Maintenance Products

&
Services Group
• What is Contamination Control
• What is Contamination
• Effects of Contamination
• Sources of Contamination
• Terminology
• Micron
• ISO
• Benefits of Controlling Contamination
 IS
THE NUMBER ONE ENEMY
OF
Anything in a Fluid that
Does not Belong
 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.

Initial contamination can occur in NEW or REBUILT

equipment and in NEW OIL.
40 Microns & Larger Under 40 Microns
 LOWER PRODUCTIVITY
HIGHER OPERATING COSTS
O Design
O Manufacturing & Assembly
O New Fluids
O Machine Operation
O Maintenance and Service
• Micron

• ISO
What is
A
Micron?
 Particles You Can Not See Are Harmful!

C atHydraulic
System Clearances

Sm allest
Visible H um an H air
to the Eye
5
2 30 40
Fuel
M IC R O N S 80
What is
An
ISO?
 International Standards Organization
(Geneva,
(Geneva, Switzerland)
Switzerland)

• Countries worldwide provide input to set standards

– Quality
– Safety
– Manufacturing Specifications

• Purpose of Standards
– Allow fair trade and commerce on a global basis
 Expresses Amount of
Contaminant in one ml of Fluid

• 29 ISO Levels

• Particle count doubles at each level

ISO Code Number of Particles / mL
23 ----------Very Dirty ---------- 40,000 - 80,000
22 20,000 - 40,000
21 10,000 - 20,000
20 5000 - 10,000
19 2500 - 5000
18 ---- Clean (Hyd. System) ---- 1300 - 2500
17 (18/15)
640 - 1300
16 ----- Very Clean (Fill Oil) ----- 320 - 640
15 (16/13)
160 - 320
14 80 - 160
13 40 - 80
12 20 - 40
11 10 - 20
10 5 - 10
9 2-5
8 1-2
 ISO Codes

V ery D irty D irty C lean V ery C lean

24 21 18 16
5 Microns 160,000 20,000 2,500 640
& Greater

19 17 15 13
15 Microns 5,000 1,300 320 80
& Greater
Explained in ISO Standard 4406

• Caterpillar uses the 2 factor code

• Express as X / Y where
X # particles > 5 um
Y # particles > 15 um

e.g. 18 / 15, where X = 18 and Y = 15

(Hydraulic System Target)
ISO Cleanliness Code

•Explained in ISO Standard 4406

• Expresses Amount of Contaminant

in one mL of Fluid

2um / 5um / 15um

AC Calibration
ISO Cleanliness Code

•Explained in ISO Standard 4406

• Expresses Amount of Contaminant

in one mL of Fluid

4um / 6um / 14um

NIST Calibration (October 1999)

 Why Is It
Critical
To Keep Fluids
Clean?
• The Timken Bearing Company

• Independent Pump Manufacturer

Reason: Reduced Bearing Life
(8000 hrs. vs. 12,000 hrs.)

Study: Introduced 20 to 30 um Particles

into New Bearings

Results: Cause of Reduced Life

was Contamination
 ISO

C
22/19 Component Life
o
n
21/17 ----
t 20/15 -----
a
m 19/16
i
n
a
18/15 ------------
t 17/14
i
o 16/13
n Clean New Oil
15/12

14/11

13/10

12/09

Component Life Over Time

 Marketing
Contamination Control
 Mine Customer
Proposal Oil Conditioning
• Objective: Determine Increased Wheel &
Differential Component Life with Oil Conditioning
Program
• Customer: Mine in NACD

• Fleet: 50 Large OHT

• Study Baseline:
• 48 Wheel Rebuilds out of 100 @ $51,785
• 24 Differential Rebuilds out of 50 @ $15,275
 Proposal Oil Conditioning

OHT Wheel Group

•42% Repairs = Planned Component Replacement
•11% Repairs = Bearing Related
•7% Repairs = Contamination / Seal Failures
•6% Repairs = Planetary Gear Failures
•34% Repairs = Unidentified
OHT Differential
•66% Repairs = Planned Component Replacement
•10% Repairs = Bearing Related
•14% Repairs = Contamination/ seal failures
•10% Repairs = Unidentified
 Proposal Oil Conditioning
OHT Wheel Group
% Elimated by % of Total
Repair Type
Conditioning Failures
Bearing Related 90 9.9
Seals 30 2.1
Gears 30 1.8
Unidentified 30 10.2
Total: 24
OHT Differential
% Elimated by % of Total
Repair Type
Conditioning Failures
Bearing Related 90 9.0
Seals 30 4.2
Unidentified 30 3.0
Total: 16.2
 Oil Conditioning Results

Total Pretax Savings: $655,800 / year

- Implementation Costs
(Labor, Equip., Filters, etc.)

Total Customer Savings: $177,342 / year

• How Much “Dirt” is present in ISO 16/13 Oil ??

