Effective Fluid Cleanliness Management

Best Practices

Simon Bishop // May 2014

Agenda

• Contamination Control Basics

– Dirt hurts, what’s a micron?

• Fluid Management
– Bulk Fluid Storage
– Fuel Management
– Machine Component / Systems
– Machine Filtration
Contamination Control: Understanding The Basics
 Contamination Control: Maximize component life

Contamination is the No. 1 enemy of fluid systems

The greatest opportunities

for increasing component life and
lowering operating costs is to effectively
manage fluid cleanliness.

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 Contamination: Anything in a fluid that doesn’t belong

CONTAMINANTS
Particulate Chemical

DIRT
THE HEAT

METALS SYSTEM WATER

FIBERS AIR

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 Contaminants are smaller than the eye can see

80

Diameter (µm)
HUMAN HAIR

BIG PARTICLE
15
AVERAGE CLEARANCE OF
10
HYDRAULIC COMPONENT
SMALL PARTICLE 5
1
FILM IN A BEARING &
FUEL SYSTEM

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Contamination Control requires measurement

Particle Count
• Measures CC efforts
• Quantifies particles by size & amount
• Performed using a lab, portable
counter or by patch test
Laboratory Pamas
The International Organization for Standardization (ISO)
has defined a method for coding the level of
contamination by solid particles
• Provides a common language
• Defines quantity of particles in one mL
• 28 Code ranges
– The higher the number the dirtier the fluid
– The particle count doubles from one code to the next
highest
• Caterpillar cleanliness targets are based on ISO 4406

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 ISO 4406 Explained
In ISO (International Organization for Standardization) publication 4406, 28 code
numbers are provided, each representing a given range of particles per milliliter. The
lowest number of particles per milliliter of sample is 0.01 and the highest number of
particles per milliliter of sample is 2,500,000. Smaller code numbers correlate to smaller
numbers of particles. Please note that the size of each code range is double the number
of the preceding range.

For example, ISO Code 10 has a range of 5 particles while ISO Code 11 has a range of
10 particles. Each one step increase in ISO Code (i.e. going from 11 to 12), for the same
channel, indicates the particle concentration is double the preceding code.

ISO 4406 establishes a three-factor code (X/Y/Z) to express fluid cleanliness. The X factor
represents the number of particles larger than 4 microns. The Y factor represents the number
of particles larger than 6 microns and Z factor indicates the number of particle larger than 14
microns. Caterpillar reports the Y and Z codes (for oils) to keep consistency with older data and
reports X, Y and Z codes for fuel.

For the example, test results where the

particles/1mL sample in the 6 micron channel
are 9108, the associated ISO Code is 20. For
the example test results where the
particle/1mL sample in the
14 micron channel is 1750, the associated ISO Code is 18.
The ISO Cleanliness Code is reported as ISO -/20/18.

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 Ensuring fluid cleanliness: Kidney Loop

• Similar to Kidney Dialysis

• Kidney loop / off-line filtration
as needed

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 Fluid contamination

The Silent Thief!

You can’t see it. You can’t hear it.

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Contamination Control: Bulk Fluid Storage
 Bulk fluids: Supplier

• Dedicated transport vehicles

• Product filtered before loading
• CC process & practices maintained:
Hose protection, quick connects, low
lint towels etc…
• Product cleanliness checked:
Particulate and water
• Preventative Maintenance program

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 Bulk fluids: Delivery

• Supplier Engagement
• Agreed delivered cleanliness
• Sample verification before off-load

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 Bulk fluids: Storage types

Fixed storage, totes & barrels

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 Bulk fluids: Tank considerations

• Stainless Steel is Best – cost

• Ferrous Iron most popular
– White or beige exterior
– Epoxy coated interior
• Sloped floor
• Water & sediment drain
• Access for cleaning
Bulk Tank
• Standpipe: Floating or 12 in. form
Bottom

Day Tank
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 Protecting bulk fluids: Entry filtration

