Basic Principles of Kidney Loop Filtering of Hydraulic Fluid Systems {0680, 0768, 5050, 5056}

(SEBF8840-18)

SMCS - 0680, 0768, 5050, 5056 i10026147

Caterpillar Products
PSP
202 -0008
All

Revision History:
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© 2023 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.

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Unauthorized use of this document or the proprietary processes therein without permission may be

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violation of intellectual property law.
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Information contained in this document is considered Caterpillar: Confidential Yellow.

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This Contamination Control Guideline enables dealers and customers to benefit from cost
reductions which were made possible through an established Contamination Control Program.
Fluids used in Caterpillar machines are highly effective unless the fluid contains damaging amounts
of contaminates. Therefore, every effort must be made to reduce the contamination level within
Caterpillar fluid systems. Caterpillar makes ongoing changes and improvements to the Caterpillar
products. This Contamination Control Guideline must be used with the latest technical information
that is available from Caterpillar. Updated technical information will ensure that such changes and
improvements are incorporated when applicable.

For technical questions when using this document, work with your Dealer Technical Communicator
(TC).

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional
repair options or modifications to reuse and salvage techniques and/or methods.

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for
feedback in the Service Information System 2.0 (SIS 2.0 web) interface.
Canceled Part Numbers and Replaced Part Numbers
This document may include canceled part numbers and replaced part numbers. Use the Numerical
Part Record (NPR) within the Service Information System 2.0 website (SIS 2.0 web) for information
about canceled part numbers and replaced part numbers. NPR will provide the current part
numbers for replaced parts.

Important Safety Information

Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills, and tools to perform
these functions properly. Safety precautions and warnings are provided in this instruction and on the
product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to
other persons. Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. Therefore, the warnings in this publication and the warnings that are on the
product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not
recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.
Ensure that the product will not be damaged or the product will not be made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are used.

Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such
as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING”
Safety Alert Symbol.

Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The safety information in this document and the safety information on the machine
are not all inclusive. Determine that the tools, procedures, work methods, and operating
techniques are safe. Determine that the operation, lubrication, maintenance, and repair
procedures will not damage the machine. Also, determine that the operation, lubrication,
maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete, most current information
before you start any job. Caterpillar dealers can supply the most current information.

Safety
 Sudden movement of the machine or release of oil under
pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows

before testing and adjusting the steering system.

Personal injury can result from hydraulic oil pressure and hot
oil.

Hydraulic oil pressure can remain in the hydraulic system after

the engine has been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the
hydraulic system.

Make sure all of the attachments have been lowered, oil is cool
before removing any components or lines. Remove the oil filler
cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.

Dispose of all fluids according to local regulations and

mandates.

Summary

NOTICE
 If the machine is being serviced due to a catastrophic failure, a
complete system cleaning operation is required before
initializing this filtration procedure. If the failure is not
addressed early, particles from the failed component will
contaminate other system components such as valves, pumps,
motors, and controls. Extra component cleaning, component
exchange, and lines flushing will be required to remove the
contaminants generated from the failure. The machine system
cleaning must be performed before the filtration procedure. This
filtration procedure and subsequent particle count testing
should be performed as part of the repair process.

Off-line filtering procedures, or kidney loop filtration, for machine fluid systems are often
complicated. A prior knowledge of filtering basics will help ensure the desired outcome. Passing oil
through a filter is only one step to managing the total system cleanliness. Successful results are
obtained when a holistic approach to the system management is applied. Issues covered in this
article relate directly to off-line filtering procedures. The following information should be applied
when filtering machine fluid systems.

