Set the Target.

The first step in identifying a

target ISO code for a
system is to identify the
most sensitive on an
individual system, or the
most sensitive component
supplied by a central
reservoir. If a central
reservoir supplies several
systems the overall
cleanliness must be
maintained, or the most
sensitive component must
be protected by filtration that
cleans the fluid to the target
before reaching that
component.
Selecting Target ISO Cleanliness Codes
When setting target ISO fluid cleanliness codes for hydraulic and lubrication systems it is important keep in mind the
objectives to be achieved. Maximizing equipment reliability and safety, minimizing repair and replacement costs,
extending useful fluid life, satisfying warranty requirements, and minimizing production down-time are attainable goals.
Once a target ISO cleanliness code is set following a progression of steps to achieve that target, monitor it, and
maintain it justifiable rewards will be yours.

Pressure Media Pressure Media Pressure Media

< 140 bar x[c] = 1000 212 bar x[c] = 1000 > 212 bar x[c] = 1000
Pumps
< 2000 psi (x = 200) 3000 psi (x = 200) > 3000 psi (x = 200)
Fixed Gear 20/18/15 22[c] (25) 19/17/15 12[c] (12) - -
Fixed Piston 19/17/14 12[c] (12) 18/16/13 12[c] (12) 17/15/12 7[c] (6)
Fixed Vane 20/18/15 22[c] (25) 19/17/14 12[c] (12) 18/16/13 12[c] (12)
Variable Piston 18/16/13 7[c] (6) 17/15/13 5[c] (3) 16/14/12 7[c] (6)
Variable Vane 18/16/13 7[c] (6) 17/15/12 5[c] (3) - -

Valves

Cartridge 18/16/13 12[c] (12) 17/15/12 7[c] (6) 17/15/12 7[c] (6)
Check Valve 20/18/15 22[c] (25) 20/18/15 22[c] (25) 19/17/14 12[c] (12)
Directional (solenoid) 20/18/15 22[c] (25) 19/17/14 12[c] (12) 18/16/13 12[c] (12)
Flow Control 19/17/14 12[c] (12) 18/16/13 12[c] (12) 18/16/13 12[c] (12)
Pressure Control
(modulating)
19/17/14 12[c] (12) 18/16/13 12[c] (12) 17/15/12 7[c] (6)
Proportional Cartridge Valve 17/15/12 7[c] (6) 17/15/12 7[c] (6) 16/14/11 5[c] (3)
Proportional Directional 17/15/12 7[c] (6) 17/15/12 7[c] (6) 16/14/11 5[c] (3)
Proportional Flow Control 17/15/12 7[c] (6) 17/15/12 7[c] (6) 16/14/11 5[c] (3)
Proportional Pressure
Control
17/15/12 7[c] (6) 17/15/12 7[c] (6) 16/14/11 5[c] (3)
Servo Valve 16/14/11 7[c] (6) 16/14/11 5[c] (3) 15/13/10 5[c] (3)

Bearings

Ball Bearing 15/13/10 5[c] (3) - - - -
Gearbox (industrial) 17/16/13 12[c] (12) - - - -
Journal Bearing (high speed) 17/15/12 7[c] (6) - - - -
Journal Bearing (low speed) 17/15/12 7[c] (6) - - - -
Roller Bearing 16/14/11 7[c] (6) - - - -

Actuators

Cylinders 17/15/12 7[c] (6) 16/14/11 5[c] (3) 15/13/10 5[c] (3)
Vane Motors 20/18/15 22[c] (25) 19/17/14 12[c] (12) 18/16/13 12[c] (12)
Axial Piston Motors 19/17/14 12[c] (12) 18/16/13 12[c] (12) 17/15/12 7[c] (6)
Gear Motors 20/18/14 22[c] (25) 19/17/13 12[c] (12) 18/16/13 12[c] (12)
Radial Piston Motors 20/18/15 22[c] (25) 19/17/14 12[c] (12) 18/16/13 12[c] (12)

