal contamination control elements. The nylon/plastic
workbench top is easy to keep clean, wipes off and will not damage metal
parts.
Wash all machines before bringing them into the shop and wash finished
components before assembly. This wash tank has a 2 micron fuel filter
incorporated on the solvent discharge line.
Use absorbent mats to soak up fluids during disassembly. Oil dry type
absorbent material is not recommended. Oil dry causes airborne dust and
will contaminate fluid systems.
Lesson 3
Oil Storage and Transfer

• Use a transfer filter cart
• Change when warm and agitated
• Use barrel covers
Contamination 1 22
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Even new oil can contain thousands of microscopic particles. Oil picks up
contaminants if it is stored in dirty drums or bulk tanks or transferred through dirty
lines. Filter new oil using a transfer filter cart. This may be costly up front, but will
pay for itself through added component life and system cleanliness.
Drive train oil is generally changed every 2000 hours, but this can be extended if it is
monitored carefully. When changing oil, drain old oil when it is warm and agitated.
Contaminants are stirred up so more are removed during the oil change. Transfer new
oil when it is cool and still, as contaminants will settle to the bottom and remain there
while the system is filled from a transfer filter cart.
Barrel covers are not only for keeping the dirt off the tops of barrels. As barrels expand
and contract due to temperature fluctuations, moisture and dirt can be pulled past the
bunghole threads. Barrel covers eliminate this problem. Storing barrels on their sides,
with the opening toward the bottom also helps eliminate this problem. If at all
possible, store barrels in a sheltered area or indoors. Caterpillar yellow barrel covers
(Part Number: 1U6156) are available for purchase.
Lesson 3
Kidney-loop Filtration System
Shown to increase oil and component life and reduce costs

Contamination 1 23
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Using a kidney-loop filtration cart on machine system fluids significantly reduces

contamination. The cart circulates the targeted system oil through the machine tank or
component, while filtering out contaminants. A kidney-loop filtration process can
circulate the oil several times a minute, filtering more and more each time, eventually
reducing the entire system contamination level to a recommended cleanliness level.
Results from an independent survey demonstrate the benefits. In a U.S. mine operating
fifty 793 off-highway trucks, differential oil was kidney-looped every 500 hours when
the trucks were in for engine service. Wheel groups and differentials ran 16-24% longer
before overhaul, for a savings of $1,093 per truck, per year. It proved to be well worth
the investment in kidney-looping the common sump oil. (Source: Caterpillar’s Dealer
Support Group).
Lesson 3
Change Filters Carefully

• Change on schedule
• Remove used filter carefully
• Do not pre-fill new filter
• Use high efficiency filters on serviced
machines
• Examine used filters
Contamination 1 24
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Oil and filter change intervals should be met. Scheduled oil sampling at these intervals will provide a
key piece of information to the health of the machine system.
The used filter should be removed carefully at change time to ensure that contaminants do not reenter
the system. The new filter should be kept in its package until it is ready to be installed.
Some manufacturers recommend pre-filling filters. Caterpillar DOES NOT recommend this because
filling an element with oil before installation can introduce contaminants into the system. Replace all
filter elements “dry,” including fuel filters.
When a system has been opened for service or repairs, Caterpillar recommends the use of high
efficiency filters to rid the system of contaminants that may have entered during service. They can be
utilized up to 250 hours, then return to the use of standard filters.
Make sure that standard filters meet the requirements of Cat equipment. The tight tolerances of
Caterpillar components require superior filtration. (The fact that most filters do not meet Cat specs is
the reason Caterpillar got into the filter business and manufactures their own brand of filters.)
Used filters should be inspected. Valuable information can be gained about the equipment the filter is
on by cutting it open. A special Filter Cutting Tool (4C-5084) can be purchased for this purpose. If
metal particles are present, a magnet can be used to determine if they are iron or steel. Pieces of
synthetic friction material or rubber seals may also be present, which may indicate a problem.
Lesson 3
Parts Handling and Storage

• Keep components packaged until ready to install
• Return parts to storage in packaging
• Protect in-process components
• Wash components before assembly
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Keeping parts inside the original packaging until they are ready to be installed will
significantly reduce contamination problems, as do the rest of these basic
recommendations.
Lesson 3
Hose Assembly and Storage

