The Hidden Enemy That Kills Your Machines

There is one thing sure to reduce component life: contamination through dirt. Some practical tips on how to get the most life out of your equipment.

Overview

This is the promised third article on improving machine life and in this case, I am going to take up contamination control.

Interestingly (on reflection), I was actually exposed to this at a very young age. My father was an earthmoving contractor and I grew up on machines, spent my formative years around them and later operated them on school holidays (heaven forbid the thought to most people in this day and age!) and one lesson that was drummed into me (early 1970’s) was the need for contamination control.

To wipe an engine dipstick with a dirty rag was cause to get a hefty clip under the ear and to put oil into a container that had not been sealed and was scrupulously clean was a ‘capital crime’.

At the time, I thought this was all a little “extreme” (Dad’s view was that “surgical cleanliness” was the only standard) and it wasn’t until many years later that I realised just how ahead of his time he was and why he was so uncompromising.

Why Contamination Control is Important

“75-85% of hydraulic system failures can be traced to fluid contamination.”
Hydraulics & Pneumatics Equipment Today

Isn’t that an interesting statistic?

One of the most interesting misconceptions I run into in the field in talking to people about contamination control is that they seem to have some idea that if you can’t see the dirt it isn’t there. This is completely false.

By way of example, let’s look at things comparatively:

• Human hair (diameter) = 80 micron
• Visible to the naked eye = 40 micron
• Hydraulic system clearances = 5-30 micron

So the dirt that is damaging the system is not visible and won’t fit through the clearances in the systems.

This is why I am so unreasonable when I am around a workshop and see components and containers left open – you are simply ruining the machine through negligence in doing so and there is no call for it.

Simple Steps to Take

1. Be utterly uncompromising about components being left open while under repair - just don't let it happen and provide the resources to ensure it can't
2. Don’t allow people to put oil into “watering cans” or other non-standard containers and then into a machine.
3. Ensure machines are completely washed before servicing.
4. Ensure “surgical” cleanliness in the handling of all oils.
5. Contact your local dealer and ask them for training in contamination control for your site personnel.

A Couple of Final Tips

Always fit magnetic plugs to all component compartments – see Some simple ideas to reduce maintenance costs for more information on this.

Secondly, use your oil sample reports as a quick management indicator of possible contamination e.g. any oil sample with over 20 ppm silica likely indicates a problem with contamination.

Summary

If you want the best life out of your machines, keep the dirt out of them. Practice good contamination control!

Please contact me if you have any questions or comments.

Steve Franklin