Test Stands, Hydrostatic

Test Stands 15/13/10 5[c] (3) 15/13/10 5[c] (3) 15/13/10 5[c] (3)
Hydrostatic Transmissions 17/15/13 7[c] (6) 16/14/11 5[c] (3) 16/14/11 5[c] (3)
Recommended* Target ISO Cleanliness Codes and media selection for systems using
petroleum based fluids per ISO4406:1999 for particle sizes 4[c] / 6[c] / 14[c]
Other Considerations
Table 1 recommends
conservative target ISO
cleanliness codes based on
a several component
manufacturers guidelines
and extensive field studies
for standard industrial
operating conditions in
systems using petroleum
based fluids. If a non-
petroleum based fluid is
used (i.e. water glycol) the
target ISO code should be
set one value lower for each
size (4[c]/6[c]/14[c]). If a
combination of the following
conditions exists in the
system the target ISO code
should also be set one
value lower:
Component is critical to
safety or overall system
reliability.
Frequent cold start.
Excessive shock or
vibration.
Other Severe operation
conditions.
Example ISO Code Comments
Operating Pressure 156 bar, 2200 psi

Most Sensitive Component Directional Solenoid 19/17/14 recommended baseline ISO Code
Fluid Type Water Glycol 18/16/13 Adjust down one class
Operating Conditions Remote location, repair difficult

Adjust down one class, combination

High ingression rate 17/15/12 of critical nature, severe conditions
*Depending upon system volume and severity of operating conditions a combination of filters with varying
degrees of filtration efficiency might be required (I.e. pressure, return, and off-line filters) to achieve and
maintain the desired fluid cleanliness.
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Current Target Target Target Target
ISO Code ISO Code ISO Code ISO Code ISO Code
2 x Life 3 x Life 4 x Life 5 x Life
28/26/23 25/22/19 22/20/17 20/18/15 19/17/14
27/25/22 23/21/18 21/19/16 19/17/14 18/16/13
26/24/21 22/20/17 20/18/15 19/17/14 17/15/12
25/23/20 21/19/16 19/17/14 17/15/12 16/14/11
25/22/19 20/18/15 18/16/13 16/14/11 15/13/10
23/21/18 19/17/14 17/15/12 15/13/10 14/12/9
Accurate oil analysis - Once the target ISO fluid cleanliness code is established it is critical to properly measure the
actual cleanliness of the system. A well designed plan to achieve cleanliness can be undermined if steps are not
taken to ensure accurate and repeatable oil analysis. When sampling the oil a wide range of variables can affect the
outcome yielding inaccurate results. For more information see Accurate oil sampling and analysis article.
Extending Roller Bearing Life.
Improving fluid cleanliness in lubrication systems for
roller bearings can exponentially increase component
life. Figure B describes attainable increases in life
expectancy of roller bearings as improvements in ISO
fluid cleanliness codes are made. Life extension for
hydraulic components can be achieved by improving
fluid cleanliness.
Oil sampling methods and practices - Bottle samples analyzed by independent laboratories is common and widely
accepted as a method of quantifying fluid cleanliness. However, there are many variables associated with bottle
sampling that can cause inaccurate readings.
Background contamination in clean sample
bottles or vacuum tubes can increase ISO codes
by 1~4 classes per size measured,
4[c]/6[c]/14[c].
Inconsistent in-plant sampling practices
(i.e. sample port flush time, bottle rinsed or not).
Exposure of sample to airborne contaminate
during sampling and analysis
Analysis lab procedure repeatability by operator
(i.e. agitation~count interval affect on suspension).
Analysis lab calibration drift.
Variability between oil analysis lab particle
Oil sampling port types and locations - Just as sampling technique and method can compromise results, sampling
port and location can also be a challenge. Sampling ports are often contamination collection points and must be
flushed for up to 6 minutes before a truly representative sample is captured. Without a proper port flush the results
can be affected. Port location is also critical to obtaining a good sample. Locating a sampling where there is
turbulent flow will provide more realistic results than a laminar area. For more information see Accurate oil sampling
and analysis article.
On-line particle counting - Connecting an on-line particle counter directly to the
hydraulic or lube system through sampling ports provides the most accurate snapshot of
fluid cleanliness and eliminates many of the inherent variables associated with bottle
sampling. Some particle counters can function with system pressure as low as 20 psi
(1.42 bar) at certain viscosities for sampling pressure line, return line, or lubrication
system. There are also particle counter options available to draw (Sip) the fluid from a
reservoir, tote, or other container directly into the particle counter when system pressure
is not available. Monitor sample port cleanliness in real time to know when the sample is
truly representative of the system and not tainted with sample port contaminate buildup.
Maintaining control of the sampling and analysis procedures increases the accuracy of your results, eliminates the
waiting game to get samples back from a lab, allows quicker response to contamination related issues, and even
save money on oil sample kits. No one knows your system better than you and once armed with the right oil analysis
approach and diagnostic equipment you can make improvements in reliability.
PTK-1 Oil analysis kit - Patch test kits are a good
complement to on-line particle counters as they provide
the capability to visually analyze contamination levels
and types in the system. The kit includes a microscope,
vacuum pump, test patches, and solvent dispenser
integrated into a carrying case. The kit also features a
reference manual to correlate visual patch appearance to
approximate ISO code.
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Pressure filters are ideal for protecting control
valves and other sensitive components from internally
generated contaminate and ingression.

