Filter Preventive Maintenance Guide
Build a PM program that catches problems early, extends equipment life, and actually saves money.
Why Filter PM Matters
The 5 Pillars of Filter PM
Scheduled Inspections
Regular visual checks of filter indicators, housings, and connections. Catch issues before they become failures.
Condition-Based Changes
Change filters based on differential pressure, not just calendar time. Get full value from every filter.
Documentation & Tracking
Record every filter change with date, hours, and condition. Build data to optimize future intervals.
Fluid Analysis
Regular oil samples verify filtration effectiveness and catch problems your eyes can't see.
Root Cause Analysis
When filters fail early, find out why. A collapsed filter is a symptom—find the disease.
PM Inspection Checklist
Use this during routine walkarounds and scheduled PM events:
Daily/Per-Shift Checks
Weekly Checks
Monthly/Quarterly Checks
What to Document
Good records turn filter changes from guesswork into data-driven decisions.
| Data Point | Why It Matters |
|---|---|
| Date & time of change | Calculate calendar intervals |
| Equipment hours at change | Calculate runtime intervals—more accurate than calendar |
| Differential pressure at change | Verify filter was actually loaded, not changed early |
| Visual condition of old filter | Collapsed pleats = changed too late; clean = changed too early |
| Filter part number installed | Verify correct filter used, track brand performance |
| Technician initials | Accountability, training feedback |
| Any abnormalities noted | Metal particles, water, unusual debris = upstream problems |
Key Performance Indicators (KPIs)
Track these metrics to measure and improve your filter program:
Average Filter Life (hours)
Hours between changes by filter location. Trending up = improving cleanliness or better filter selection.
Cost Per Operating Hour
Filter cost ÷ hours of service. Compare across brands and types.
Bypass Events
Count of times bypass opened. Should be zero—each event means unfiltered fluid.
ISO Cleanliness Trend
From oil analysis. Should be stable or improving. Rising particle counts = problem.
Sample PM Schedule
| Filter Type | Inspection | Analysis | Change Trigger |
|---|---|---|---|
| Hydraulic & Lube Oil | |||
| Hydraulic return | Daily indicator check | Quarterly oil sample | ΔP indicator or 2000 hrs |
| Hydraulic pressure | Daily indicator check | Quarterly oil sample | ΔP indicator or 3000 hrs |
| Lube oil | Every oil change | Every oil change | With oil change (250-500 hrs) |
| Compressed Air | |||
| Compressor inlet | Weekly visual | N/A | Restriction indicator or 2000 hrs |
| Coalescing filter | Weekly ΔP check | Dewpoint monitoring | ΔP >10 psi or annually |
| Particulate filter | Weekly ΔP check | N/A | ΔP >10 psi or annually |
| Carbon/adsorption | Monthly ΔP check | Oil vapor testing | ΔP or 8000 hrs max |
| HVAC & Air Filtration | |||
| HVAC panel (pre-filter) | Monthly visual | N/A | ΔP or 90 days max |
| HVAC bag/rigid | Monthly ΔP check | N/A | ΔP or 12 months max |
| HEPA filter | Monthly ΔP check | Annual integrity test | ΔP or integrity failure |
| Dust Collection | |||
| Cartridge collector | Weekly ΔP check | N/A | ΔP exceeds baseline + 2" |
| Baghouse | Daily ΔP check | Stack emissions test | ΔP or bag failure |
| Engine & Fuel | |||
| Engine air | Weekly visual | N/A | Restriction indicator or 500 hrs |
| Fuel filter | Weekly visual | Fuel sampling | Scheduled or 500 hrs |
Pro Tip: Cut Open Used Filters
Periodically cut open removed filter elements and inspect the media. You'll see exactly what contaminants your system is generating and whether filters are being fully utilized. Metal particles in a hydraulic filter = component wear happening upstream.
Common PM Mistakes
Calendar-only changes
"Every 3 months" regardless of usage wastes money on low-use machines and risks high-use ones.
No documentation
Without records, you can't optimize intervals or troubleshoot recurring problems.
Ignoring oil analysis
Your filter indicator says "good" but particle counts are rising. Without samples, you're flying blind.
Wrong filter inventory
Running out of filters leads to extended bypass operation or using whatever's available.
Building Your PM Program
Inventory all filter locations
Create a master list of every filter in your facility with equipment ID, location, and current filter P/N.
Set baseline intervals
Start with manufacturer recommendations, then adjust based on actual conditions.
Implement tracking
CMMS system, spreadsheet, or even a notebook—something that captures every change with date and hours.
Start oil analysis program
Quarterly samples on critical systems. Monthly on high-value equipment.
Review and optimize quarterly
Look at actual filter life vs. targets. Adjust intervals, investigate outliers, refine the program.
Need help with your filter PM program?
We can review your current setup and recommend improvements.