AS4059 REV.

F
AEROSPACE
STANDARD Issued 1988-06
Reaffirmed 2011-03
Revised 2013-09

Superseding AS4059E

(R) Aerospace Fluid Power - Contamination Classification for Hydraulic Fluids

RATIONALE

Revision F of this standard has been prepared to include comments received from the international community, principally
to simplify the coding system to either a single number contamination class that is the same as the obsolete NAS 1638
class, or as a contamination code indicating the contamination levels at a number of distinct particle size ranges. Also,
normative references to using the obsolete calibration procedure ISO 4402 were removed.

1. SCOPE

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.

2. APPLICABLE DOCUMENTS

The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications
shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the
event of conflict between the text of this document and references cited herein, the text of this document takes
precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption
has been obtained.

2.1 SAE Publications

Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside
USA and Canada) or 724-776-4970 (outside USA), [Link].

AS598 Aerospace Microscopic Sizing and Counting of Particulate Contamination for Fluid Power Systems

ARP5376 Methods, Locations and Criteria for System Sampling and Measuring the Solid Particle Contamination of
Hydraulic Fluids

__________________________________________________________________________________________________________________________________________
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SAE INTERNATIONAL AS4059F Page 2 of 10

2.2 AIA Publications

Available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel:
703-358-1000, [Link].

NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems (Inactive for new design and not for use
with automatic particle counters)

2.3 ISO Publications

Available from International Organization for Standardization, ISO Central Secretariat, 1, ch. de la Voie-Creuse, CP 56,
CH-1211 Geneva 20, Switzerland, Tel: +41-22-749-01-11, [Link], American National Standards Institute, 25 West
43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, [Link] or from the National Fluid Power Association,
3333 N. Mayfair Road, Suite 211, Milwaukee, WI 53222-3219, Tel: 414-778-3344, [Link].

ISO 4402 (1991) Hydraulic fluid power - Calibration of automatic-count instruments for particles suspended in liquids -
Method using classified AC fine test dust (standard withdrawn and replaced by ISO 11171)

ISO 4407 Hydraulic fluid power - Fluid contamination - Determination of particulate contamination by the
counting method using an optical microscope

ISO 11171 Hydraulic fluid power - Calibration of liquid automatic particle counters

ISO 11500 Hydraulic fluid power - Determination of the particulate contamination level of a liquid sample by
automatic particle counting using the light-extinction principle

3. DEFINITIONS

3.1 CONTAMINATION LEVEL

The maximum number of counts for a given particle size range.

3.2 CONTAMINATION CODE

A series of 5 or 6 numbers separated by a forward slash used to describe the fluid sample contamination levels at
standardized particle size ranges as defined in Tables 1 and 2.

3.3 CONTAMINATION CLASS

The highest contamination level number within the contamination code.

3.4 PARTICLE SIZE

The longest dimension of the particle in the case of microscopic counting or the diameter of a circle with area equal to that
of the projected image in the case of automatic particle counting.
SAE INTERNATIONAL AS4059F Page 3 of 10

4. AS4059 CONTAMINATION LEVELS

4.1 Contamination Levels

Table 1 provides AS4059 contamination levels for differential particle counts and Table 2 provides AS4059 contamination
levels for cumulative particle counts.

These tables list the maximum contamination limits established to provide a set of criteria for specifying the fluid
contamination levels, code and class. The contamination level is based on the particle size range and particle count. Note
that the symbol µm(c) is used in Tables 1 and 2 and throughout this document to designate that the particle size was
determined using a liquid automatic particle counter calibrated per ISO 11171 or a microscope using image analysis
software to calculate the diameter of a circle with the equivalent projected area.