• Keep hoses plugged and capped
• Use Cat hose cleaner
Contamination 1 26
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Protect bulk hoses and all hose assemblies with caps and plugs and keep stored couplings
covered.
The hose assembly process creates contaminants, so cleaning hoses, tubes and piping before
installation is critical. The Cat Hose Cleaner Group fires a foam projectile that removes
internal contamination as it travels through the tube, around bends, and through the
couplings. The savings from keeping contaminants out of the system will quickly offset the
cost of the hose cleaner.
Lesson 3
Care in Operation and Maintenance

• Perform daily inspections
• Keep hydraulic tank filled
• Maintain valves
• Use rod protectors
• Watch temperature
gauges
Contamination 1 27
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Alert operators and service technicians are also an important element in contamination
control efforts. Make sure equipment is inspected daily for leaks and fixed immediately
if any are found.
Always keep the hydraulic tank between “Full “ and “Add.” Insufficient fluid levels are
the leading cause of pump cavitation, which can lead to pump failure and contamination
of the entire system. Low fluid levels can also result in high oil temperatures, which can
also cause oil to degrade.
Maintain oil cooler and relief valves properly. Only a trained technician should increase
the relief valve setting. It is important to find the real source of pressure loss and fix it.
In applications with fine dust, banked rock, or corrosive material, use cylinder rod
protectors to protect cylinder rods.
Finally, operator attention to system temperatures is very important. Heat reduces oil
viscosity, increases fluid oxidation, and can “bake” seals.
Lesson 3
Particle Counting
• The way to measure your contamination control

efforts
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Eliminating contamination is nearly impossible without the science of particle counting. A

system is needed to measure the amount of contamination before and after any service work
has been performed.
Lesson 3
Measuring Contamination
EQUIP. # WL701
JOBSITE * BIG SUMP
• Spectrographic Analysis
MAKE CAT
Henry Walker Contracting P/L MODEL 994
Att: Mr Alan Carson SERIAL No. 9YF00040
PO Box 294 COMPARTMENT PUMP DRIVE
Clov erdale OIL BRAND & TYPE BELRAY TL4
WA 6105 OIL CHGD? Y
• Identifies elements in oil ORDER No.

LABEL #
LAB.I.D. #
EVALUATION CODE
YANDI
13-45
96X52691
B
• Only up to 10-15 microns in Date

Taken
12/12/96 OIL TOTAL HOURS
ADDED HOURS ON OIL
IRON ELEVATED - POSSIBLY DUE TO DIRTY ENTRY.PARTICLE COUNT RESULTS
TO BE ADDED WHEN AVAILABLE.
CHECK SEALS AND BREATHERS FOR DIRT ENTRY POINTS. CHECK MAGNETIC
CURRENT PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
size REC'D
181296
Date
N 19850 324
Taken IRON ELEVATED - POSSIBLY DUE TO DIRTY ENTRY.PARTICLE COUNT RESULTS

15-11-96 CHECK SEALS AND BREATHER FOR DIRT ENTRY POINTS.
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR
REC'D #1 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE
201196 N 19526 244
Date
Taken IRON IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS APPER NORMAL.
19-10-96
ELEMENT OIL CONDITION/CONTAMINANTS
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR FOR
REC'D #2 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
CONCENTRATIONS IN PPM 251096 N % OF
19282261 ALLOWABLE
Date
DATE CU FE CR PB AL SI MO NA MG SN ZN W Taken
F A ST OXI NIT SULFORTBN PCT
HOURS ON TANHIGH.
OIL IS SLIGHTLY PQ *** ELEMENTS TEST RESULTS
ALL OTHER
6/10/96 APPEAR NORMAL
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - -
PREVIOUS - - - - - -
CHECK MAGNETIC PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT
REC'D #3 THIS SERVICE.
201196 15 301 2 5 32 75 - 42 - #1 2 - N -
141096 - N -19021 - 279 - - - 314 - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - -ELEMENT- - - - 2 - - OIL CONDITION/CONTAMINANTS
-
141096 8 211 1 1 7 13 - 11 - #3 1 - N -
DATE
- -
CONCENTRATIONS
CU FE
- IN PPM-
CR
-
PB AL SI MO NA MG
-
SN
14
ZN
-
W F
- -% OF ALLOWABLE
A ST OXI NIT SUL TBN PCT TAN PQ ***
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - - - - - - - -
201196 15 301 2 5 32 75 - 42 - #1 2 - N - - - - - - - 314 - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - - - - - - 2 - - -
141096 8 211 1 1 7 13 - 11 - #3 1 - N - - - - - - - 14 - - -
Contamination 1 29
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Understanding how to measure contamination starts with a brief S.O.S fluids analysis
lesson. Two methods are used to measure particles in a fluid sample.
The first is spectrographic analysis. It can identify the individual metal or alloy that
makes up a particle. Its size limit is about 10 to 15 microns and smaller, so it is blind to
larger particles that can often signal pending failure.
Spectrographic limits are an instrument limitation.