Machine tools without a pressure filter protecting valve
manifolds after the pump.

Power units on CNC lathes and milling equipment,
Plastics injection molding, mobile equipment, and other
small industrial machines with sensitive control valves.

Focus: Solving contamination issues
resulting from insufficient filtration on
power units and machine tools.
Machine Tool Contamination Field Study
The Problem - Insufficient filtration
APPLICATIONS
Machine tools and power units are frequently designed
without the filtration necessary to maintain recommended
fluid cleanliness levels for the system. A fluid cleanliness
case study of three CNC lathes (A, B, C) raised some
concern. The only filtration present was either a coarse
suction strainer or coarse return-line screen. Baseline oil
analysis (see fig 1) revealed that
the fluid cleanliness levels of the
hydraulic fluids (per ISO 4406
code chart) were higher than
recommended levels for the
system components (see fig 2).
fig. 1
Machine ISO code*
A 22 / 20 / 14
B 23 / 20 / 14
C 23 / 21 / 16
fig 2.
Pumps <2000 psi 2000~3000 >3000 psi
Fixed gear 20/18/15 19/17/15
Fixed vane 20/18/15 19/17/14 18/16/13
Fixed piston 19/17/14 18/16/13 17/15/12
Variable vane 18/16/13 17/15/12
Variable piston 18/16/13 17/15/13 16/14/12
Valves 2000~3000 >3000 psi
Directional (solenoid) 20/18/15 19/17/14
Proportional 17/15/12 16/14/11
Servo Valve 16/14/11 15/13/10
Contamination Basics & Sources
Particulate contamination is the number one
cause of hydraulic component failure, and
70~75% of failures are related to surface
degradation caused by mechanical wear.

Sources of particulate contamination
Built-In contamination (assembly
environment, dirty new components and
hoses, metal fabrication)
Ingested contamination ( leaky reservoirs,
no reservoir breather, worn rod wipers and
bearing seals, dirty replacement
components, system exposure during
maintenance, new oilsee fig 3.)
Internally generated contamination
(abrasive wear, adhesive wear, stress
related wear, corrosion, fluid breakdown)


Fig 3 (new oil typical ISO code 24/21/18).

