KLEENOIL Hydraulic Applications

PRODUCT DATASHEET

SDU9788KU85HYD By-Pass Hydraulic Unit The SDU9788KU85 filtration vessel is designed for inline or bypass integration into pressurized hydraulic and lubrication systems. This setup utilizes a PRV block assembly for pressure reduction and relief, ensuring the filter operates within optimal safety margins. The PRV Modules can be installed to hydraulic systems, compressors, or any system with oil at pressure up to 350 BAR. The flow through the Kleenoil Filter is controlled to approximately 4 ltrs / mi-nute at 3.5 BAR. to give a flow rate low enough to offer negligible effects on most 'System Pressures', Yet high enough to ensure that oil is being kept in 'as new' condition. Filtration Level: Particulate contamination in accordance with BS 5540 Part 4: 1981 and ISO/DIS 4406 14/9, equivalent to NAS 1638 Class 6 (Hydraulic Oil Specification). Hydraulic Line Integration with Pressure Regulation Valve (PRV)

Product Snapshot

SDU9788KU85HYD Hydraulic - Bypass Oil Filtration Unit Kleenoil Filtration Ltd UK Hydraulic systems, lubrication systems, bypass filtration setups

Model: Type: Brand: Manufactured: Applications:

SDU9788KU85HYD

Key Benefits

Extends oil life up to 10x (hydraulic) Environmentally friendly : cellulose media, biodegradable

Reduces downtime , wear, and service costs Compatible with mineral, synthetic & bio oils Removes particles down to 3 micron absolute Removes 99.9% water (free, emulsified, and dissolved)

How It Works? The SDU9788KU85HYD operates as a bypass system, drawing a small flow of oil from the system and filtering it slowly but exceptionally finely, without affecting line pressure.

Bypass Feed with Pressure Control Oil is diverted from the main hydraulic line using a bypass circuit. A Danfoss PRC06E05000 cartridge valve housed in a custom PRV block reduces incoming pressure. Relief protection is provided by a LC038015M Spring integrated into the valve poppet housing, which allows for controlled discharge in case of pressure spikes. Function of the PRV Valve Block The valve block upstream of the SDU9788KU85 performs the following: 1. Pressure Reduction Main line pressure (up to 3000 PSI / 207 bar) is reduced to ~40 PSI for safe filtration. 2. Overpressure Relief The Spring-loaded poppet opens to relieve back pressure or flow restriction scenarios. 3. Sample Port Integration A dedicated sample port allows for live monitoring of oil condition pre- or post-filtration. System Compatibility Suitable for use in hydraulic systems, gearboxes, or compressors. Supports integration into return or offline loops. Flow Rate & Efficiency Flow regulated to approximately 4 LPM @ 40 PSI. Designed to continuously condition oil with ultra-fine filtration down to 1 micron and water removal to <0.05%.

SDU9788KU85HYD

Flow Path Summary

Oil diverted via bypass. PRV block reduces and regulates pressure. Excess pressure relieved via spring-poppet mechanism. Filtered oil returns to tank or reservoir. 1. 2. 3. 4. Key Benefits Protects filter media and vessel from high-pressure damage. Ensures continuous high-efficiency filtration without compromising the main system. Ideal for systems with high pulsation or variable flow.

Technical Specs

Specification

Features

Filtration Water Absorption Flow Rate Operating Temp Max input Pressure Material Lid torque pressure Dry Weight Height Diameter Replacement Filter Code

3 micron absolute, cellulose cartridge Aprx 750ml 120–250 L/h

-20°C to +120°C 350 bar Pre PRV Aluminium LM6 (BS1490) 18ft lbs. 3 bolt seal 6.8 kg

165mm 220mm SDFC1888KF85 FILTER CARTRIDGE

Certifications ISO 9001:2015 Manufacturing ISO 16889 & ISO 4572

ROHS Compliant REACH Compliant FSC-certified filter media Castings tested to BS1490 LM6-MSDU9788KU85

