A GUIDE

To Particulate Contamination of Hydraulic,

Lubricating and Fuel Systems, and Particle
Contamination Standards
Third Edition 2020
 A Guide to Particulate Contamination and
Contamination Standards
The purpose of this booklet is to help fluid power users understand,
measure and control particulate contamination:

• What is contamination?
• Generally accepted and widely used cleanliness specification
levels and tables for liquid samples
• A summary of calibration methods for automatic optical
liquid-borne particle counters.

Beckman Coulter and HIAC trust that this guide will prove useful to
engineers, technicians, quality control personnel and fluid power
users involved in contamination control, predictive and proactive
maintenance regimes, and to liquid particle counter users
in general.

Table of Contents
What are Particles…………………………………..…………………………………..…………………………………..…………………………………..……………………….. 3

Examples of Contamination……………………………………………………………………………………………………………………………………………………….. 4

Effects of Contamination………………………………………..…………………………………………………………………………………………………………………… 5

Use of Cleanliness Specification Tables…..……………………………………………………………………………………………………………………………… 6

The Standards………………………………………………………………………………………………………………………………………………………………………………… 7

• ISO 4406:2017…………………………………………….…………………………………………………………………………………………………………………….. 8

• SAE AS 4059F……………………………..…………………………………………………………………………………………………………………………………… 9

• NAS 1638…………………………………………………..……………………………………………………………………………………………………………….......... 10

Calibration…………………………………………………..………………………………………………………………………………………………………………………………….. 11

• ISO 11171…………………………………………………..………………………………………………………………………………………………………………………….. 11

A Note about Viscosity Ratings...............…..…………………………………………………………………………………………………………………………….. 12

Take Control of Your Fluid Cleanliness with HIAC...............…..………………………………………………………………………………………..….. 12

Notes...............…..……………………………………………………………………………………………………………………………...................................................... 14

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What are Particles?

Particle contamination comes in many shapes and sizes and can be composed of various materials. Particulate
contamination is the single most important factor affecting the life and performance of fluid power systems,
and in extreme cases can result in catastrophic system failure.

Typical contaminants found in hydraulic systems are:

• Metallic wear particles • Rubber
• Dirt • Sand
• Water • Soot
• Air

Particles are generally invisible to the human eye. Particles as small as 0.5 micron can impact the efficiency
of a hydraulic system.

Characterized by Ingenuity | 3
 Examples of Contamination

• Casting and machining • Metallic

debris (silica, metallic)
• Seal materials
• Hose debris (rubber,
metallic)
• Polishing compounds
(alumina)
• Fibrous and other
materials
• Fluid contamination

• External ingression • Built-in contamination and

break-in wear debris
O Mineral
contaminants • Fluid contamination
(dirt/dust)
O Water
• Internal generation
o Component wear
(metallic, seal
material)
o Fluid degradation
products
(thermal breakdown
products, additive
precipitation, etc.)

Effects of mixing oil with

incompatible fluids

Oil of varying levels of contamination, from new to used (left to right)

Dissolved, emulsified and free water in oil, left to right

4 |
Effects of Contamination

85% of all system failures are directly caused by contamination*.

Contamination results in:
• Production downtime
• Increased running costs
• Increased fluid replacement
• Increased fluid disposal costs
• Increased maintenance costs
• Reduced system efficiency
• Damage to lubrication properties of oil
• Increased environmental impact

• Risk to personnel

*The Handbook of Hydraulic Filtration, Parker Hannifin

Characterized by Ingenuity | 5
 Use of Cleanliness Specification Tables

These tables are generated by organisations from many different industries. Each table is different, and you should
exercise some caution when using them.

Some tables are defined in cumulative counts, e.g., number of counts greater than 4µm. These are represented
as “> 4µm”. Others are represented as differential counts, e.g., number of counts between 4 µm and 14 µm.
These are represented as “4-14 µm”.

All standards are in counts per volume. The specific volume can differ between standards. Some are expressed as
counts per mL, others are in counts per 100 mL, counts per liter, or even counts per bottle.

Most standards define one cleanliness level, although they require measurements at multiple sizes. For these
standards, the cleanliness class is determined by the particular size or size range that is the most highly
contaminated. Another way to state this is that the counts must be less than the cleanliness class at each size or
size range specified. This could mean that although a sample classified using SAE AS 4059 was Class 4 at the
largest size, but Class 1 at all others, the sample would be classified as Class 4. In contrast, ISO 4406 specifies the
classification at 3 values, representing 4, 6 & 14µm (c).