Lesson 3
Measuring Contamination
• Particle Count Par ticle Count
Size Categor ies
• Quantifies particles 1-200
> 2 M icr ons
microns
> 5 M icr ons
> 10 M icr ons
> 15 M icr ons
> 25 M icr ons
> 50 M icr ons
> 75 M icr ons
> 100 M icr ons
Contamination 1 30
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Particle count identifies the number of particles in a one mL sample of oil. It can not
identify specific elements or distinguish metal from non-metal. The advantage to
particle counting is the size range it can handle. It will identify particles from two
microns to greater than 200 microns in size.
The spectrographic analysis and the particle count are the backbone of S.O.S fluids
analysis. The focus of this lesson is only on particle counting.
Lesson 3
Understanding Particle Counting

• ISO codes
• 28 code ranges
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A worldwide federation, the International Standards Organization (ISO) (based in

Geneva, Switzerland), has identified ranges of cleanliness based on particles in a one
milliliter sample. This portion of the list shows how each range has a maximum and
minimum number of particles.
Notice how every step increase in ISO Code indicates the fluid is twice as dirty as the
preceding code.
Lesson 3
ISO Cleanliness Code

•Explained in ISO Standard 4406
•Expressed Amount of Contamination in one mL of Fluid
2μm / 5μm / 15μm
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The ISO fluid cleanliness code is expressed in three terms and is explained in ISO
Standard 4406. It is expressed as the amount of contaminant in one mL of fluid.
The first position refers to the amount of contaminants 2 micron and larger, the
second position refers to the amount of contaminants 5 micron and larger and the
third position refers to the amount of contaminants 15 microns and larger in one mL
of fluid. Caterpillar monitors the last two ISO positions since these measurements
indicate particles detrimental to the clearances in our hydraulic systems.
Lesson 3
ISO Codes
• Expressed in X/Y form
• X = number of particles larger than 5
microns (>5)
• Y = number of particles larger than 15
microns (>15)
• Example: 16/13
Contamination 1 33
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ISO Codes are expressed as a two-factor code. The first number, X, indicates the range of
particles that are larger than 5 microns in each milliliter of oil. The second number, Y,
indicates the range of particles larger than 15 microns in each milliliter of oil.
For example, a sample with 550 particles per mL greater than 5 microns and 68 particles per
mL greater than 15 microns would be classified as 16/13 oil.
The greater than 5 and the greater than 15 micron sizes were chosen because the greater
than 5 micron size indicates wear particles that can cause “silting” or clogging of electro-
hydraulic controls and transmissions, while the greater than 15 micron size particles can
indicate the presence of rapid wear and potential early failure. All are damaging to
Caterpillar components.
Lesson 3
ISO Code Chart

28 ISO Codes Number of Particles / mL
23 40,000 - 80,000
22 Dirty 20,000 - 40,000
21 10,000 - 20,000
20 5000 - 10,000
19 2500 - 5000
18 1300 - 2500
17 640 - 1300
16 Clean 320 - 640
15 160 - 320
14 80 - 160
13 40 - 80
12 20 - 40
11 Cleaner 10 - 20
NOTE:
10 5 - 10 Particle count
9 2-5 doubles at
8 1-2 each level
Contamination 1 34
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This is the ISO Code chart. When the ISO Code increases by one, it
means that there is a doubling of particles. The ISO code refers to the
number of particles per mL, not the size.
Lesson 3
Compare the Difference

Very Hydraulic/
Dirty Minimum Steering Fill
Oil Target Targets Oils
24 21 18 16
5 Microns
& Greater 160,000 20,000 2,500 640
19 17 15 13
15 Microns
& Greater
5,000 1,300 320 80
Contamination 1 35
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Here is the difference in ISO ratings. ISO 18/15 is the recommended target for
hydraulic systems and vehicles with electronic transmissions. ISO 16/13 is the fill oil
target. Fill oil needs to be 16/13 to keep the system below 18/15, which means that
cleaner fill oil is needed to meet the targeted specification.
Although the numbers are within two, 18/15 oil is actually four times as
contaminated as 16/13. This can be seen by looking at the particle numbers in each
of these targets.
Lesson 3
Compare the Difference