SDU9788KU85HYD

Advisory: Installing the Kleenoil SDU9788KU85 Unit with PRV Block on a Machine’s Hydraulic Line Installation Guidelines Installation Method: Bypass Circuit Install the Kleenoil unit on a bypass line rather than the main pressure or return line. This allows the system to operate continuously without interrupting or throttling the machine’s normal hydraulic functions. 1. Component Overview Filtration Unit : Kleenoil SDU9788KU85 PRV Block Assembly : Flow Regulator (Optional) : Inline flow restrictor or orifice plate to ensure steady flow 2. Step-by-Step Installation Step 1 : Identify Tap-In Point (Pressure Source) 3. Locate a high-pressure access point on the hydraulic line, such as a test port or spare auxiliary port. Pressure must not exceed 3000 PSI at this point. Step 2 : Install the PRV Block Assembly Connect the source pressure line into the inlet port of the PRV block. The Danfoss PRC06E05000 will reduce pressure to ~40 PSI. The Lee Spring poppet mechanism provides safety relief in case of downstream blockage or spikes. Step 3 : Connect to the SDU9788KU85 Vessel Sample Port : Upstream or downstream of the unit Flexible Hoses or Hard Lines : For return to tank Run hydraulic hose from PRV block outlet to the inlet of the Kleenoil unit. Ensure proper support/bracketing for stability and vibration isolation. Step 4 : Return Line The filtered oil outlet should be connected to: o The hydraulic reservoir return port , OR o A low-pressure return line (under 5 bar). Avoid backpressure beyond design limits. Step 5 : Sample Port Installation Install the sample port just before the filter inlet or after the outlet , depending on monitoring preference. Use a test port with quick-connect for oil analysis or pressure readings.

SDU9788KU85HYD Step 6 : Secure the Assembly Mount the Kleenoil unit vertically (filter top upright). Ensure hoses are free of kinks or undue strain. 4. Schematic Overview

Main Hydraulic Line

Tap-Off Point

PRV Block with PRC06E05000

Kleenoil SDU9788KU85 Unit

Return to Tank or Return Line

Design & Safety Notes Flow Rate : Regulated to approx. 4 L/min. Use restrictor if needed. Temperature Limits : Ensure fluid temp remains within unit specs (e.g., 0–80°C typical). Pressure Ratings : 5. o Inlet: Up to 3000 PSI o Outlet: 40 PSI (regulated) Relief Path : Ensure relief line (from poppet port) drains to reservoir safely. Maintenance Access : Allow clearance for filter element replacement. Operational Check Post-Install Check pressure drop across unit and oil sample clarity over first few hours of operation. 6.

SDU9788KU85HYD

BOM & Exploded View

SDU9788KU85HYD By-Pass Hydraulic Unit

TITLE

QTY.

SR NO

1 2 3 4 5 6 7 8 9

SDU9788KU85 - Body SDU9788KU85 - Disc Insert SDFC1888KF85 Filter Cartridge SDU9788KU85 - Lid Gasket for SDU9788KU85 (OTS) Silicon O-Ring, 8mm ID (OTS) Plate Adapter to Match Feed/Return PRV Bypass Hydraulic Unit - Assembly (OTS) SDU9788KU85 Super Duty Bracket Stainless Steel Hex Head Screw, M8 x 1.25 mm Thread, 35 mm Long, Partially Threaded (OTS) Medium-Strength Steel Flange Nut-Class 8 Zinc Plated, M8 x 1.25 mm Thread (OTS) 18-8 Stainless Steel Hex Head Screw, M10 x 1.25 mm Thread Size, 25 mm Long (OTS)

1 1 1 1 1 4 1 1 1 4

10

11

4

12

2

PRV Bypass Hydraulic Unit

TITLE

QTY.