References
Table 2
References
Media Number Publication Type & Title
Special Publication
PEGJ0045
"Reporting Particle Count by ISO Code" (1)
Special Publication
PEGJ0047
"How To Take A Good Oil Sample" (1)
Special Publication
PERJ1017
"Dealer Service Tools Catalog" (1)
Tool Operating Manual
NEHS0848
" 204-7392 Filter Cart Group" (2)
Contamination Control Guidelines
SEBF8482
"Obtaining Oil Sample for Analysis" (2)
(1) Available through catpublications.com
(2) Available through SIS 2.0

Kidney Loop Filtration Basics

Kidney loop filtration is a process where a certain amount of fluid is removed from a system, filtered,
and then returned to the system. Kidney loop filtration is different than full flow filtration, which is
common in machine return filter applications. In a kidney loop filtration process:
 Oil is removed from the system

Filtered

Returned to the system for mixing

The contamination level of the whole system is reduced slightly during each pass of the kidney
looped oil. The total contamination level will decrease steadily, over time. Kidney loop filtration is a
slow process. However, kidney loop filtration is less costly than oil changes and the resulting labor
or other types of system clean-up. The kidney loop filtration process can be implemented during a
scheduled PM interval or after a catastrophic failure. Kidney loop filtration is an addition to your
normal maintenance procedures.

As the oil viscosity increases, ease of filtration decreases. The filter elements are not designed to
filter out around or above 600 particles.

Filtering Time
S·O·S sampling is the best method of determining the system contamination level. On-site S·O·S
information will guide you with this decision. When the contamination level has been lowered to the
recommended ISO target or cleaner, discontinue the filtering process. On-site S·O·S information
can easily be obtained using a Caterpillar Portable Particle Counter. Information on the use of a
Portable Particle Counter during kidney loop filtering is located in various machine filtration
guidelines.

A time measurement is another method of determining the proper system filtering duration. Time
measurement is a general method, but can provide some guidance when a Portable Particle
Counter is not available.

Oil Filtration Guidelines:

1. The filtering system must pass each fluid unit of compartment oil through the kidney loop filter.
To accomplish kidney loop filtration, the filter unit must move seven times the compartment fluid
capacity through the filter. The filtration of seven times the compartment fluid is due to the
mixing mechanics and dead compartment areas.
Example: If a tank has a capacity of 37.9 L (10 US gal), the filter unit must move 265 L
(70 US gal) of oil through the filter one time for every unit of oil to pass through the filtering unit.

2. To clean and lower the system contamination to a level determined by the filter media. All the
filtered oil must pass through the filter media 5 times.
Example: A system is being filtered through a 10um filter. Due to the filter media efficiency, all
oil needs to pass through the filter media 5 times (multi-pass). Incorporating a multi pass
 filtration increases the number of times the filter sees each unit of oil. The filter cart removes
greater amounts of contaminants with each additional cycle.

Given the two guidelines above, filtering time can be summarized in the following example.

1. System capacity is 113.56 L (30 US gal).

2. 7 x 113.56 L (30 US gal) = 794.94 L (210 US gal) (to pass each unit of oil through the filter, one
time).

3. 5 x 794.94 L (210 US gal) = 3974.68 L (1050 US gal) (to properly filter the particles out of the
oil down to the rated size of the filter media).

4. The example kidney loop filter cart capacity is rated at 15 gallons per minute. The filter cart
must operate for 70 minutes (1050/15=70) to achieve Caterpillar filtration guidelines.
Remember, using this time formula is not exact. To verify the final fluid cleanliness, approved
methods must be used.

Filter unit capacity is to be properly selected to move the required amount of oil 3974.68 L
(1050 US gal) through the filter in the targeted time frame. Other parameters for the filter cart
operation and efficiency will be discussed later in this article. Vehicle-specific filtration times are also
located within the various Caterpillar Contamination Control Guidelines.

Recommended System Operating Levels

Caterpillar Machine operating levels do not dictate an allowed level of system contamination.
Contamination control guidelines are available to enhance the fluid system health for the life of the
product. Guidelines are not specifications, but are the maximum contamination operating levels
recommended by Caterpillar. Operating the machine systems at or below these contamination
levels will help achieve the engineered life of the system components. A system management
strategy would be difficult to implement without these guidelines. Based on historic S·O·S data,
component life is directly related to proper fluid health and cleanliness management. Contamination
Control procedures utilizing high efficiency filters or off board (kidney loop) filtration procedures will
reduce or eliminate the contamination-related failures so often seen in poorly maintained vehicles.

Older machine filtration may not be adequate to achieve the new recommended cleanliness levels.
Older machines will benefit from a higher level of system contamination control management. The
engineered life of any component is attainable by eliminating wear and contamination-related
failures.