TABLE 1 - MAXIMUM CONTAMINATION LIMITS FOR DIFFERENTIAL PARTICLE COUNTS (PARTICLES/100 mL) (3)

5, incl. to 15, excl. to 25, excl. to 50, excl. to

(1) >100 µm
Contamination 15, incl. µm 25, incl. µm 50, incl. µm 100, incl. µm
Levels 6, incl. to 14, excl. to 21,excl. to 38, excl. to
(2) >70 µm(c)
14, incl. µm(c) 21, incl. µm(c) 38, incl. µm(c) 70, incl. µm(c)
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16 000 2850 506 90 16
7 32 000 5700 1012 180 32
8 64 000 11 400 2025 360 64
9 128 000 22 800 4050 720 128
10 256 000 45 600 8100 1440 256
11 512 000 91 200 16 200 2880 512
12 1 024 000 182 400 32 400 5760 1024

(1) Size range, microscope particle counts, based on longest dimension as measured per AS598 or ISO 4407.
(2) Size range, APC calibrated per ISO 11171 or an optical or electron microscope with image analysis software, based on projected area
equivalent diameter.
(3) Contamination classes and particle count limits are identical to NAS 1638.
SAE INTERNATIONAL AS4059F Page 4 of 10

TABLE 2 - MAXIMUM CONTAMINATION LIMITS FOR CUMULATIVE PARTICLE COUNTS (PARTICLES/100 mL)

>1 >5 >15 >25 >50 >100

Contamination (1) µm µm µm µm µm µm
Levels >4 >6 >14 >21 >38 >70
(2) µm(c) µm(c) µm(c) µm(c) µm(c) µm(c)
000 195 76 14 3 1 0
00 390 152 27 5 1 0
0 780 304 54 10 2 0
1 1560 609 109 20 4 1
2 3120 1217 217 39 7 1
3 6250 2432 432 76 13 2
4 12 500 4864 864 152 26 4
5 25 000 9 731 1731 306 53 8
6 50 000 19 462 3462 612 106 16
7 100 000 38 924 6924 1224 212 32
8 200 000 77 849 13 849 2449 424 64
9 400 000 155 698 27 698 4898 848 128
10 800 000 311 396 55 396 9796 1696 256
11 1 600 000 622 792 110 792 19 592 3392 512
12 3 200 000 1 245 584 221 584 39 184 6784 1024

(1) Size Range, Optical Microscope, based on longest dimension as measured per AS598 or ISO 4407.
(2) Size Range, APC Calibrated per ISO 11171 or an optical or electron microscope with image analysis software, based on projected area
equivalent diameter.

4.2 Specifying and Determining the AS4059 Contamination Class

4.2.1 Converting NAS 1638 Class Specifications to AS4059 Classes

NAS 1638 classes used in current specifications can be converted directly to AS4059 contamination classes. In the
simplest form, where NAS 1638 Class 6 is currently specified, AS4059 Class 6 applies. Similarly, to designate a fluid
contamination class equivalent to NAS 1638 Class 6 one would specify: Fluid contamination class shall meet AS4059
Class 6.

4.2.2 Determining the AS4059 Contamination Class Using Differential Particle Counts

This method is applicable to those currently using NAS 1638 classes and desiring to maintain the methods, format, and
results equivalent to those specified in NAS 1638.

Table 1 applies to acceptance criteria based on differential particle counts, and provides a definition of particulate limits
for Classes 00 through 12. A contamination level shall be determined for each particle size range. The combined list of
contamination levels can be reported as a contamination code. The reported AS4059 contamination class of the sample
is equal to the highest contamination level number determined among all the given particle size ranges.

NOTE: The classes and particle count limits in Table 1 are identical to NAS 1638. Measurements of particle counts are
allowed by use of an automatic particle counter (calibrated per ISO 11171), or an optical or electron microscope
with image analysis software. The size ranges measured and reported should be determined from Table 1 based
on the measurement method.

[Link] Example Using Microscopic Particle Counts

Table 3 shows example particle counts measured with a microscope based on longest dimension, and the determination
of the AS4059 contamination class. The reported contamination class is determined as the maximum contamination level
for all size ranges, or in the case, class 9.
SAE INTERNATIONAL AS4059F Page 5 of 10

TABLE 3 - EXAMPLE CLASS DETERMINATION USING MICROSCOPIC DIFFERENTIAL PARTICLE COUNTS

5, incl. to 15, excl. to 25, excl. to 50, excl. to

Size range in µm >100 µm
15, incl. µm 25, incl. µm 50, incl. µm 100, incl. µm
Particle count per
114 000 9200 3920 172 52
100 mL
Contamination
9 8 9 7 8
Level
Contamination
AS4059 Contamination Code [9/8/9/7/8]
Code
AS4059
Contamination AS4059 Class 9
Class

4.2.3 Determining the AS4059 Contamination Class Using Cumulative Particle Counts

This method is applicable to those using the methods of previous revisions of AS4059 and/or cumulative particle counts.
Table 2 applies to acceptance criteria based on cumulative particle counts, and provides a definition of particulate limits
for levels 000 through 12. A contamination level shall be determined for each particle size range. The combined list of
contamination levels can be reported as a contamination code. The reported AS4059 contamination class of the sample
is equal to the highest contamination level determined among all the given particle size ranges.

