PTK1 ANALYSIS KIT REFERENCE MANUAL

PATCH TEST KIT INSTRUCTIONS

Solvent filter Carrying case

Sample funnel and

filter patch holder
Solvent dispenser

Vacuum pump

Microscope light
Waste bottle

Microscope
Forceps for patch

Filter patch

• Install funnel-patch assembly into the vacuum • Draw the sample through the patch by
pump and install empty waste bottle onto the creating a vacuum with the vacuum pump. If
bottom of the vacuum pump. the fluid is cold or very viscous it should be
heated to make the process quicker. Heating
• Place solvent filter onto solvent dispenser tip. the funnel with a heat gun while the sample is
being vacuumed through the patch will also
• Rinse funnel-patch assembly with solvent and move the process along.
draw the solvent through by pulling on the
vacuum pump. • Rinse the funnel again with the filtered solvent
and pull that fluid through the filter patch as
• Remove the funnel-patch assembly from the well.
vacuum pump and separate the funnel from the
patch support with tube. • Once the entire sample has passed through
the filter patch separate the funnel from the
• Install a filter patch on the patch support tube patch supporter and remove the patch using
(ink-side up), reattach the funnel, and reinstall the forceps.
the funnel-patch assembly into the top of the
vacuum pump. • Place the patch on a clean index card and
immediately cover it with cover lamination.
• Turn the locking device on the vacuum pump
until a seal is formed between the pump and • Analyze the patch with the 100x microscope.
funnel/patch support tube. The light source needs to be applied directly
over the sample to see it properly.
• Pour the fluid to be analyzed into the funnel until
the level reaches the 25ml level (first line
graduation on the inside of the funnel).
ISO CLEANLINESS CODE 16 / 14 / 11
Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 492 320 ~ 640 16

6µ[c] 149 80 ~ 160 14
10µ[c] 41
14µ[c] 15 10 ~ 20 11
21µ[c] 5
38µ[c] 1

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Fine metallic and oxidized metallic
particles.

ISO CLEANLINESS CODE 19 / 17 / 14

Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 3169 2500 ~5000 19

6µ[c] 1283 640 ~ 1300 17
10µ[c] 319
14µ[c] 109 80 ~ 160 14
21µ[c] 31
38µ[c] 2

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Silica, metallic, and some rust
particles.
ISO CLEANLINESS CODE 20 / 17 / 13
Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 6361 5000~10000 20

6µ[c] 1200 640~1300 17
10µ[c] 210
14µ[c] 79 40 ~ 80 13
21µ[c] 27
38µ[c] 2

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Silica and some metallic particles

ISO CLEANLINESS CODE 21 / 19 / 16

Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 3169 2500 ~5000 19

6µ[c] 1283 640 ~ 1300 17
10µ[c] 319
14µ[c] 109 80 ~ 160 14
21µ[c] 31
38µ[c] 2

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Silica, metallic, and some rust
particles.
ISO CLEANLINESS CODE 24 / 22 / 19
Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 151773 80000~160000 24

6µ[c] 38363 20000~40000 22
10µ[c] 8229
14µ[c] 3339 2500~5000 19
21µ[c] 1048
38µ[c] 112

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Silica, metallic particles, and fibers

ISO CLEANLINESS CODE 25 / 24 / 16

Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 286480 160000~320000 25

6µ[c] 100541 80000~160000 24
10µ[c] 4092
14µ[c] 615 320~640 16
21µ[c] 96
38µ[c] 6

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Oxidized meta particles with a high
concentration of fine contaminant.
ISO CLEANLINESS CODE 25 / 25 / 22
Xµ[c] denotes particle counter calibration per ISO 11171 using NIST traceable contaminant

Particle Particles ISO 4406 ISO 4406

Size per ml Code range Code

4µ[c] 314475 160000~320000 25

6µ[c] 266087 160000~320000 25
10µ[c] 133174
14µ[c] 39129 20000~40000 22
21µ[c] 4919
38µ[c] 471

Slide Magnification: 100x

Fluid Volume: 25ml
Scope scale division (mm): 1 = 10µ[c]
Scope scale division (IN): 1 = 14µ[c]

Photo Analysis:
Metallic and a high concentration
of rust particles

IDENTIFYING CONATMINANT TYPES

Bright metal particle Combination bright metal, Silica

typically from internal silica (orange, opaque).
contaminant generation. and fiber materials.

Oxidized fine metal Fine rust particles. Large fiber

 UNDERSTANDING ISO CODES
The ISO cleanliness code is used to quantify particulate contamination levels per milliliter of fluid at 3 sizes 4µ[c], 6µ[c],
and 14µ[c]. The ISO code is expressed in 3 numbers (ie 19/17/14). Each number represents a contaminant level code
for the correlating particle size. The code includes all particles of the specified size and larger. It is important to note
that each time a code increases the quantity range of particles is doubling.

ISO 4406 Chart

Range Particles per milliliter
Code More than Up to/including Sample 1 (see photo 1)
24 80000 160000 Particle Particles ISO 4406 ISO
Size per ml* Code range Code
23 40000 80000
4µ[c] 151773 80000~160000 24
22 20000 40000
6µ[c] 38363 20000~40000 22
21 10000 20000 10µ[c] 8229
20 5000 10000 14µ[c] 3339 2500~5000 19
19 2500 5000 21µ[c] 1048
18 1300 2500 38µ[c] 112

17 640 1300
16 320 640
15 160 320 Sample 2 (see photo 2)
14 80 160 Particle Particles ISO 4406 ISO
Size per ml* Code range Code
13 40 80
4µ[c] 492 320 ~ 640 16
12 20 40
6µ[c] 149 80 ~ 160 14
11 10 20 41
10µ[c]
10 5 10 14µ[c] 15 10 ~ 20 11
9 2.5 5 21µ[c] 5
8 1.3 2.5 38µ[c] 1

7 0.64 1.3
6 0.32 0.64

Photo 1 Photo 2
 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.