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Solution Part I - System Clean-up
The pressure filter assembly, including 12[c] = 1000 filter element and
element condition indicator, was added to each of the three machines
(see fig 4) after the pressure pump (piston type). After nine days of
operation the indicators on machines A and C were signaling terminal
pressure drop. At that time all three elements were serviced and the
oil was analyzed (see fig 5). The ISO codes improved, but not to the
level recommended for servo valves. The next step was to set target
cleanliness codes and enhance the filtration efficiency to reach the
target. The spent elements that were removed contained large
particles including piping putty (from installation of new hoses) and
other large debris
that was not being
removed by the
suction strainer.
fig. 5
Mach. ISO code before
Pressure filter
ISO code after 9 days
(12[c] = 1000)
A 22 / 20 / 14 19 / 18 / 12
B 23 / 20 / 14 21 /18 / 12
C 23 / 21 / 16 20 / 18 / 13
A target ISO Cleanliness Code of 16 / 14 / 11 (measured at filter effluent) was established for all three machines to
protect and maximize piston pump and solenoid valve life. New filter elements were installed with a more efficient rating
of 5[c] = 1000 (3 = 200 according to old standards) to achieve
the target. After 60 days of service the oil from all three
machines was analyzed (see fig 7), even though none of the
assemblies were indicating terminal pressure drop.
Machines B and C were able to attain the target while A did not,
although adding of the pressure filter made considerable
improvement in cleanliness. The oil was sampled after 180 days
using an on-line particle counter connected to the drain plug of
the filter bowl. This location represents one of the dirtiest points
on the system since the oil has been through the system and in
the reservoir. Sampling with an on-line particle
counter and proper flushing techniques eliminates
variables associated with bottle sampling. Figure 8
illustrates increased life expectancy for hydraulic
components that can be realized by reducing fluid
cleanliness codes. The benefits of clean fluid justify
the cost of filtration.

Benefits of clean fluid
Minimize unplanned equipment downtime.
Reduce maintenance costs and labor.
Reduce expensive component repair or
replacement costs.
Improve operating efficiency of equipment
with sensitive components.
Extend service life of fluids.


Adding a desiccant breather to the reservoir assures that the air ingested is dry and
clean. Reducing water content reduces chemical compound formation, biological
growth, oxidation and extends fluid life. Desiccant breathers also control particulate
contaminate ingression down to 4[c] or 2 with absolute efficiency. Filler-breather
caps commonly found on reservoirs dont properly control particulate contamination.
Specific desiccant breathers also adsorb water and oil mist as the reservoir exhales.
A full range of adapters is commonly available to retro-fit any reservoir.
Solution Part II - Enhanced Filtration and Target Cleanliness Codes
fig. 7
Mach. ISO code
before filter
ISO code after
60 days
(5[c] = 1000)
ISO code after
180 days
(5[c] = 1000)
A 22 / 20 / 14 17 / 15 / 11 11 / 9 / 7
B 23 / 20 / 14 15 / 13 / 8 13 / 11 / 9
C 23 / 21 / 16 16 / 12 / 10 14 / 11 / 9
fig. 8
Current Target Target Target Target
ISO Code ISO Code ISO Code ISO Code ISO Code
2 x Life 3 x Life 4 x Life 5 x Life
28/26/23 25/22/19 22/20/17 20/18/15 19/17/14
27/25/22 23/21/18 21/19/16 19/17/14 18/16/13
26/24/21 22/20/17 20/18/15 19/17/14 17/15/12
25/23/20 21/19/16 19/17/14 17/15/12 16/14/11
25/22/19 20/18/15 18/16/13 16/14/11 15/13/10
23/21/18 19/17/14 17/15/12 15/13/10 14/12/9
22/20/17 18/16/13 16/14/11 15/13/10 13/11/8
21/19/16 17/15/12 15/13/10 13/11/8 -
20/18/15 16/14/11 14/12/9 - -
19/17/14 15/13/10 13/11/8 - -
18/16/13 14/12/9 - - -
17/15/12 13/11/8 - - -
Fig 4.
Hydraulic Component
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