Particle counting by the combination method, utilizes both APCs and optical microscopic counting. This method was
included because some APCs are not routinely calibrated using the latex method of ISO 11171 for particle sizes above
50 µm(c). Using an APC for counting in the 4-38 µm(c) range and a microscope for 70 µm(c) (100 µm) allows such APCs
to be used. Of course, this would preclude the particle count from being measured on-line.

[Link] Example Using Automatic Particle Counts

Table 4 shows example particle counts measured with an automatic particle counter calibrated per ISO 11171 and the
determination of the AS4059 contamination class. The contamination class is determined as the maximum contamination
class for all size ranges, or in the case, class 9.

NOTE: It is possible that the same fluid contaminant level or particle count results may get assigned a different
Contamination Class by Table 1 and Table 2.

NOTE: When using cumulative particle counts to determine the contamination code or class the series of 6 levels or class
should be preceded by “cpc”.

TABLE 4 - EXAMPLE CLASS DETERMINATION USING AUTOMATIC PARTICLE COUNTS

Size range in µm >4 µm(c) >6 µm(c) >14 µm(c) >21 µm(c) >38 µm(c) >70 µm(c)
Particle count
382 000 127 000 13 300 4140 224 52
per 100 mL
Contamination
9 9 8 9 8 8
Level
Contamination
AS4059 Contamination Code cpc[9/9/8/9/8/8]
Code
AS4059
Contamination AS4059 cpc Class 9
Class
SAE INTERNATIONAL AS4059F Page 6 of 10

5. SAMPLING AND ANALYSIS

5.1 Procedures

Sampling and analysis of fluid shall be in accordance with ARP5376 or ISO 11500.

Note 1: Sampling errors - Extracting a fluid sample from a fluid system can generate large particles above 50 µm
[38 µm(c)] that can enter the sample and distort the contamination count. When a sample has an unusually high
count in one of the larger size ranges, the sampling device or technique should be considered as a possible
cause, and additional sampling is recommended.

Note 2: Dilution - High levels of contamination may cause coincidence in automatic particle counters; therefore, counts
greater than 75% of the coincidence limit of the counter may be suspect. When it is necessary to count particles
at a level approaching the coincidence limit or greater, it will be necessary to dilute the sample. Care must be
exercised when the fluid sample is diluted in order to reduce particle counts below the coincidence limit of the
counter. The dilution fluid must be very clean, at least 4 classes cleaner than the fluid being analyzed, and must
be compatible with the hydraulic fluid and the optical qualities of the fluid used in APC calibration. Dilution
presents two major problems. First, any error in dilution will be reflected in total counts. Second, the dilution fluid
will contain some particles of various sizes resulting in an erroneous increase in particle counts. With these
problems in mind, it is obvious that extremely clean dilution fluid and accurate measurement of the dilution ratio
are necessary.

5.2 Particle Count Measurement

Particle counts shall be made in accordance with one of the following methods:

5.2.1 Method A - Automatic Particle Counters

Automatic Particle Counters (APCs) shall be calibrated per ISO 11171 and particle counting performed in accordance
with ARP5376 or ISO 11500.

5.2.2 Method B - Optical Microscope

Optical microscopic particle counting shall be conducted in accordance with AS598 or ISO 4407. Image analysis software
is required for reporting projected area equivalent diameter.

5.2.3 Method C - Combination Method

This method permits the use of automatic particle counters without the need for latex calibration to count 70 µm(c)
(100 µm) and larger particles. An optical microscope is used to count particles >100 µm in length. Optical counting of
these size large particles or fibers is relatively fast. This method replicates the original NAS 1638 requirements for large
size particles (see Appendix B).