For most standards the levels are absolute. If the limit for Class 15 is 320 counts, then 321 counts is Class 16, even if
a product fails at Class 16. This can raise the question “Why does my product fail for just 1 particle?” The reason for
this is that the preferred operating level of the system should be well below the limit. Operating a process so close
to the allowable limit that is occasionally fails is not good manufacturing practice. Note that for most standards the
count levels for adjacent classes differs by a factor of 2. Thus, although two measurements that differ by 1 count
can be in different classes, two measurements that differ by up to 50% can also be in the same class. As a result a
process should typically run well below the class limits.

These standards provide a simple method of converting particle count data into limits that are easily understood
and to remember. By noting the specific requirements of the standard, particle count data can be accurately
converted to contamination levels.

Some standards refer to particle sizes as μm, and others refer to particle sizes as μm(c).

• μm refers to ACFTD (air Cleaner Fine Test Dust) particle distributions.

• μm(c) refers to MTD (ISO-Medium Test Dust) particle distributions

6 |
The Standards

A brief synopsis of typical Industrial Fluid Standards:

1. ISO 4406 – Displays cumulative counts per milliliter for the 4 μm(c), 6 μm(c), 10 μm(c), 14 μm(c),
21 μm(c), 25 μm(c), 30 μm, 38 μm, and 70 μm sizes. Reports classification codes per the ISO 4406
standard.
2. NAS 1638 – Displays differential counts per 100 milliliters for the 5, 15, 25, 50, and 100 μm sizes. These
sizes are translated to ISOMTD sizes for ISOMTD calibrated units. Reports classification codes per the
NAS 1638 standard.
3. SAE AS4059 – Displays cumulative counts per 100 milliliters for the 4 μm(c), 6 μm(c), 14 μm(c), 21 μm(c),
38 μm, and 70 μm sizes. Reports classification codes per the SAE AS4059 standard.
4. NAVAIR 01-1A-17 – Displays differential counts per 100 milliliters for the 5, 10, 25, 50, and 100 μm sizes.
These sizes are translated to ISOMTD sizes for ISOMTD calibrated units. Reports classification codes per
the NAVAIR 01-1A-17 standard.
5. DEFSTAN 91-91 – Displays cumulative counts per milliliter for the 4 μm(c), 6 μm(c), 14 μm(c), 21 μm(c), 25
μm(c), and 30 μm sizes. Reports classification codes per the ISO 4406 standard.
6. GOST 17216 – Displays cumulative counts per milliliter for the 4 μm(c), 6 μm(c), and 14 μm(c) sizes.
Reports classification codes per the ISO 4406 standard.
7. ASTM D7619-12 – Displays cumulative counts per milliliter for the 4 μm(c), 6 μm(c), and 14 μm(c) sizes.
Reports classification codes per the ISO 4406 standard.

The following pages contain extracts of the three reporting standards more commonly used in industry.

Characterized by Ingenuity | 7
 ISO 4406:2017 Scale Numbers Table 1 from ISO 4406:2017

NOTE: The original code (ISO 4406:1987) stated the Number of Particles Per
Milliliter Scale Number
reporting at two sizes ≥ 5 μm and ≥ 15 μm. The sizes in
(Counts/mL)
the current version account for the use of a different
calibration standard for optical automatic particle More Than Up To and
counters (APCs). The reported sizes are ≥ 4 μm(c), ≥ Including
6 μm(c) and ≥ 14 μm(c), the last two of these being 2 500 000 >28
basically equivalent to the 5 μm and 15 μm particle sizes 1 300 000 2 500 000 28
obtained using the ISO 4402:1991 method of calibrating
640 000 1 300 000 27
APCs. Throughout this current ISO 4406 the use of
μm(c) means that particle size measurements are carried 320 000 640 000 26
out using an automatic particle counter that has been 160 000 320 000 25
calibrated in accordance with ISO 11171. 80 000 160 000 24
ISO 4406 is a three-digit code that represents cumulative 40 000 80 000 23
counts/mL at ≥ 4 μm(c), ≥ 6 μm(c) and ≥ 14 μm(c). The 20 000 40 000 22
counts at each size are compared to the table to find 10 000 20 000 21
a contamination scale number. The code is written as
5 000 10 000 20
three numbers separated with a slash, ‘/’, between them.
For example, 19/17/14 or 23/20/18. The first number 2 500 5 000 19
represents the scale number at ≥ 4 μm(c), the second 1 300 2 500 18
number the scale number at ≥ 6 μm(c), and the third
640 1 300 17
number the scale number at ≥ 14 μm(c).
320 640 16
NOTE: Reproducibility below scale number 8 is affected 160 320 15
by the actual number of particles counted in the fluid
80 160 14
sample. Raw counts should be more than 20 particles.
If this is not possible, then refer to para 3.4.7 of the 40 80 13
standard, which says ‘When the raw data in one of the 20 40 12
size ranges results in a particle count of fewer than 20 10 20 11
particles, the scale number for that size range shall be
5 10 10
labelled with the symbol ≥’
2.50 5 9
1.30 2.50 8
0.64 1.30 7
0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0.00 0.01 <1