18/15 (clean)
16/13 (very clean)
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Under magnification the difference between an ISO rating of 18/15 and 16/13
becomes clear.
Lesson 3
Pamas S-40
Particle Counter
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Shown is the Pamas S-40 portable particle counter. It measures the amount and the
different sizes of contaminants in a fluid sample.
Lesson 3
Particle Counter Printout

Pamas
ID: Hydro Oil
3/16/02 21/18/14
2: 18032
5: 2036
10: 754
15: 155
20: 92
25: 36
50: 2
100: 1
Contamination 1 38
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This is the printout from the Pamas particle counter. Shown in red is the name of
the sample entered by the operator.
The numbers in green are the ISO rating. The first number is the ISO rating for 2
micron and larger particles. The next two numbers are the greater than 5 and
greater than 15 micron particles.
Shown in blue are the actual particle counts for the greater than 5 micron particles
(2036) and the greater than 15 micron particles (155). This equals an ISO rating of
18/14. The greater than 5 and greater than 15 are the numbers that Caterpillar uses
for its fluid analysis because hydraulic clearances in Caterpillar systems are
between 5 and 30 microns.
Lesson 3
Recommended Cleanliness Targets

Fill Oil …………………………………………….…………………..……. ISO16/13
Hydraulic Systems (Implement & Steering)....………………………. ISO18/15
Transmission Systems
Electronic ……………………….……………………….……ISO18/15
Mechanical Transmissions……………………………….. ISO21/17
Component Rebuild
Engines (Roll-off) ...………………….…Pending……….. ISO18/15
Transmission, Pumps, Governors Etc ………..…..…… ISO16/13
Fuel …………………………………………………………???……… ISO18/16/13

Injector Testing Equipment Calibration Fluid……..………………… ISO15/13
Contamination 1 39
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ISO 16/13 or lower oil cleanliness is recommended for system fill oil. Caterpillar’s
recommended cleanliness target for pressurized hydraulic systems is ISO 18/15.
System cleanliness is monitored by trending particle count oil analysis. If
contamination levels trend upward by two ISO codes or more, action should be
taken to determine the cause and return the system to the desired level. There are
some exceptions to the ISO 18/15 cleanliness levels such as older mechanical
transmissions that do not have the close clearances and do not require oil cleanliness
at an ISO 18/15 level. However, the same contamination control service and
maintenance procedures should be used across all Caterpillar products.
Lesson 3
Visualizing Contamination
How much “dirt” can be present in a 55-gallon

drum of oil and still meet ISO 16/13?
Contamination 1 40
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Modern Caterpillar machines have very tight tolerances.

Contamination control plays an important part in keeping them
running.
Lesson 3
Visualizing Contamination
• Half a teaspoon
Contamination 1 41
Control
This slide demonstrates the extreme tolerances on today’s equipment.
The half teaspoon of dust in the photo actually exceeds the standard for
16/13 fill oil.
(For metric units, the unit of measurement is 160 mg (about 1/2 the size of
an aspirin).
Lesson 3
Contamination Control Example

How much difference will cleaning oil from ISO
19/16 to 16/13 really make?
Example: 32 GPM pump working 8

hours/day for 200 days
Contamination 1 42
Control
How much of a difference will cleaning oil make if 16/13 is really such a small
amount? Look at the possibilities...
Lesson 3
Contamination Control Example

Amount of “Dirt” Flowing
Amount of “Dirt” in Oil Through Pump in One Year
ISO 19/16 157.7 lb/yr

ISO 18/15 78.9 lb/yr
ISO 16/13 19.7 lb/yr
Contamination 1 43
Control
By reducing system contamination levels from ISO 19/16 to ISO 18/15 to ISO 16/13 the amount of pure
“dirt” flowing through a system can be significantly reduced. SAE Fine Test Dust Gravimetric Levels
provide a way to compare ISO codes to the actual weight of the test material. Using the following published
standards: 4.00 milligrams/liter for ISO 19/16 - 1.93 milligrams/liter for ISO 18/15 - 0.77 milligrams/liter for
ISO 16/13.
The amount of “dirt” flowing through a system can be calculated during a specific time period.
Assuming the use of a pump with 32 Gallons /Hour (121 Liter/Hour) flow operating for 8 hours a day and
200 days per year we find:
For ISO 19/16:
6.16 milligrams/liter 3.785 liters/gallon 32 gallons/minute 60 minutes/hour
8 hours/day 200 days/year 1000 milligrams/gram 454 grams/pound = 157.7 Lb(71.5Kg)/year
For ISO 18/15:
For ISO 16/13:
The ISO 19/16 will have nearly 20 times the amount of contamination pass through it compared to the ISO
18/15 and 52 times as much as the 16/13.
The pump will last its engineered life at the target of ISO 18/15
Lesson 3
Contamination Control
Support Available
Tools
Equipment
Methods
Procedures
}
Available for All Products (95%)
Contamination 1 44
Control
Caterpillar offers a variety of tools, equipment, methods, procedures and support for
95% of its machines.
Lesson 3
https://nacd.cat.com/infocast/frames/prodsupp/cc/
https://cosa.cat.com/infocast/frames/prod_supp
/service/contamination/
Contamination 1 45
Control
The NACD internet site on Contamination Control is another way to access