SR NO

1 1 2

8.1 8.2 8.3 8.4 8.5

PRV Bypass Hydraulic Unit Pressure Reducing/Relieving Valve

Copper Washer for 1/4 BSP Straight Connector 316 Stainless Steel, Poppet Spring with Brass Cap Copper Washer for 3/8 BSP Straight Connector 316 Stainless Steel, Straight Connector, 1/4 BSP Male to 1/4 BSP Male 316 Stainless Steel, Straight Connector, 3/8 BSP 8.7 Male to 3/8 BSP Male 8.6

1 1 1

1 1 2

8.8 8.9 8.10

1/8 BSP Male Test Port Rubber Seal for PRV Bypass Hydraulic Unit Alloy Steel Socket Head Screw, M6 x 1 mm Thread, 35 mm Long, Partially Threaded

4

SDU9788KU85HYD

Packaging & Shipping UK Packaging

Packed in cartons of 1 Box dimensions: 250x250x220mm Shipping weight: 6.8kg

International Packaging

Recommended export box of 4 Shipping weight: 24.8kg Outer Box dimensions 500x500x220mm

“Cleaner oil means longer life – for your machinery, your oil and your business” Trust Kleenoil – Clean Fluids. Smarter Systems

Kleenoil Filtration Ltd sales@kleenoil.co.uk www.kleenoil.co.uk

Contact Us

PRODUCT DATASHEET

HDU9778KU50HYD By-Pass Hydraulic Unit The HDU9778KU50 filtration vessel is designed for inline or bypass integration into pressurized hydraulic & lubrication systems. This setup utilizes a PRV block assembly for pressure reduction and relief, ensuring the filter operates within optimal safety margins. The PRV Modules can be installed to hydraulic systems, compressors, or any system with oil at pressure up to 350 BAR. The flow through the Kleenoil Filter is controlled to approximately 4 ltrs / mi-nute at 3.5 BAR. to give a flow rate low enough to offer negligible effects on most 'System Pressures', Yet high enough to ensure that oil is being kept in 'as new' condition. Filtration Level: Particulate contamination in accordance with BS 5540 Part 4: 1981 & ISO/DIS 4406 14/9, equiva-lent to NAS 1638 Class 6 (Hydraulic Oil Specification). Hydraulic Line Integration with Pressure Regulation Valve (PRV)

Product Snapshot

HDU9778KU50HYD Hydraulic - Bypass Oil Filtration Unit Kleenoil Filtration Ltd UK Hydraulic systems, lubrication systems, bypass filtration setups

Model: Type: Brand: Manufactured: Applications:

HDU9778KU50HYD

Key Benefits

Extends oil life up to 10x (hydraulic) Environmentally friendly : cellulose media, biodegradable

Reduces downtime , wear, and service costs Compatible with mineral, synthetic & bio oils Removes particles down to 3 micron absolute Removes 99.9% water (free, emulsified, and dissolved)

How It Works? The HDU9778KU50HYD operates as a bypass system, drawing a small flow of oil from the system and filtering it slowly but exceptionally finely, without affecting line pressure.

Bypass Feed with Pressure Control Oil is diverted from the main hydraulic line using a bypass circuit. A Danfoss PRC06E05000 cartridge valve housed in a custom PRV block reduces incoming pressure. Relief protection is provided by a LC038015M Spring integrated into the valve poppet housing, which allows for controlled discharge in case of pressure spikes. Function of the PRV Valve Block The valve block upstream of the HDU9778KU50 performs the following: 1. Pressure Reduction Main line pressure (up to 3000 PSI / 207 bar) is reduced to ~40 PSI for safe filtration. 2. Overpressure Relief The Spring-loaded poppet opens to relieve back pressure or flow restriction scenarios. 3. Sample Port Integration A dedicated sample port allows for live monitoring of oil condition pre- or post-filtration. System Compatibility Suitable for use in hydraulic systems, gearboxes, or compressors. Supports integration into return or offline loops. Flow Rate & Efficiency Flow regulated to approximately 4 LPM @ 40 PSI. Designed to continuously condition oil with ultra-fine filtration down to 1 micron and water removal to <0.05%.

HDU9778KU50HYD

Flow Path Summary

Oil diverted via bypass. PRV block reduces and regulates pressure. Excess pressure relieved via spring-poppet mechanism. Filtered oil returns to tank or reservoir. 1. 2. 3. 4. Key Benefits Protects filter media and vessel from high-pressure damage. Ensures continuous high-efficiency filtration without compromising the main system. Ideal for systems with high pulsation or variable flow.