5.2.4 Method D - Electron Microscope

This is an acceptable method to determine particle count per this specification, although the high equipment cost limits
the use of this method to well equipped laboratories. Image analysis software is required for reporting either longest
dimension or projected area equivalent diameter.

6. DATA REPORTING

6.1 AS4059 Contamination Data Sheet

Because sampling, automatic particle counter calibration procedures, and other factors are so important in determining
fluid contamination, the AS4059 Fluid Contamination Data Sheet (either DS-1 for Table 1, section 3.2.2 or DS-2 for
Table 2, section 3.2.3) or equivalent shall be used for each sample (see Appendix A).7.
SAE INTERNATIONAL AS4059F Page 7 of 10

7. DOCUMENT INFORMATION

7.1 Users have permission to reproduce the data sheet without copyright infringement.

7.2 The following publications form a part of this document to the extent specified herein. The latest issue of SAE
publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the
purchase order. In the event of conflict between the text of this document and references cited herein, the text of
this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations
unless a specific exemption has been obtained.

8. NOTES

8.1 A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical
revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left
of the document title indicates a complete revision of the document, including technical revisions. Change bars and
(R) are not used in original publications, nor in documents that contain editorial changes only.

PREPARED BY SAE SUBCOMMITTEE A-6C1, CONTAMINATION & FILTRATION OF

COMMITTEE A-6, AEROSPACE ACTUATION, CONTROL AND FLUID POWER SYSTEMS
SAE INTERNATIONAL AS4059F Page 8 of 10
APPENDIX A

AS4059 FLUID CLEANLINESS DATA SHEET (DS-1)

(For Differential Particle Counts)

Required AS4059 Class _____________________(equivalent to NAS 1638)

Cleanliness: Other ______________________________________________________________

Sample Aircraft Application ___________________________________________________

Identity: System Location _____________________________________________________

Sampling Bottle _____ Bottle Cleanliness Class ____________________________________

Procedure: On-line ____ Other (describe) _________ Sample volume ____________________

Counting ___ Automatic Particle Counter ___ Optical Microscope

Procedure: ___ Method C (APC & Optical Microscope) ___ Electron Microscope

Automatic Brand & Model ______________________________________________________

Particle Sensor Model _______________________________________________________
Counter: Date Calibrated ______________________________________________________
Calibration Method ___________________________________________________
Sensor Flow Rate: _______________________________________________mL/min
Volume counted per run ______________________________________________mL

Dilution: Dilution fluid ____________________Cleanliness___________________________

Size Range Counted

Microscope Size, APC Particle Volume Count per Contaminatio
µm (1) or Count Counted 100 mL n Class per
Microscope Table 1
Size, µm(c) (2)
5 incl. to 15 incl. 6 to 14
15 excl. to 25 incl. 14 to 21
25 excl. to 50 incl. 21 to 38
50 excl. to 100 incl. 38 to 70
> 100 > 70

AS4059 Contamination Code: [ __ / __ / __ / __ / __ ]

AS4059 Contamination Class:

Notes/Visual Observations:

(1) Based on longest dimension in accordance with report form in AS598 or ISO 4407
(2) Based on projected area equivalent diameter per ISO 11171
SAE INTERNATIONAL AS4059F Page 9 of 10
AS4059 FLUID CLEANLINESS DATA SHEET (DS-2)
(For Cumulative Particle Counts)

Required AS4059 Class/Classes ________________________________________________

Cleanliness: Other ______________________________________________________________

Sample Aircraft Application ___________________________________________________

Identity: System Location _____________________________________________________

Sampling Bottle _____ Bottle Cleanliness Class ____________________________________

Procedure: On-line ____ Other (describe) ___________ Sample volume __________________

Counting ___ Automatic Particle Counter ___ Optical Microscope

Procedure: ___ Method C (APC & Optical Microscope) ___ Electron Microscope

Automatic Brand & Model ______________________________________________________

Particle Sensor Model _______________________________________________________
Counter: Date Calibrated ______________________________________________________
Calibration Method ___________________________________________________
Sensor Flow Rate: _______________________________________________mL/min
Volume counted per run _______________________________________________mL