Permission to reproduce Table 1 from BS ISO 4406:2017 is granted by BSI Standards Limited (BSI). No other use of this material
is permitted. The complete British Standard can be purchased from the BSI online shop: https:// shop.bsigroup.com

8 |
SAE AS 4059F (2013)

(From the SAE website) “This SAE Aerospace Standard (AS) defines contamination classes and levels for
particulate contamination of hydraulic fluids and includes methods of reporting related data (Appendix A). The
contamination levels selected are based on the widely accepted NAS 1638 cleanliness classes. The conversion from
NAS 1638 cleanliness class specifications to AS4059 class specifications is defined. The comparison of the NAS
1638 classes to AS4059 classes and levels is provided and are defined and the differences explained (Appendix B).
NAS 1638 classes based on weight of particles are not applicable to these classes and are not included.
A contamination code has been added to describe the contamination levels of the fluid at the specified particle
size ranges.”*

SAE AS4059 has been designed to replace NAS 1638-01/1964. Data is sorted into cumulative particle counter
per 100 mL, and is expressed as either the total number of particles for a given size (e.g. AS4059 Class 6) or by
designating a class for each size range (e.g.: 6B/5C/4D/3E/3F)

Maximum contamination limits, particles per 100 mL

MTD >4 μm (c) >6 μm(c) >14 μm(c) >21 μm(c) >38 μm(c) >70 μm(c)
ACFTD >2 μm >5 μm >15 μm >25 μm >50 μm >100 μm
Size Code A B C D E F
000 195 76 14 3 1 0
00 390 152 27 5 1 0
0 780 304 54 10 2 0
1 1 560 609 109 20 4 1
2 3 120 1 220 217 39 7 1
3 6 250 2 430 432 76 13 2
4 12 500 4 860 864 152 26 4
5 25 000 9 730 1 730 306 53 8
6 50 000 19 500 3 460 612 106 18
7 100 000 38 900 6 920 1 220 212 32
8 200 000 77 900 13 900 2 450 424 64
9 400 000 156 000 27 700 4 900 848 128
10 800 000 311 000 55 400 9 800 1 700 256
11 1 600 000 623 000 111 000 19 600 3 390 512
12 3 200 000 1 250 000 222 000 39 200 6 780 1 024

* sae.org/standards/content/as4059f

Characterized by Ingenuity | 9
 NAS 1638 (revised 1992, superseded by SAE AS 4059)

Cleanliness Requirements of Parts Used in Hydraulic Systems

NAS 1638 was originally developed in 1964 for measuring cleanliness levels of aerospace components, and was
adopted throughout the industrial and aerospace fluid power industry

NAS 1638 is normally reported as a single class (e.g. NAS 6), which represents the maximum permitted particle
counts per 100 mL of fluid. The ‘worst case’ would always be considered as the most important measure. For
example, if all particle counts fell into class 4, apart from the measurement between 25-50 micron, which fell into
class 6, the result would be expressed as NAS 6.

NAS 1638 Cleanliness Code

Maximum Number of Particles / 100 mL
Class 5 - 15 15 - 25 25 - 50 50 - 100 > 100
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1 000 178 32 6 1
3 2 000 356 63 11 2
4 4 000 712 126 22 4
5 8 000 1 425 253 45 8
6 16 000 2 850 506 90 16
7 32 000 5 700 1 012 180 32
8 64 000 11 400 2 025 360 64
9 128 000 22 800 4 050 720 128
10 256 000 45 600 8 100 1 440 256
11 512 000 91 200 16 200 2 880 512
12 102 400 182 400 32 400 5 760 1 024

10 |
Calibration

The calibration standard in use across the fluid power industry is ISO 11171. Introduced in 1999, ISO 11171 provided
the hydraulic particle counting industry with definitive methodology by which a suitable hydraulic particle counter
could be fully characterised and calibrated using NIST traceable calibration suspensions and equipment. The
current iteration is ISO 11171:2016. It is worth noting that at the time of writing ISO 11171 is currently under review by
the various ISO Technical Committees around the world.