Set the Target. Recommended* Target ISO Cleanliness Codes and media selection for systems using
The first step in identifying a petroleum based fluids per ISO4406:1999 for particle sizes 4µ[c] / 6µ[c] / 14µ[c]
target ISO code for a Pressure Media Pressure Media Pressure Media
system is to identify the < 140 bar βx[c] = 1000 212 bar βx[c] = 1000 > 212 bar βx[c] = 1000
most sensitive on an < 2000 psi 3000 psi (βx = 200) > 3000 psi (βx = 200)
Pumps (βx = 200)
individual system, or the Fixed Gear 20/18/15 22µ[c] (25µ) 19/17/15 12µ[c] (12µ) - -
most sensitive component Fixed Piston 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ) 17/15/12 7µ[c] (6µ)
supplied by a central Fixed Vane 20/18/15 22µ[c] (25µ) 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
reservoir. If a central Variable Piston 18/16/13 7µ[c] (6µ) 17/15/13 5µ[c] (3µ) 16/14/12 7µ[c] (6µ)
reservoir supplies several Variable Vane 18/16/13 7µ[c] (6µ) 17/15/12 5µ[c] (3µ) - -
systems the overall
cleanliness must be Valves
maintained, or the most Cartridge 18/16/13 12µ[c] (12µ) 17/15/12 7µ[c] (6µ) 17/15/12 7µ[c] (6µ)
sensitive component must Check Valve 20/18/15 22µ[c] (25µ) 20/18/15 22µ[c] (25µ) 19/17/14 12µ[c] (12µ)
be protected by filtration that Directional (solenoid) 20/18/15 22µ[c] (25µ) 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
cleans the fluid to the target Flow Control 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
before reaching that Pressure Control 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ) 17/15/12 7µ[c] (6µ)
component. (modulating)
Proportional Cartridge Valve 17/15/12 7µ[c] (6µ) 17/15/12 7µ[c] (6µ) 16/14/11 5µ[c] (3µ)
Proportional Directional 17/15/12 7µ[c] (6µ) 17/15/12 7µ[c] (6µ) 16/14/11 5µ[c] (3µ)
Proportional Flow Control 17/15/12 7µ[c] (6µ) 17/15/12 7µ[c] (6µ) 16/14/11 5µ[c] (3µ)
Proportional Pressure 17/15/12 7µ[c] (6µ) 17/15/12 7µ[c] (6µ) 16/14/11 5µ[c] (3µ)
Other Considerations Control
Table 1 recommends Servo Valve 16/14/11 7µ[c] (6µ) 16/14/11 5µ[c] (3µ) 15/13/10 5µ[c] (3µ)
conservative target ISO
cleanliness codes based on Bearings
a several component Ball Bearing 15/13/10 5µ[c] (3µ) - - - -
manufacturers guidelines Gearbox (industrial) 17/16/13 12µ[c] (12µ) - - - -
and extensive field studies Journal Bearing (high speed) 17/15/12 7µ[c] (6µ) - - - -
for standard industrial Journal Bearing (low speed) 17/15/12 7µ[c] (6µ) - - - -
operating conditions in Roller Bearing 16/14/11 7µ[c] (6µ) - - - -
systems using petroleum
based fluids. If a non- Actuators
petroleum based fluid is Cylinders 17/15/12 7µ[c] (6µ) 16/14/11 5µ[c] (3µ) 15/13/10 5µ[c] (3µ)
used (i.e. water glycol) the Vane Motors 20/18/15 22µ[c] (25µ) 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
target ISO code should be Axial Piston Motors 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ) 17/15/12 7µ[c] (6µ)
set one value lower for each Gear Motors 20/18/14 22µ[c] (25µ) 19/17/13 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
size (4µ[c]/6µ[c]/14µ[c]). If a Radial Piston Motors 20/18/15 22µ[c] (25µ) 19/17/14 12µ[c] (12µ) 18/16/13 12µ[c] (12µ)
combination of the following
conditions exists in the Test Stands, Hydrostatic
system the target ISO code Test Stands 15/13/10 5µ[c] (3µ) 15/13/10 5µ[c] (3µ) 15/13/10 5µ[c] (3µ)
should also be set one Hydrostatic Transmissions 17/15/13 7µ[c] (6µ) 16/14/11 5µ[c] (3µ) 16/14/11 5µ[c] (3µ)
value lower: *Depending upon system volume and severity of operating conditions a combination of filters with varying
• Component is critical to degrees of filtration efficiency might be required (I.e. pressure, return, and off-line filters) to achieve and
safety or overall system maintain the desired fluid cleanliness.
reliability.
• Frequent cold start. Example ISO Code Comments
• Excessive shock or Operating Pressure 156 bar, 2200 psi
vibration. Most Sensitive Component Directional Solenoid 19/17/14 recommended baseline ISO Code
• Other Severe operation Fluid Type Water Glycol 18/16/13 Adjust down one class
conditions.
Operating Conditions Remote location, repair difficult Adjust down one class, combination
High ingression rate 17/15/12 of critical nature, severe conditions