Technical Specs

Specification

Features

Filtration Water Absorption Flow Rate Operating Temp Max input Pressure Material Lid torque pressure Dry Weight Height Diameter Replacement Filter Code

3 micron absolute, cellulose cartridge Aprx 400ml 120–250 L/h

-20°C to +120°C 350 bar Pre PRV Aluminium LM6 (BS1490) 18ft lbs. 3 bolt seal 4 kg

165mm 190mm HDFC1878KF50 FILTER CARTRIDGE

Certifications ISO 9001:2015 Manufacturing ISO 16889 & ISO 4572

ROHS Compliant REACH Compliant FSC-certified filter media Castings tested to BS1490 LM6-MHDU9778KU50

HDU9778KU50HYD

Advisory: Installing the Kleenoil HDU9778KU50 Unit with PRV Block on a Machine’s Hydraulic Line Installation Guidelines Installation Method: Bypass Circuit Install the Kleenoil unit on a bypass line rather than the main pressure or return line. This allows the system to operate continuously without interrupting or throttling the machine’s normal hydraulic functions. 1. Component Overview Filtration Unit : Kleenoil HDU9778KU50 PRV Block Assembly : Flow Regulator (Optional) : Inline flow restrictor or orifice plate to ensure steady flow 2. Step-by-Step Installation Step 1 : Identify Tap-In Point (Pressure Source) 3. Locate a high-pressure access point on the hydraulic line, such as a test port or spare auxiliary port. Pressure must not exceed 3000 PSI at this point. Step 2 : Install the PRV Block Assembly Connect the source pressure line into the inlet port of the PRV block. The Danfoss PRC06E05000 will reduce pressure to ~40 PSI. The Lee Spring poppet mechanism provides safety relief in case of downstream blockage or spikes. Step 3 : Connect to the HDU9778KU50 Vessel Sample Port : Upstream or downstream of the unit Flexible Hoses or Hard Lines : For return to tank Run hydraulic hose from PRV block outlet to the inlet of the Kleenoil unit. Ensure proper support/bracketing for stability and vibration isolation. Step 4 : Return Line The filtered oil outlet should be connected to: o The hydraulic reservoir return port , OR o A low-pressure return line (under 5 bar). Avoid backpressure beyond design limits. Step 5 : Sample Port Installation Install the sample port just before the filter inlet or after the outlet , depending on monitoring preference. Use a test port with quick-connect for oil analysis or pressure readings.

HDU9778KU50HYD Step 6 : Secure the Assembly Mount the Kleenoil unit vertically (filter top upright). Ensure hoses are free of kinks or undue strain. 4. Schematic Overview

Main Hydraulic Line

Tap-Off Point

PRV Block with PRC06E05000

Kleenoil HDU9778KU50 Unit

Return to Tank or Return Line

Design & Safety Notes Flow Rate : Regulated to approx. 4 L/min. Use restrictor if needed. Temperature Limits : Ensure fluid temp remains within unit specs (e.g., 0–80°C typical). Pressure Ratings : 5. o Inlet: Up to 3000 PSI o Outlet: 40 PSI (regulated) Relief Path : Ensure relief line (from poppet port) drains to reservoir safely. Maintenance Access : Allow clearance for filter element replacement. Operational Check Post-Install Check pressure drop across unit and oil sample clarity over first few hours of operation. 6.

HDU9778KU50HYD

BOM & Exploded View

HDU9778KU50HYD By-Pass Hydraulic Unit

TITLE

QTY.

SR NO

1 2 3 4 5 6 7 8

HDU9778KU50 - Body HDU9778KU50 - Disc Insert HDFC1878KF50 Heavy Duty Filter Cartridge HDU9778KU50 - Lid Gasket for HDU9778KU50 (OTS) Silicon O-Ring, 8mm ID (OTS) PRV Bypass Hydraulic Unit - Assembly (OTS) HDU9778KU50 Heavy Duty Bracket Stainless Steel Hex Head Screw, M8 x 1.25 mm Thread, 35 mm Long, Partially Threaded (OTS) Medium-Strength Steel Flange Nut-Class 8 Zinc Plated, M8 x 1.25 mm Thread (OTS) 18-8 Stainless Steel Hex Head Screw, M10 x 1.25 mm Thread Size, 25 mm Long (OTS)

1 1 1 1 1 3 1 1 3

9

10

3

11

2

PRV Bypass Hydraulic Unit

TITLE

QTY.