important information about CC. The web address is shown in the slide.
Lesson 3
Contamination Control Tooling

Portable
S-40 Contamination Kit Hose Cleaning Kit
Transfer Cart And Rear Axle Small System

Fluid Recovery System Filter Buggy Filtration Cart
Contamination 1 46
Control
This slide shows some of the tooling available for a contamination control program.
The S-40(shown), S-2 and CM-20 are particle counters used for immediate on site
particle count measurement. Also shown are a hose cleaning kit, transfer cart and
fluid recovery system, hydraulic filter buggy and a portable contamination kit. All
tooling is available through CSTG.
Lesson 3
Cleanliness Responsibility
An important Caterpillar responsibility is to ship clean

machines, engines, and components. Keeping them
clean once they leave the factory is the shared
responsibility of dealers and customers.
Contamination 1 47
Control

U1l3s Basic Contamin Cont

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Lesson 3: Contamination Control

Lesson 3: Contamination Control

This lesson covers the effect of contamination, methods of measuring

Upon completion of this lesson, the student will be able to:

Fluid Contamination--the silent thief (Video) PERV4632

• Contamination Control Overview

First, an overview of Contamination Control:

Cleanliness targets for hydraulic systems:

Why Contamination Control?

Why Contamination Control?

Why Contamination Control?

The result of using these sophisticated machine systems is higher sensitivity to

Why Contamination Control?

Why Contamination Control?

In tests conducted by Caterpillar, engineers overwhelmingly concluded that monitoring the

• The #1 enemy of fluid systems

Contamination can be considered anything in a fluid that does not belong.

Contamination can be introduced in a number of ways. One possibility is at the

Two Types of Contamination

40 Microns & Larger Under 40 Microns

Small Particle Contamination

The typical piece of human hair measures 80 microns.

100 microns (μm) - grain of table salt

The Silent Thief is available in various languages as a video and as a CD.

-- Hydraulics & Pneumatics, June 1998

The effects of contamination often lead to component failure. In fact, it is estimated

Component Life Over Time

One pump manufacturer performed a study to investigate the effect of

Contamination prevention starts in the shop. This is a workstation with

Oil Storage and Transfer

Kidney-loop Filtration System

Shown to increase oil and component life and reduce costs

Using a kidney-loop filtration cart on machine system fluids significantly reduces

Change Filters Carefully

Parts Handling and Storage

Hose Assembly and Storage

Care in Operation and Maintenance

• The way to measure your contamination control

Eliminating contamination is nearly impossible without the science of particle counting. A

• Identifies elements in oil ORDER No.

• Only up to 10-15 microns in Date

Taken IRON ELEVATED - POSSIBLY DUE TO DIRTY ENTRY.PARTICLE COUNT RESULTS

Spectrographic limits are an instrument limitation.

Understanding Particle Counting

A worldwide federation, the International Standards Organization (ISO) (based in

ISO Cleanliness Code

•Expressed Amount of Contamination in one mL of Fluid

2μm / 5μm / 15μm

ISO Code Chart

Compare the Difference

Compare the Difference

Particle Counter Printout

Recommended Cleanliness Targets

Hydraulic Systems (Implement & Steering)....………………………. ISO18/15

Fuel …………………………………………………………???……… ISO18/16/13

How much “dirt” can be present in a 55-gallon

Modern Caterpillar machines have very tight tolerances.

This slide demonstrates the extreme tolerances on today’s equipment.

Contamination Control Example

Example: 32 GPM pump working 8

Contamination Control Example

ISO 19/16 157.7 lb/yr

The NACD internet site on Contamination Control is another way to access