SOS

SM
The buildup of wear particles in oil is a key indicator of potential
machine problems. Observing the rise in small particles of a
specific element can identify what is wearing. Also, tracking the
amount and buildup rate of large and small particles over time
indicates the severity of system wear. This is why our SOS
SM
program interpreters use two tests: traditional Spectrographic
Analysis that trends the small elemental particles, to tell what
might be wearing, and now Particle Count that quantifies the
buildup of all sized particles whatever their composition, to tell
the severity of wear. Spectrographic Analysis test results are mea-
sured in parts per million, while Particle Count results are mea-
sured in particle counts per unit volume. But Particle Count
results are converted to another useful and efficient way to
express findingsthe ISO Code.

Caterpillar

Product Information
Product Bulletin
Introduction
Reporting Particle
Count by ISO Code
Table of Contents
2
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
What ISO Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
The Two Methods for Reading Particles . . . . . . . . . . . . . . . . . . . .4
Measuring Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Applying ISO Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
How ISO Codes Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sample Report 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sample Report 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Look for More Diagnostic Data on ISO Codes . . . . . . . . . . . . . . .11
Quiz: Check Your Understanding . . . . . . . . . . . . . . . . . . . . . . . . . .12
What ISO Means
The International Organization for Standardization (whose
Americanized acronym ISO comes from the Greek isos
meaning equal) is an international standards organization
based in Geneva, Switzerland. It is comprised of members
from national standards bodies in 100 countries.
A major ISO goal is to develop uniform technical standards
that facilitate international exchange of goods and services.
In preparing its standards, ISO combines the interests of
producers, users, governments, and the scientific community.
ISO work is carried out by some 2,754 technical bodies
involving over 30,000 experts worldwide. To date, their work
has resulted in 9,178 published ISO technical standards.
Glossary of Terms
Introduction
3
Alloy
Asubstance of two or more metals, or a metal and a nonmetal.
Elemental Constituents
The specific metal or alloy that make up particles.
Micron
A unit of measurement equal to a micrometer or
1/1,000,000 of a meter. One micron is 1/25,000 of an inch.
Spectrographic Analysis
The SOS test that identifies the specific elemental
composition of particles in fluids. This test can quantify and
identify elemental particles up to 10 to 15 microns in size.
Test results are measured in parts per million.
Particle Count
The SOS test that counts all particles, but cannot
distinguish their composition. This test quantifies particles
from one to over 200 microns in size. Test results are
measured in particle counts per unit volume.
Channels
Size ranges used to record particle counts.
Two Factor Code
Code used to express fluid cleanliness. Expressed in terms
X/Y, where X represents the number of particles larger than
5 microns and Y stands for the number of particles larger
than 15 microns.
Silting
Fine particles that accumulate and clog the flow of fluids.
This causes close-tolerance valves to stick.
4
The Two Methods for Reading
Particles
Description
80
70
60
50
40
30
20
10
0
200
180
160
140
120
100
80
60
40
20
0
Particle Count Values (000)
Wear Metal Fe Values (PPM)
Particle Count
Iron
Service Meter Readings
2500 3000 3500 4000 4500 5000 5500 6000
The ISO Code rating system is a standard way of measuring oil
cleanliness and is used to express the Particle Count test results
now offered in the SOS program. Knowing what the Particle
Count test does is important to understanding ISO Codes.
Spectrographic Analysis
First, Spectrographic Analysis is the SOS test that identifies
the elemental constituents present in the oil. That is, it identifies
the specific metal or alloy that make up particles. So, over the
course of several samples, it can spot particles of various metals
that may be increasing in volume; this often signals potential
problems. And by identifying the kinds and combinations of
metals, it can generally point to the specific wearing component.
But Spectrographic Analysis can only handle particles in the oil
up to about 10 to 15 microns in size. So its blind to larger parti-
cles that can often signal an impending failure.
Particle Count
Particle Count now comes into play; it can quantify particles
from one micron to greater than 200 microns in size (see
adjacent graph). So it can detect additional signs of abnormal
wear and dirty oil that Spectrographic Analysis may not catch.
But it counts all particles, both metal and nonmetal, and cant
distinguish between the two. This is where the two methods
complement each other: Spectrographic Analysis by quantifying