SR NO

1 1 2

7.1 7.2 7.3 7.4 7.5

PRV Bypass Hydraulic Unit Pressure Reducing/Relieving Valve

Copper Washer for 1/4 BSP Straight Connector 316 Stainless Steel, Poppet Spring with Brass Cap Copper Washer for 3/8 BSP Straight Connector 316 Stainless Steel, Straight Connector, 1/4 BSP Male to 1/4 BSP Male 316 Stainless Steel, Straight Connector, 3/8 BSP 7.7 Male to 3/8 BSP Male 7.6

1 1 1

1 1 2

7.8 7.9 7.10

1/8 BSP Male Test Port Rubber Seal for PRV Bypass Hydraulic Unit Alloy Steel Socket Head Screw, M6 x 1 mm Thread, 45 mm Long, Partially Threaded

4

HDU9778KU50HYD

Packaging & Shipping UK Packaging

Packed in cartons of 1 Box dimensions: 200x200x220mm Shipping weight: 5kg

International Packaging

Recommended export box of 8 Shipping weight: 40.5kg Outer Box dimensions 420x420x420mm

“Cleaner oil means longer life – for your machinery, your oil and your business” Trust Kleenoil – Clean Fluids. Smarter Systems

Kleenoil Filtration Ltd sales@kleenoil.co.uk www.kleenoil.co.uk

Contact Us

CASE STUDY ROTHEN GROUP - CANAL & RIVER WEED-CUTTING FLEET HYDRAULIC OIL PROTECTION WITH KLEENOIL

WHO IS THE ROTHEN GROUP

Located at Mancetter Wharf, Warwickshire, CV9 2RD , The Rothen Group Ltd specialise in: Waterway contracting & maintenance — work on canals, rivers, and lakes in the UK. Projects include dredging, lock and bank maintenance, marina/silt management, river & canal restoration. Marine plant & workboat hire — providing craft such as crane-boats, powered and non powered vessels, pontoon/digger hoppers, reed/weed boats, and other specialist marine equipment for hire. Civil engineering & maritime infrastructure — piling, piling repairs, access & utilities, ecology related work, marinas etc. They combine practical marine/contracting experience with environmental / ecological awareness (e.g. restoration work, reed ‐ weed management).

WHY THEY MATTER / WHAT THEY’RE GOOD AT

They provide niche but essential services that keep the UK’s inland waterways functioning safely. They both own and hire out specialist equipment and workboats — meaning they have a vested interest in maintaining high standards of equipment reliability. Because much of their work is marine / hydraulic / water ‐ exposed, equipment is exposed to moisture, silt, bio ‐ growth etc. This makes proper filtration, maintenance, and equipment protection especially important.

BACKGROUND

A specialist fleet of Conver weed-cutting boats operates across England’s canals and rivers, working up to 9 months of the year to maintain waterways. In addition to these vessels, shallow-drafted tugs and crane boats are also in continuous operation, all relying heavily on hydraulic systems. To protect these critical assets, the fleet operator has adopted Kleenoil SDU9788KU85 bypass hydraulic filtration units across the fleet.

THE CHALLENGE

The vessels run on bio hydraulic oil , which presents unique challenges: Bio oils naturally carry a small amount of moisture content . Condensation in hydraulic tanks, especially in marine environments, adds further water load. o o o o o Even with new, filtered oil at fill-up, contamination quickly builds during operation — as seen in the heavily loaded filter removed from the 12-month-old refurbished vessel, Wey . Moisture and particulate contamination in hydraulics cause: Accelerated wear of pumps, motors, and valves. Sludge formation, blocked filters, and system downtime. Reduced oil life and higher disposal costs.

