Contamination Control

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Contamination Control
Contamination Control Basics
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Contents

• Contamination Control Overview
• Particle Counting ISO Codes
• Contamination Control Tooling
• Cleanliness Targets

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Why Contamination Control?

• Customers are demanding .
• More power
• Greater breakout forces
• Faster cycle times

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Why Contamination Control?

• Industry trends
• Electro-hydraulics
• Higher system pressures
• Tighter clearances

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Why Contamination Control?

• Result Todays fluid systems are more sensitive
  to contamination
• Hydraulics
• Transmissions / Final drives
• Fuel systems
• Engines

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Why Contamination Control?

• Contaminated fluid systems
• Shorten component and fluid life
• Reduce productivity
• Can lead to catastrophic failure and
  costlydowntime and repairs

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Why Contamination Control?

• Tests prove clean oil improves life
• Increased bearing life
• No contamination-related failures from 6,000 to
  11,000 hours

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What Is Contamination?

• Anything in a fluid that doesnt belong
• The 1 enemy of fluid systems

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Contamination Sources

• Built-in
• New fluids
• Introduced contamination
• Cylinder wiper seals
• Reservoir vent ports
• Poor maintenance
• Generated internally

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Two Types of Contamination
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Small Particle Contamination
Even Particles Too Small to See are Harmful!
Human Hair
Cat System Clearances
Smallest Visible to the Eye
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30
40
MICRONS (?m)
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What is a Micron?
1 Millionth of a Meter
100 microns (?m) - grain of table salt 80 microns
(?m) - diameter of a human hair
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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
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Pump Manufacturer
Component Life
----
-----
------------

Clean New Oil
Component Life Over Time
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Effects of Contamination

• Erratic steering
• Cylinder drift
• Slower performance
• Unreliable operation
• Lower productivity
• Machine downtime
• Higher operating costs

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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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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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Housekeeping
Floor Dry
Hand Pump
Parts Packaging/Storage
Parts Cleaner
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Housekeeping
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Oil Storage and Transfer

• Use a transfer filter cart
• Change when warm and agitated
• Use barrel covers

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Kidney-loop Filtration System
Shown to increase oil and component life and
reduce costs
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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 for debris

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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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Hose Assembly and Storage

• Keep hoses plugged capped
• Use Cat hose cleaner proper process

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Care in Operation and Maintenance

• Perform daily inspections
• Keep hydraulic tank filled
• Maintain valves
• Use rod protectors
• Watch temperature
• gauges

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Particle Counting

• The way to measure your contamination control
  efforts

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Measuring Contamination

• Spectrographic Analysis
• Identifies elements in oil
• Only up to 10-15 microns in size

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Understanding Particle Counting

• ISO codes
• 28 code ranges

• Particle Count
• Quantifies particles 1-200 microns

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ISO Cleanliness Code

• Explained in ISO Standard 4406
• Expressed Amount of Contamination in one mL of
  Fluid

4µm / 6µm / 14µm
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ISO Codes

• Expressed in X/Y form
• X number of particles larger than 6 microns
  (gt6)
• Y number of particles larger than 14 microns
  (gt14)
• Example 16/13

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ISO Code Chart
Number of Particles / mL 40,000 - 80,000 20,000 -
40,000 10,000 - 20,000 5000 - 10,000 2500 -
5000 1300 - 2500 640 - 1300 320 - 640 160 -
320 80 - 160 40 - 80 20 - 40 10 - 20 5 - 10 2 -
5 1 - 2
28 ISO Codes 23 22 21 20 19 18 17 16 15 14 13 12 1
1 10 9 8
NOTE Particle count doubles at each level
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Compare the Difference
Very Dirty Oil
Hydraulic/ Steering Targets
Minimum Target
Fill Oils
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18
24
16
160,000 20,000 2,500
640
15
13
19
17
5,000 1,300 320 80

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Compare the Difference
18/15 (clean)
16/13 (very clean)
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Contamination Control Tooling
Portable Contamination Kit
Hose Cleaning Kit
S-40
Transfer Cart And Fluid Recovery System
Rear Axle Filter Buggy
Small System Filtration Cart
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Particle Counter Printouts Patch Kit Results
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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
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Visualizing Contamination

• How much dirt can be present in a 55-gallon
  drum of oil and still meet ISO 16/13?

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Visualizing Contamination

• Half a teaspoon

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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
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Contamination Control Example
Amount of Dirt Flowing Amount of Dirt
in Oil Through Pump in One Year

ISO 19/16 ISO 18/15 ISO 16/13
157.7 lb/yr
78.9 lb/yr
19.7 lb/yr
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Contamination ControlSupport Available

Tools Equipment Methods
Procedures Available for All
Products (95)
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Contamination ControlResults

• Lower Cost
• Repair Time
• Preventive Maintenance
• Component Life Extension
• Oil Extension
• Increased Availability