ISO 4406 Method for coding the level of contamination

by solid particles.
ISO (International Organization of Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). ISO 4406:2017 specifies the code to be used in defining the quantity
of solid particles in the fluid used in a given compartment fluid power system. An automatic particle
counter derives the equivalent size of a particle from the particle cross-sectional area. Particle
counts are affected by various factors. These factors include procurement of the sample, particle
counting accuracy, the sample container, where used, and fluid cleanliness. Proper care should be
taken during sample procurement to ensure that the sample obtained is representative of the fluid
circulation in the system.

The code for contamination levels using automatic particle counters comprises three scale
numbers, for example X/Y/Z.

X - The number of particles that is equal to or larger than 4 microns.

Y - The number of particles that is equal to or larger than 6 microns.

Z - The number of particles that is equal to or larger than 14 microns

Currently Caterpillar does not require the reporting of the (X) scale number since the hydraulic
tolerances exceed the 4 micron value, therefore a (-) is used in place of the (X). For example, a
particle count is read as -/Y/Z, meaning that there was no requirement to count particles equal to or
larger than 4 microns.

System Intervention
When should off board fluid filtration be implemented? When should action be taken on a
contaminated system? The following are several symptoms or signs indicating possible system
intervention is required:

Opening any hydraulic system for repair or service

Identification of poor maintenance practices

Leaks

System overheating

Poor system efficiency

Normal/possibly elevated wear

S·O·S analysis indicates high contamination levels for any reason

What Intervention is Appropriate?

There are several levels of intervention to consider when addressing system contamination.
 Customer education

High efficiency filters

PSP
202 -0008
Kidney loop filtration

Complete oil changes

Complete system flushing 3

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Any of the above measures may be appropriate for a given system contamination level and

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condition. Incorporate the proper intervention level as required.

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After a catastrophic component failure of any kind, the complete
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fluid system MUST be thoroughly cleaned. Kidney loop filtration
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as the first or only system cleaning procedure is not an option.

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Manual cleaning may include some or all the following steps:

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Flushing all system lines

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Major component removal and cleaning or exchange

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Steam cleaning large housings or tanks

Complete oil replacement

Caterpillar filter carts are NOT designed, nor intended, to be the sole filtration after a catastrophic
system failure. The hydraulic system must have the proper degree of manual cleaning intervention
prior to filtration cart use.

The service provider must determine the proper intervention measures. The provider is the one
closest to the machine operation and history.

Kidney Loop Filter Cart Applications

Caterpillar offers a complete line of kidney loop filtration carts to support kidney loop procedures.
Caterpillar filter carts are designed to reduce elevated levels of contamination in the oil. The filtering
efficiency of any filter cart is determined by many factors:

Oil viscosity (temperature and weight) plays a large part in determining how fast the oil will flow
through the filter and filtering unit. Oil viscosity also determines the contaminant mixing or lack
thereof in the compartment oil. Oil viscosity can also dictate GPM.

Oil movement (GPM/LPM) through the filter may be impacted by:

 Viscosity

Filtering unit air pressure

Filter unit plumbing

Filter media size

Filter media dirt saturation

Filter bypass condition

All Caterpillar filter unit capacities are rated with 10W oil at 21.1° C (70° F). If moving oils with
different viscosity ratings than the parameters above, the rated oil movement or filtering capacity of
the filter unit will change proportionately. If any part of the filter cart is changed or modified from the
as-shipped condition from the manufacturer, the filter cart may not operate as designed. Filter Cart
changes include:

Hose length

Hose diameter

Fitting size

Filter media

Common Filtering Issues

Following are common issues, which may affect your filtering results:

Amount of oil to be filtered

100% of the system oil is not in the reservoir. 30-40% of the system fluid capacity is in the system
piping and components. The system must be exercised to exchange the dirty oil with the clean oil in
the reservoir or compartment where the oil can then be filtered.

Kidney loop vs. full flow filtration

Kidney loop filtration has continuous mixing of the clean and dirty oil. Oil in sheltered parts of a
compartment may not properly mix with the returning clean oil. Oil in sheltered parts may require
longer filtering times for this sheltered oil to mix and then pass through the filter unit. Use the proper
equation in the “Filtering Time” section above. Remember, if the contaminated oil never reaches the
cart filter media, the oil will NEVER be cleaned.