KLEENOIL’S SOLUTION

Installation of the Kleenoil SDU9788KU85 bypass filtration unit on all hydraulic systems across the fleet. Regular cartridge changes scheduled during vessel servicing cycles. Filtration designed to: Continuously remove water and particulate down to 1 micron. Keep bio oil clean and dry in service. Protect system components from moisture-driven wear and corrosion. o o o

RESULTS ACHIEVED

Visual inspection of filters from the Wey demonstrated the level of contamination captured within the 12 months — confirming the system’s role in protecting the oil and components. Despite operating on bio oil (more moisture-prone than mineral oil), hydraulic oil has remained in good working condition between filter changes. System reliability improved, with reduced downtime for unplanned maintenance. Oil life extended, reducing the need for frequent full reservoir drain-and-replace cycles.

BENEFITS

Extended Oil Life – Bio oil maintained in service for longer, with stable performance. Reduced Moisture Issues – Bypass filters continuously remove water introduced by condensation and bio oil’s natural absorption. Lower Maintenance Costs – Cartridge swaps are quick and predictable, avoiding costly unplanned downtime. Asset Protection – Pumps, valves, and cylinders safeguarded from wear and corrosion. Fleet-Wide Standardisation – Same Kleenoil unit now being fitted on weed cutters, shallow drafted tugs, and crane boats.

CONCLUSION

The experience of the canal and river fleet shows that Kleenoil bypass filtration is essential for bio hydraulic oil systems : Even new oil quickly absorbs water and contaminants in marine environments. Kleenoil units continuously remove this contamination, keeping oil “as new” in service. Regular cartridge changes deliver predictable maintenance and protect system health. For marine and hydraulic fleets, Kleenoil offers a proven, practical solution that extends oil life, reduces costs, and increases uptime — ensuring critical assets like weed cutters, tugs, and crane boats remain in service throughout their demanding working seasons.

CONTACT YOUR NEAREST SUPPORT FOR MORE INFORMATION

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01977 682810

sales@kleenoil.co.uk

CASE STUDY TRAVEL LIFT – HYDRAULIC OIL PROTECTION IN CONCRETE MANUFACTURING

CUSTOMER BACKGROUND

A travel lift used in a concrete manufacturing facility was suffering from severe hydraulic oil contamination. The very dry climate and constant silica dust from concrete accelerated wear on critical components.

THE CHALLENGE

The operator faced constant and expensive failures caused by dirty oil: Hydraulic hoses and seals replaced monthly. Hydraulic pumps replaced every 9–12 months. Significant machine downtime. The result was unreliable operation and rising maintenance costs .

KLEENOIL’S SOLUTION

Kleenoil proposed fitting a Heavy Duty Bypass Hydraulic Filter to continuously clean the oil, removing both fine dust and water contamination. Pressure take-off installed, diverting <5% of total flow . Pressure Reducing Valve (PRV) fitted to ensure safe system pressures. Oil returned to the tank via top-up point. Installation was simple, did not affect normal hydraulics, and included a baseline oil sample for comparison. Installation Details:

RESULTS ACHIEVED

Independent oil analysis (ISO 4406 / ASTM D7647) confirmed the Kleenoil system’s effectiveness:

4 micron particles: reduced from 116,763 to 6,203 . 6 micron particles: reduced from 44,642 to 920 . 14 micron particles: reduced from 1,604 to 27 . Contamination Reduction After 1 Month: Nearly 96–99% of contamination removed in just one month. No hose failures (saving $1,000/month). No oil changes required in 12 months (saving $3,000). No pump replacements/rebuilds. No unplanned downtime. Cost & Maintenance Impact: Total annual savings: $15,000+ per machine. Payback period: less than 1 month.

BENEFITS TO THE CUSTOMER

Cleaner Oil: Maintained to “as new” condition. Lower Maintenance Costs: Eliminated recurring hose and pump replacements. Increased Uptime: No downtime caused by oil contamination. Fast ROI: Paid back in under 30 days. Long-Term Reliability: Critical travel lift kept in service with minimal interruptions.

KEY TAKEAWAY

By installing Kleenoil filtration, the customer transformed their travel lift from a maintenance burden into a reliable workhorse , saving over $15,000 per year and achieving ROI within weeks.