Dilution: Dilution fluid ____________________Cleanliness___________________________

Size Range Counted

Microscope Size, APC Particle Volume Dilution Count Contaminatio
µm (1) or Count Counted Ratio per 100 n Class per
Microscope mL Table 2
Size, µm(c) (2)
>1 >4
>5 >6
> 15 > 14
> 25 > 21
> 50 > 38
> 100 > 70

AS4059 Contamination Code: cpc[ __ / __ / __ / __ / __ / __ ]

AS4059 cpc Contamination Class:

Notes/Visual Observations:

(1) Based on longest dimension in accordance with report form in AS598 or ISO 4407
(2) Based on projected area equivalent diameter per ISO 11171
SAE INTERNATIONAL AS4059F Page 10 of 10
APPENDIX B - DIFFERENCES BETWEEN AS4059 AND NAS 1638

B.1 SCOPE

This Appendix provides information on the variations between NAS 1638 and AS4059.

B.2 BACKGROUND

When NAS 1638 was developed, the principal means of counting particles was the optical microscope with particles sized
by the longest dimension per AS598. When Automatic Particle Counters (APCs) came into use they provided a method
of analyzing a sample much faster that the AS598 method. A method of calibrating APCs was developed, although they
measured area and not length, such that comparable results to that of AS598 or ISO 4407 could be obtained from the
same sample. Now, automatic particle counters are the primary method used to count particles and the projected area of
a particle determines size. Because of the way particles are sized with the two methods, automatic particle counters and
optical microscopes do not always provide the same results. NAS 1638 has now been made inactive for new design and
has been revised to indicate it does not apply to use of automatic particle counters. This standard incorporates the
features of NAS 1638, including the use of AS598 or ISO 4407, and is intended to provide a uniform classification system
independent of the particle size analysis method.

Prior to ISO 11171:1999, the previous APC calibration method most widely utilized was ISO 4402, which used Air Cleaner
Fine Test Dust (ACFTD) as the reference calibration material. ACFTD is no longer manufactured and the ISO 4402
method using this dust has been made obsolete. The industry developed the method ISO 11171, which supercedes
ISO 4402, with a calibration standard based on NIST-certified samples of test dust suspended in hydraulic oil. There is a
difference between the particle measurements by ISO 4402 and ISO 11171. To retain the same contamination class
measure, calibrations using ISO 11171 are conducted to a corrected particle count scale. For example, particles reported
as 5 µm with the ISO 4402 method are reported as 6 µm(c) by the ISO 11171 method. In fact 5 µm corresponds to 6.4
µm(c), and some round off was conducted for simplification.

B.2.1 Differences between NAS 1638 and AS4059

AS4059 was developed to have classes equivalent to NAS 1638. However, there are differences.

B.2.1.1 Cumulative Counts versus Differential Counts in a Size Range

NAS 1638 was designed for use with an optical microscope and therefore particle counts were specified in particle size
ranges. Section 3.2.2 of this standard utilizes this same approach, so as to minimize differences in resulting fluid
classifications from the original NAS 1638 standard. AS4059 was originally designed for use primarily with automatic
particle counters, which can easily count particles larger than a selected size. Therefore, 3.2.3 provides a method for
reporting cumulative particle counts to determining the AS4059 class, which can be useful for evaluating filter
performance, for example. Cumulative particle counts need to be calculated If particle counts are made using an optical
microscope in the size intervals specified by AS598 or ISO 4407. The cumulative particle counts at each size can easily
be calculated by adding all the counts for larger sizes. For example, to determine the number of particles greater than 15
µm, simply add the particles obtained in the 15-25, 25-50, 50-100, and >100 size ranges.

B.2.1.2 Counting of Smaller Particles

AS4059 allows the analysis and reporting of smaller particle sizes than NAS 1638.

B.2.1.3 Counting Large Particles and Fibers

In some samples, it has been observed that many of the particles larger than 100 µm are fibers. However, automatic
particle counters size particles based on projected area rather than longest dimension and do not differentiate between
fibers and particles. Therefore, fibers will be reported as particles with dimensions considerably less than the length of
the fibers. A problem with fibers is that they may not be present in fluid in the system but rather have been introduced as
the result of poor sampling techniques or poor handling during analysis.