ISO 11171
Table 1 of the standard details the elements that are required to be either characterized or calibrated. The term
Calibrated for the purpose of this Guide will be defined as meeting a specification or Pass/Fail criteria. The term
Characterized for the purpose of this Guide will be defined as determining the instrument performance.

Those elements are defined as follows:

• Clause 6: Sizing calibration procedure (Calibration)

• Annex A: Preliminary instrument check (Characterization)
• Annex B: Coincidence error limits (Characterization)
• Annex C: Flow rate limits (Calibration and Characterization)
• Annex D: Resolution (Calibration)
• Annex E: Accuracy (Calibration)

For more information refer to the current version of ISO 11171, or contact your local Beckman Coulter office
or representative.

Characterized by Ingenuity | 11
 A Note about Viscosity Ratings

Viscosity refers to the ease at which an oil flows at a specified temperature. ‘Thin’ oils will have a lower viscosity
and will pour easily at lower temperatures than ‘thick’ oils.

The viscosity of a hydraulic fluid is measured in Centistokes (cSt) and usually at temperatures of 40°C and 100°C.
The value will always have the temperature next to it as without this the value will be meaningless. A fluid’s
viscosity is measured in a lab using a viscometer.

Clearly, temperature will affect viscosity – if the oil is colder it will have a higher viscosity than when it is warmer.
The chart below illustrates this for various viscosities**:

At Beckman Coulter viscosity ratings for HIAC particle counters are expressed at room temperature – around
22°C. Therefore, a fluid with an ISO 32 viscosity rating at 40°C will have a viscosity at room temperature of
approx. 60 cSt; a HIAC instrument with a viscosity rating of 400 cSt at room temperature indicates that it will be
able to run fluids of approx. 150 cSt ISO VG rated at 40°C.

This does not mean that higher viscosities cannot be analysed – the user simply needs to dilute their sample with
a compatible, clean, solvent, and use the dilution factor on the analyzer to calculate the correct results.

** Reprinted with permission from Fluid Power Pro (see FluidPower.pro/oil-viscosity)

12 |
 Take Control of your Fluid Cleanliness with HIAC

Reporting Fluid
Product Applications Features
Standards Viscosity

ISO 4406 1 to 425 cSt*

• Hydraulic fluids SAE AS4059 with shop air
HIAC PODS+ • Fuels NAS 1638 pressure at 100 ISO-MTD: 4, 6, 10,
ASTM D7619-12 psig
Portable Liquid • Oil GOST 17216
14, 21, 25, 30, 38,
and 70 μm
Particle Counter • Water DEF STAN 91-91 1 to 150 cSt*
NAVAIR 01-1A with internal
• Glycol
User defined pump

• Lab sampling
• Large volume
ISO 4406
samples defined
NAS 1638 0.5 μm to 600
HIAC 8011+ • Corrosives SAE AS4059 Capable of μm (sensor
dependent)
• Hydraulic fluids GOST 17216 testing fluids
Laboratory NAVAIR 01-1A from 1 cSt to
Liquid Particle • Fuel oils DEFSTAN 91-91 425 cSt* without
Counter • Water ASTM D7619 dilution Interchangeable
• Alcohol User defined sensors
Raw counts
• Solvents
• Glycols

• Multipoint system
monitoring
• Hydraulic presses
and machines
Minimum 2 cSt
HIAC ROC
• Filter carts
ISO 4406
• Fluid fill stations NAS 1638
Suitable for 24/7 trend
Online Liquid use on systems monitoring
Particle Counter
• Hydraulic power SAE AS4059 up to 500 bar
units
7500 PSI
• Reclamation
station
• Component test
stands

*at 22°C

Discover more at beckman.com/HIAC

Characterized by Ingenuity | 13
 Notes

14 |
Characterized by Ingenuity | 15
With thanks to Pall Corporation for permission
to use sections of the Pall Pocket Book

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