TESTIMONIAL

“Before Kleenoil, we were replacing hoses every month and pumps every year. Now, after a simple installation, oil is clean, failures have stopped, and we’re saving thousands in downtime and repairs.” MAINTENANCE MANAGER, CONCRETE MANUFACTURING PLANT

CONTACT YOUR NEAREST SUPPORT FOR MORE INFORMATION

Click Here

01977 682810

sales@kleenoil.co.uk

CASE STUDY FORKLIFTS IN FOUNDRY OPERATIONS – ENGINE, HYDRAULIC & TRANSMISSION PROTECTION

CUSTOMER BACKGROUND

A customer operating a fleet of Komatsu forklifts in a foundry environment faced rapid machine wear and frequent failures. The combination of intense heat and airborne metal carburundum contaminated the oils in the engine, hydraulics, and transmission systems , leading to short machine lifespans and unplanned downtime.

THE CHALLENGE

Extreme working conditions: Hot, dirty, and abrasive atmosphere. Rapid oil contamination: Engine, hydraulic, and transmission oils degraded quickly. High failure rates: Machines required frequent repairs & suffered from reduced operating life. The customer needed a comprehensive solution capable of addressing oil contamination across all three fluid systems at once.

KLEENOIL’S SOLUTION – H.E.T SYSTEM

Kleenoil engineered a tailored solution: a three-unit bracket system using the smaller LDFU9768KU16 filter modules. H = Hydraulic E = Engine T = Transmission

Each system had its own dedicated Kleenoil filter, mounted together as a fixed unit (see installation detail photo, page 3). This ensured that all three vital oil systems were continuously cleaned down to 3 microns , while also removing water. For the hydraulic system, a Pressure Reducing Valve (PRV) module was added, enabling safe operation up to 3000 PSI without affecting system pressures.

RESULTS ACHIEVED

Extended Oil Life: Cartridges recommended for change every 250 hours, with only a yearly oil change required. Cleaner Oil: Oil quality maintained “as new,” meeting strict cleanliness standards (ISO/DIS 4406 14/9; NAS 1638 Class 6). Reduced Failures: Significantly less wear across engine, hydraulic, and transmission components. Extended Machine Life: Forklifts that were once written off as short-life assets were restored to reliable, long-term operation. Lower Downtime & Maintenance: Cartridge swaps could be completed in minutes, avoiding disruptive, labour-heavy maintenance.

BENEFITS TO THE CUSTOMER

Comprehensive Protection: All critical oil systems (engine, hydraulics, transmission) safeguarded. Increased Reliability: Forklifts lasted far longer in previously destructive conditions. Reduced Costs: Fewer oil and filter changes, plus fewer component repairs. Less Downtime: Simple cartridge replacements instead of full servicing. Predictable Maintenance: Routine 250hr cartridge changes kept systems consistently clean.

KEY TAKEAWAY

By applying Kleenoil filtration across all three oil circuits on Komatsu forklifts, the customer transformed their maintenance outcomes. What were once high-failure, short-life machines became reliable, long-service assets , saving both money and downtime in one of the harshest industrial environments.

TESTIMONIAL

“Before Kleenoil, we accepted that our forklifts would have very short lifespans. With filtration on the engine, hydraulics, and transmission, the difference was immediate — longer life, less downtime, and clean oil across the board. Now we just have to resolve our issue with melting tyres ”

MAINTENANCE MANAGER, FOUNDRY OPERATIONS

CONTACT YOUR NEAREST SUPPORT FOR MORE INFORMATION

Click Here

01977 682810

sales@kleenoil.co.uk

CASE STUDY TAYLOR ENGINEERING PLASTIC INJECTION MOULDING

CLIENT

Taylor Engineering , a plastic injection moulding company running multiple hydraulic systems under continuous heavy workloads.

CHALLENGE

The client’s machines were running on brand new, unused oil from storage . Despite being fresh, testing showed that the stored oil was not as clean or stable as expected once compared against oil in service. Goals: 1. Improve oil cleanliness and reliability under heavy workloads. 2. Extend oil life and reduce waste. 3. Ensure machine uptime and performance with a proven solution.

SOLUTION

SEE FULL REPORT

Trial of the Kleenoil bypass filtration system on one moulding machine.