and identifying specific metal wear particles below 15 microns;
Particle Count by quantifying particles larger than can be
detected by Spectrographic Analysis.
Particle Count has been used for many years by the fluid power
industry to monitor debris levels in close-tolerance hydraulic
systems. Its ability to warn of severe wear across a wide range
of materials and micron sizes makes it a very useful tool in
trending wear debris levels in most construction equipment
compartments: transmissions, final drives, pump drives,
hydraulics, etc.
5
An Efficient Partnership
Together, Spectographic Analysis and Particle Count form an
efficient partnership in identifying abnormal wear. Heres how.
The small metal particles that Spectrographic Analysis sees may
rise sharply and then level off. But at the same time, large
particles may show a sharply rising trend, signaling a failure in
progressone that only Particle Count can spot because of the
size of the particles. So Particle Count sounds the alarm on
abnormal wear and impending failure. Then, Spectrographic
Analysis, by identifying the wear metals that rose and then
levelled off, can point to the specific component in trouble.
Diameter of a
human hair
80 microns
Talcum powder
15 microns
1 micron
A micron is a metric measure equal to
one millionth of a meter, or 1/25,000th
of an inch. The smallest particle visible
to the naked eye is 40 microns across.
A human hair is 80 microns in diame-
ter, and a single grain of talcum powder
is 15 microns. Typical clearances in
hydraulic systems are 10-30 microns.
Description
6
Any valid measuring system must give consistent results
calibrated the same waytime after time. This is crucial to
measuring contamination because it enables interpreters to
identify wear trends in consecutive samples from a single
machine. It also enables component cleanliness targets to be
set and accurately monitored. Both are important considerations
in making repair-before-failure decisions.
Understanding Particle Count
Particle Count is reported in the number and size (in microns)
of particles in a volume of fluid, using a valid particle counting
system. Particle Counts are divided into size ranges or
channels, each based on a specific size particle. Figure 1
shows a typical array of such channels and sample particles per
milliliter results. These channels can be varied to report on any
particle size relevant to the fluid or machine system involved.
Measuring Contamination:
Comparing Apples to Apples
Description
Particle Count data is reported as the number of particles greater
than a certain size. Thus, the graph shows the sample contains
5230 particles larger than 2 microns, 102 particles larger than 5
Figure 1
Channels >2m >5m >10m >15m >25m >50m >100m >150m
Particle Count 5230 102 74 32 6 3 1.1 .3
Description
7
Applying ISO Codes to Particle
Count Data
microns, 32 particles larger than 15 microns, etc. Bear in
mind that the particle count for each channel includes all the
particles in all the larger channels as well. Note: This data
shows only particle size, not the specific particle composition
(metal or nonmetal).
By trending this information over a series of samples, changes
in the concentration of particles by size can be used to spot
abnormal wear and forestall problems before they turn into
failures. Then, Spectrographic Analysis on the same samples can
often identify the metal makeup of the particles involved and
point to probable components that might be heading for failure.
ISO Codes are a simple way to quantify particulate matter by
size. These codes were established by the International
Standards Organization (ISO), a worldwide federation of
national standards bodies (see page 2), and are the most widely
used method for identifying fluid cleanliness. In our business,
they apply to all non-engine lubricating fluidswith one of the
greatest benefits accruing to close-tolerance hydraulic systems.
Heres how ISO Codes work.
Under the ISO Code system (see Figure 2), 28 code
numbers are set up, each representing a given range of particles
per milliliter, ranging from 0.01 to 2,500,000 particles.
The smaller the code number, the fewer number of particles.
Youll note that the size of each code range is double the num-
ber of the range that precedes it.
ISO Minimum Maximum
Code (excluded) (included)
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
18 1300 2500
19 2500 5000
20 5000 10000
ISO Minimum Maximum
Code (excluded) (included)
21 10000 20000
22 20000 40000
23 40000 80000
24 80000 160000
25 160000 320000
26 320000 640000
27 640000 1300000
28 1300000 2500000
Figure 2
ISO 4406 Code Levels
Particle Count Range (per ml)
ISO Minimum Maximum
Code (excluded) (included)
1 0.01 0.02
2 0.02 0.04
3 0.04 0.08
4 0.08 0.16
5 0.16 0.32
6 0.32 0.64
7 0.64 1.3
8 1.3 2.5
9 2.5 5.0
10 5.0 10
8
Description
For example, ISO Code 10 has a range of 5 particles, ISO Code
11 has a range of 10 particles, ISO Code 12 has a range of 20,
etc. This means that each one-step increase in ISO Code (i.e.
going from 11 to 12) indicates the fluid is twice as dirty (in