Full flow filtration would seem to be fast and easy. If the system is an open loop system, the
resulting filtration is still a kidney loop operation. Oil flows from the tank, through the pump and then
to the filter. The oil is eventually returned to the tank resulting in a kidney loop type operation.

Single pass filtering is NEVER an absolute or efficient means of filtering. Multi-pass filtration is a
superior type of filter process to reach your filtration goal.

Filtering media size

Filter media has rated efficiencies for different sizes of contaminants. A 10-micron (µm) absolute
filter will remove most 10µm and larger particles and a decreasing percentage as the particle sizes
decrease from 10µm. A 5µm filter will take out most of the 5µm and larger particles and a
decreasing percentage as the particle sizes decrease from 5µm. In other words, a given absolute
filter media size will only remove a certain percentage of a given particle size. The oil contamination
level will eventually stabilize for a given filter media. Additional filtering from that point would NOT be
valuable, or economical, unless a smaller micron filter media is used. See the chart below:

Illustration 3 g06339830

Filtering Time
Filtering time is determined by all the above conditions, but can generally be based on the oil flow
through the filter media. However, the filtering time will always depend on the specific situation. A
portable particle counter provides a good indication when measuring contaminant levels.

Portable particle counters are not a substitute for lab particle counting. Portable particle count is
intended to give an ongoing record of the reduction of contamination during the filtering process.
Portable particle count is used as an on-sight trending analysis tool for machine systems in remote
locations.
System contamination (mixing the oil) can only be thoroughly mixed by exercising the machine and
system components. By exercising the machine system, the oil is warmed, viscosity is lowered, and
contaminant mixing takes place at a higher rate. More importantly, when contamination is mixed and
placed into suspension, contamination will be carried to the filter unit easier and quicker.
Remember, if the contamination does not get to the filter unit, the filter CANNOT remove
contamination!

The above information provides the basic filtration principals required to perform a system off-board
or kidney loop filtration procedure and help troubleshoot poor procedural results.

Caterpillar Cleanliness Targets

Cat dealers need to help ensure that Cat machines meet Caterpillar recommended cleanliness
targets. Caterpillar recommends that cleanliness targets apply to new equipment to which dealers
add attachments, add work tools, or perform final assembly. Cleanliness targets are to encompass
used, rental, or repaired equipment.

In general, the recommended cleanliness targets for Caterpillar machines operating in the field are
the same as Caterpillar minimum roll-off cleanliness levels for new equipment. These targets are
expressed in two-factor (X/Y) ISO Codes determined from Particle Count data obtained from the
Scheduled Oil Sampling (S·O·S) program. The first factor (X) represents the number of particles
larger than 6 microns in size. The second factor (Y) represents the number of particles larger than
14 microns in size. Refer to Contamination Control Guideline, PEGJ0045, "Reporting Particle Count
by ISO Code" examines ISO Codes and Particle Counting in more detail.

Recommended Cleanliness Targets

FOR CATERPILLAR MACHINES OPERATING IN THE FIELD
Table 3
Hydraulic/Transmission Systems ISO Code
Hydraulic Systems (Implement & Steering) ISO 18/15 or cleaner
Electronic Transmissions ISO 18/15 or cleaner
Mechanical Transmissions ISO 21/17 or cleaner
Power Train Systems ISO 18/15 or cleaner

Note: Older technology machines in the field may not be able to maintain the cleanliness levels of
newer models. However, the same Contamination Control service and maintenance procedures
should be used on all Caterpillar equipment.
FOR RECONDITIONED/REBUILT CATERPILLAR
COMPONENTS
Machine operating cleanliness targets are not to be confused with component cleanliness targets.
Caterpillar recommends that cleanliness target for reconditioned/repaired Caterpillar components
should be two ISO Code levels below (cleaner than) the recommended machine system operating
cleanliness target.

FOR FILL OILS

Caterpillar recommended target for fill oils – hydraulic, transmission, and final drive – is ISO 16/13
or cleaner.

PSP-00088EAF
2023/12/12
18:33:21-06:00
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© 2023 Caterpillar Inc.
Caterpillar:
Confidential Yellow