• ISO 16/13 = 0.77 mg of Dirt / liter of Oil

• How Much Dirt Can Be in a Barrel of Oil

so the Oil Still Meets ISO 16/13?
 An Aspirin contains
325 mg
0.77 mg/L x 3.785 L/gal x 55 gal = 160 mg

160 mg of
Contamination = ISO 16/13
in 55 Gallons
of Oil
How Much of a Difference Will Cleaning Your Oil from
ISO 21/17 to ISO 18/15 Really Make?

Example
Example::
32 GPM Pump Working 8 Hours / day for 200 Days

?
 ISO

C
22/19 Component Life
o
n
21/17 ----
t 20/15 -----
a
m 19/16
i
n
a
18/15 ------------
t 17/14
i
o 16/13
n Clean New Oil
15/12

14/11

13/10

12/09

Component Life Over Time

 Does it Make a Difference?
(2.08 or 16.24)mg/L x 3.785 L/gal x 32 GPM = 93.3 mg/min
x 60 min/hr x 8 hr/day for 200 days/year =
193,481,933 mg/year divided 1000 mg/gal divided 454 gal/lb =

Amount of “Dirt” Flowing

Amount of “Dirt” in Oil Through Pump in One Year

ISO 21/17 426.2 lb/yr

ISO 18/15 54.6 lb/yr
ISO 16/13 19.2 lb/yr
How do we
get this oil
cleaned up?
We use good
filters
&
filter carts
Dirt
&
Water
Filters are rated on the basis of their ability to separate
particulate matter of certain size levels from a fluid, under
specific operating conditions.

Nominal Filtration Rating -- An arbitrary value determined by

the filter manufacturer, who may claim a nominal filtration rating
based on a % retention by weight of a specified artificial
contaminant to a given concentration under specified test
conditions.
Absolute Filtration Rating -- The diameter of the largest hard
spherical particle that will pass through a filter under specified test
conditions. This is an indication of the largest opening in the
filter element.
 Nominal Rating Absolute Rating
% Efficiency - Beta % Efficiency - Beta

90 10,00 100,00 Infinity

80 5,00 99,99 10.000
70 3,33 99,99 2.000
60 2,50 99,90 1.000
50 2,00 99,85 666
40 1,67 99,80 500
30 1,43 99,75 400
20 1,25 99,50 200
10 1,11 99,00 100
0 0 98,67 75
Does it Make a Difference?
Does it Make a Difference?
Filter Carts
Transfer Carts
S40 Particle Counter
Misc CC Tooling
Portable Contamination Kit

ISO 16/13

ISO 18/15

Problem
Videos, Literature, Special Instruction, Guidelines, etc.
Vehicle Guidelines Coverage for Filtration Procedures
Vehicles and Ranges Hydraulic Trans. Axles
Off Highway Trucks
769-797 SEBF8446
76 9-793B SEBF8445
793C X
797 X
769-777 SEBF8454
785-797 SEBF8438
Wheel Loader
Wheel Loaders with E/D SEBF8452 In Routing
Wheel Loaders W/O E/D SEBF8458 In Routing
994D SEBF8459
Track Type Tractors
D3-D6 SEBF8455
D7-D11 SEBF8456
D6R-D11R SEBF8465 In Routing
Excavators
311-375 SEBF8447
Motorgraders
ALL SEBF8453
All Except 24H SEBF8461 Development
24H SEBF8462 Development
Wheel Tractor Scrapers
All SEBF8457
611-651E SEBF8463
 NEW FDAO OIL
Final Drive
Fluids at
Caterpillar
IRM #
PELE0761 Why Replace TDTO 50 with FDAO?
PELE0715
PEHP9530 Lab Test Results for FDAO
Service Pub. • Bearing life (fatigue) { 2X TDTO}

8/04/00 • FZG gear (pitting) { >4X TDTO }

• Seal compatibility { exceeded TDTO }
• FZGwear { equal to TDTO }
• FZG scuffing { equal to TDTO* }
Final Drive
• D8N4-sq. (Thin-filmwear) { exceeded* }
Lab Test
• Lubricant parameter { higher @hi temp }
• Pour point { -15Cvs. -12C}
• 17other tests { no negatives}

* Being improved
 Seems like a lot of
trouble
for what it’s worth?
Benchmarking
 Benchmarking Activities
O Solvent Stand Analysis
O Batu Hijau Benchmarking
– 793C Final Drives
– 793C Differentials
– Other Activities
O Fuel Systems
O Other Activities
CC Can Save You Money

Solvent Stand
SEBF8448

Initial Parts Cost = $82.36

 Dealer Example Analysis

Safety Kleen Program

¾16gal drum / 8gal solvent

1 service = new solvent, used solvent disposal and labor = $99.25
$99.25 * 12 months = $1,191.00/yr

¾30gal drum / 17gal solvent

1 service = new solvent, used solvent disposal and labor = $137.00
$137.00 * 12 months = $1,644.00/yr
 Solvent Stand Cost Analysis

Current Status

Quantity : 15 (16gal drum / 8gal solvent) solvent

Service Interval : 1/Month
Cost : $99.25 / stand

Modified Status
Implementation of SEBF8448 – Procedure for Adding Filter Capability to Solvent Stands