those sizes) as the preceding code (see Figure 3).
Using the ISO Codes
The governing ISO standard (ISO 4406) establishes a two-factor
code (X/Y) to express fluid cleanliness. The first factor (X)
represents the number of particles larger than 5 microns and the
second (Y) stands for the number of particles larger than15 microns.
X = number of particles larger than (>) 5 microns
Y = number of particles larger than (>) 15 microns
For example, if in a given sample the particles/volume of >5
micron particles is 1350, and the particles/volume of >15 micron
particles is 105, the ISO Cleanliness Code would be 18/14.
The >5 and >15 micron sizes were picked because the smaller
size indicates wear particles that can cause silting in the fluid
(and whose specific metal makeup can be read by Wear Metal
Analysis), while the >15 micron size particles can indicate the
presence of rapid wear and potential early failure.
This formatthe >5 micron range first, the >15 micron range
second, separated by a slashis the universal signature for
expressing a fluids ISO Cleanliness Code.*
* An ISO committee is considering extending this to include a Code range
for >2 micron particles, to identify the volume of particles most likely to
cause severe silting. If this becomes effective, it will come first in the
Cleanliness Code signature, which will then appear >2/>5/>15.
ISO Minimum Maximum
Code (included) (excluded)
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
Figure 3:
ISO 4406 Code Levels
Particle Count Range (per ml)
Every step increase in ISO
Code indicates the fluid
is twice as dirty as the
preceding code.
C
A
B
An ISO Code is a kind of cleanliness shorthand thats easy to
work withan instant identifier that sums up oil contamination
in only two numbers.
As those numbers change between tests of samples from the
same compartment, they can be the first indication of trouble.
And such changes would be the signal to get a complete channel
breakdown and compare it to Wear Metal Analysis data to
identify a problem. Here are some sample reports:
Sample Report 1
Notice the increase in particle
count trend at 8,764 hours
in samples taken from this
D8N transmission. The oil and
filter were changed at this time
and after the next sample at
9,800 hours. But notice the (A)
sample at 10,045 hours, with
just 245 hours on the oil, showed
a very large increase in particle
count and aluminum (B). Also,
iron (C) had quickly risen to 53
PPM. These trends indicated an
imminent torque converter
problem, and tear-down revealed
a failed torque converter seal.
The reverse can also be true. That
is, an adverse trend in Spectrographic
Analysis data can call for a closer
analysis of ISO Cleanliness Codes,
using additional channels relevant to
the compartment being sampled.
9
How ISO Codes Work With Present
Measuring Systems
Applying ISO Codes
Sample Report 2
This one time only sample with no oil hours reported reveals wear
metal readings high enough to definitely indicate dirt entry. Particle
Count then further quantified the dirt entry as very severe (A),
clearly calling for immediate remedial action to avoid serious
system damage (B).
So ISO Codes define and summarize Particle Count results
by quickly and visibly red-flagging adverse trends
in particle concentrations. This
invites analyzing more
detailed Particle Count infor-
mation, in different particle
size ranges, to find the magni-
tude of the problem. And in
many instances,
Spectrographic Analysis is
used to identify
the specific metal in particles
below 10 to 15 microns.
In short, Spectrographic
Analysis and Particle Count
work together to alert you of
potential problems before
they cause costly damage.
10
Applying ISO Codes
B
A
11
ISO Codes are the international language of fluid cleanliness.
We will use them increasingly in the data we supply you on
fluid analysis, wear trends, and problem identification. They will
not only provide easier-to-read signals of changing contamina-
tion levels; they will enhance the value of both Spectrographic
Analysis and Particle Count.
This standard language provides a unique cleanliness code for
particle concentrations of any size particle relevant to the fluid
being tested. ISO Codes meet the requirements of all types of
fluid cleanliness specs and criteria that will be used in the future.
Thus, their value will eventually extend to nearly all fluids
important to machine and equipment diagnostics.
Summary
Look for More Diagnostic Data
on ISO Codes
Check Your Understanding
2000 Caterpillar
Printed in U.S.A.
A N S W E R S
1 a . 1 6 / 1 0 1 b . 1 8 / 1 3 1 c . 1 5 / 6 2 . > 5 m i c r o n r a n g e : 2 5 0 0 - 5 0 0 0 > 1 5 m i c r o n r a n g e : 1 0 - 2 0
PEJT5025-02

Quiz: Check Your Understanding

To make sure you know how to convert Particle Count data
into ISO Codes, run through these quick examples.
(Answers below.)
1. What is the ISO Cleanliness Code for a sample, if the >5
micron and >15 micron particle counts are:
a. 540 and 9
b. 2110 and 74
c. 285 and .50
2. If the ISO Cleanliness Code is 19/11, what are the >5
micron and >15 micron particle count ranges?