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Three sample points analysed: 1. New storage oil (unused baseline). 2. Extend oil life and reduce waste. 3. In-service oil after Kleenoil installation and operation.

Laboratory testing covered particle counts, water content, and cleanliness levels , benchmarked against ISO standards.

RESULTS

Before Kleenoil: the in-service oil had deteriorated, showing significant particulate contamination compared to new oil. After Kleenoil: the in-service oil was restored and maintained at a level cleaner than the brand new oil in storage , despite being under heavy machine loads. The system not only matched “new oil” conditions, but outperformed them in real operational conditions , proving that Kleenoil provides continuous purification and stability where static storage cannot.

Results Comparison (Particle Counts & Moisture)

Relative Cleanliness & Stability

ISO Code

Oil Condition

Particle Counts (per ml)

Moisture (ppm)

Key Findings

Baseline sample showed initial contamination levels despite being unused. In-service oil had deteriorated, with higher particle counts and reduced stability. Oil restored to a condition cleaner than the new oil in storage , even under heavy workloads.

2,500 (>4µ) / 600 (>6µ) / 80 (>14µ) 5,000 (>4µ) / 1,200 (>6µ) / 160 (>14µ) 1,200 (>4µ) / 200 (>6µ) / 25 (>14µ)

Clean, but not perfect.

New Oil (from storage)

18 / 16 / 13

150 ppm

Before Kleenoil

20 / 18 / 15

Worse than new oil.

280 ppm

After Kleenoil

15 / 13 / 10

Superior to new oil.

80 ppm

Particles reduced by ~75% + compared to both new and in-service oil. Moisture cut by over 70% , ensuring better lubrication and preventing oxidation. Oil in heavy use with Kleenoil is actually cleaner and drier than oil straight from storage.

IMPLEMENTATION & ONGOING PROGRAM

On the strength of these results, Taylor Engineering: Rolled out Kleenoil systems across their other machines. Introduced a quarterly service program , including: o Scheduled filter changes . o System performance checks . o Trending laboratory analysis of oil samples, building a long-term reliability profile.

This program ensures oil life is maximised, equipment protection is sustained, and maintenance is fully data-driven.

BUSINESS IMPACT

Oil in constant operation is now maintaining itself better than oil in storage , proving real world resilience and reliability. Extended oil life delivers cost savings and reduces waste oil disposal. Cleaner oil under heavy load protects machines, reduces downtime & extends component life. Planned service regime gives predictable costs and proactive condition monitoring. Sustainability gains through reduced oil use and environmental impact. Sustainability By extending the life of their oil through Kleenoil’s continuous filtration, the client has also embraced a strong green initiative . The system reduces the need for frequent oil changes, cutting down on the consumption of new oil while simultaneously minimising waste oil disposal . Instead of discarding used oil, the company is now able to recycle and reuse existing oil in a safe, reliable condition — aligning operational efficiency with environmental responsibility. This approach not only lowers costs but also supports broader sustainability goals , reducing the carbon footprint associated with oil production, transport, and disposal. By extending oil life 5× on a 600-litre injection moulding machine, we avoid ~960 litres of oil per year , cutting the carbon footprint by ≈2.8–3.4 tonnes CO₂e annually per machine , before counting the added benefits from fewer stoppages and improved productivity.

Red bar (baseline): ~4,200 kg CO₂e/yr from oil production + disposal with 6- monthly changes (1,200 L/yr). Green bar (with Kleenoil): ~840 kg CO₂e/yr when oil life is extended 5× (240 L/yr). That’s a reduction of ~3.4 tonnes CO₂e per machine per year , along with all the cost, downtime, and sustainability benefits.

KEY TAKEAWAY

Taylor Engineering’s trial proved that Kleenoil doesn’t just keep oil clean — it makes inservice oil cleaner and more stable than brand new oil in storage, even under heavy workloads . This gave the client the confidence to expand Kleenoil protection across their entire facility, securing both operational efficiency and long-term sustainability .

CONTACT YOUR NEAREST SUPPORT FOR MORE INFORMATION

Click Here

01977 682810

sales@kleenoil.co.uk