Quantity : 15 (16gal drum / 8gal solvent) solvent

Service Interval : 1/Quarter (Safety Clean)
1/Quarter : Fuel Filter
2/Year : Filter Bag
Solvent Stand Cost Analysis
¾16gal drum / 8gal solvent
•Total cost/year =
$82.36 (1st year only)
+ ($11.57/ fuel filter * 4)
+ ($3.90 / filter bag * 2)
+ 4 Safety Kleen Services (99.25 * 4)
= $533.44/yr

¾30gal drum / 17gal solvent

•Total cost/year =
$82.36 (1st year only)
+ ($11.57/ fuel filter * 4)
+ ($3.90 / filter bag * 2)
+ 4 Safety Kleen Services (137.00 * 4)
= $684.44/yr
 Summary Cost Analysis

¾Original Cost : $89,325

¾Current Cost : $35,066

¾Cost Savings : $54,259 or over 60% for 5 years.

Note: Dealer also assures clean parts and rebuilds since the
solvent stand fluid is consistently clean due to the addition of
filters.
 Mine Component Life - 793C
Objective: Determine Component Life with Mine New, Undamaged
Components put into Service Meeting ISO 18/15.
Wheel Groups, Final Drive & Differentials - 793C

Contract: MARC Bid @ 8000 hrs,. (running average - 6,000hrs)

Process:
• Mine Site Bulk Oil Tanks: ISO 16/13
• Kidney Loop systems every PM (500hrs) back to roll-off spec: 18/15
• Particle Count at Service Intervals
– Record Data (e.g.) Truck 121, 1000 SMU, Measured ISO 19/17
on Hydraulics. Kidney Loop to ISO 18/15
• Record Component Failure/Change-Out Hours and Plot Data
for Fleet
– Compare to Average Data from Past Component Change-Out
at Other Mine Sites
 793C Results
•Rear Wheel Groups
–Life extended to 13,000 - 16,000 minimum
– No Bearing failures to date (43 trucks)
–Trucks running 18,000+
–Bearings shown @ Mine-Expo
–Timken Recommended NOT to Change

•Rear Axle Oil

– Drain Interval Extended from 2,000 To 4,000
– Oil Savings : $1714/truck
–$70,274 per year (43 trucks)

•Future Plans
–Add Hydraulics
–Add Wheel Loaders
 Fuel System Benchmark
Objective: Determine Fuel Injector Component Life
Running with Clean Fuel (OHT in Mine Sight)

Process:

• Clean Bulk Fuel using Water & Debris 5um Nominal

•Discharge Filters
• 2um Series Secondary Fuel Filters on Engines

Results:

• 20,000 hours on injectors

• 2 1/2% Average Efficiency Loss
–Tested on same test stand as originally built
• Plan to add Filtered Breathers
Additional Bench Mark Work
•3 Mine Sights
» 2 US & 1 Overseas
» Power Train, Hydraulics, Differentials, Wheel Groups
» Extended Differential Drain Intervals
–1200 to........ 2400 to ...........3600????
–Dealer monitored S-O-S analysis.

•Future Plans
»1 Additional Mines
» 1 Rental Fleet (small machines)
» Dealer Business Study
Wrap Up
&

Review
 Caterpillar
ƒRecognized the Benefits

ƒCommitted to Contamination Control

ƒEstablished Contamination Control Teams

ƒPromotes at Plants, Dealers, and to Customers

 Recommended Fluid Contamination
ISO Targets
Fill Oil ……………………………………………….…………………..…..ISO16/13

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

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

Hydraulic Oil Extension IRM # FLU01-02…………………………….PELE0824

Vehicles With Electronic Transmissions..……………………….……ISO18/15

Vehicles With Mechanical Transmissions…………………………….ISO21/17

(777-797)OHT Filtered Differentials & Wheel Groups(Roll-off).…...ISO18/15

New and Rebuilt Engine(Roll-off)...……………………………………. ISO18/15

Component Rebuild (Roll-off)

Transmission, Pumps, Governors Etc…………..…………….………ISO16/13

Injector Testing Equipment Calibration Fluid……..…………………ISO15/13

Pressurized, Non-Filtered Compartments…Target To Be Established

Note: Older technology machines in the field may not be able to maintain the cleanliness
levels of newer models. However, the same contamination control service and maintenance
procedures should be used on all Caterpillar product.
Shared Responsibility
An important Caterpillar responsibility is to ship
clean machines, engines, and components
components..

Keeping them clean once they leave the factory

is the shared responsibility of dealers and
customers.
¾ Contamination Targets
¾ Education / Training
¾ Cultural Changes
¾ Methods and Procedures
¾ Contamination Control Tooling
 Increases Component Life
and
Reduces Owning & Operating
Costs
 Customers
‹ Must Recognize the Need

‹ Commit to Contamination Control

‹ Develop a Strategy and Establish a Plan

‹ Implement Your Contamination Control Plan

Improving Reliability
through
Contamination Control
for
Life Cycle of Product
Keep It Clean
Keep It Cool
Keep It Closed
Keep It Cat