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 Protecting bulk fluids: High efficiency breather

4 um breather with Vent Not Recommended

ability to remove water

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 Protecting bulk fluids: Storage

Bulk tank fluid sampling

Start with clean storage tanks

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 Protecting bulk fluids: Tank PM Program

• Tank cleaning
• Filtration
• Breathers
• Dispensed oil / fuel
cleanliness targets

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 Ensure fluid cleanliness: Dispensing filtered oil

• Point of use filtration and

dispensed at ISO -/16/13
• Quick connects used

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 Waste oil handling improves efficiency

• Vacuum equipment is connected

directly to the machine / component
reservoir or is used to remove oil
directly from a drain cart
• Technicians productivity increase
• Quick connects used

Waste oil handling improves efficiency

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 Protecting fluids: Lube and Fuel Trucks

• Fluids filtered entering and at the

dispensing point
• 4 micron breather filter with moisture
removal capability
• Clean compartment to transport filters
• Oil fill and grease nozzles clean
• PM program on vehicle & compartments

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Contamination Control: Fuel Management
 Bulk fuel filtration removes particulates and water

• Cost Avoidance
• Reliability improvement
• Maintenance budget impact

Cat® Models:
190 / LPM (50 GPM) - 370-8568
380 / LPM (100 GPM) - 370-8569
760 / LPM (200 GPM) - 370-8570
1135 / LPM (300 GPM) - 370-8571

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 Protect against contamination during refueling

Clean fueling ports and nozzles before fueling and cover them after fueling.

Fueling ports

Nozzles

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 Maintain machine fuel tanks

• Drain tanks of sediment and water

• At PM, per machine OMM, or as
needed
• Part of PM/Inspection Checklist

Result: Clean and dry fuel

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Contamination Control: Machine System
 Sampling & particle counting to ensure cleanliness

Ongoing S.O.S.SM program Fleet consistency meets particle count

including particle count cleanliness PM & repair (shop & field)

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 Kidney loop filtration increase life & reduces costs

Cart circulates oil through the

machine system / component
to filter out contaminants.

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 Example: Without kidney loop filtration

Without kidney looping

793C final drive wheel bearings at 13,000 SMU

1,200-hour oil change intervals

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 Example: With kidney loop filtration

With kidney looping

793C final drive wheel bearings at 18,000 SMU

4,000-hour oil change intervals

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 Filter oils before reuse

Oil reuse
• Cost avoidance
• Sustainability

Fluid recovery carts

• Kidney Loop functionality
• Dispense through filters
• Meets ISO -/16/13
• Connections clean and protected

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Contamination Control: Fuel Management
 Machine filters provide final filtration

High efficiency secondary fuel filter

• Captures the most harmful (fine) particles

Water separator / primary filter

• Prevents injector water damage
• 100% free water
• 90% emulsified water
• Extends secondary filter life

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 Higher efficiency improves system cleanliness

• Higher efficiency filters

• Improve system cleanliness
• Improve component / system life
• Minimize / avoid “spikes” in
cleanliness between PM
• NOT available for all systems /
components.
– Filter by-pass when cold
– Amount of break-in
– Flow and pressure
• Consult your Cat® Dealer

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 Use an appropriate tank breather

• Efficiency: Good or better than

downstream filter
• Location: Convenient to inspect and
change
• Change intervals: Every fluid change
or when they appear clogged

785C Engine Fuel System Filtered Fuel Cap Breather

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 CC assessments: Contact your Cat® Dealer

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Key takeaways

• Contamination is the No. 1 enemy of

fluid systems
• Work with supplier for clean fluids
• Filter all fluids
• Dispense fluids at Caterpillar cleanliness
targets
• Comply with Caterpillar Roll-Off targets
at PM & repair
• Clean fluids, facilities, processes and
parts are essential components of a
formal contamination control program
 THANK YOU
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and
product identity used herein, are trademarks of Caterpillar and may not be used without permission.

©2014 Caterpillar All Rights Reserved.

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