FOR ENGINE MODEL

DK-20

Picture for reference only. For actual

scope of supply refer to the attachments

OM.05-AN
Rev. 00 MAR 11
15/03/11 Page 1 of 21
TABLE OF CONTENTS

1. OVERVIEW page 3
2. CAUTIONS & WARNINGS FOR HS&E HAZARDS page 4
3. INTRODUCTION page 5
4. CHARACTERISTICS OF THE FILTERING SET page 6
5. FILTER SECTIONAL DRAWING WITH PARTS LIST page 7
6. INSTALLATION OF THE FILTERING SET page 10
6.A INSTALLATION SCHEME – TYPICAL page 11
7. START-UP page 12
8. OPERATION page 13
8.A FILTRATION AND CLEANING PHASE page 14
9 MAINTENANCE page 15
10 INSPECTION AND CLEANING OF THE FILTERING UNIT page 16
10.A SELF-CLEANING FILTERING ELEMENT page 17
11 TROUBLESHOOTING page 20
12 SPARE PARTS page 21
13 TEST REPORT page 22

Filtrex assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice.

Rev. 00 OM.05-AN
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Page 2 of 21
1. OVERVIEW

IMPORTANT!
In order to have the maximum benefit from your Filter, we suggest that you read through
this manual’s sections concerning installation and operation prior to the product’s
installation, and when the product is operated or serviced. Do not hesitate to contact
Filtrex S.r.l. or our local branch for any further technical information you may require.

This manual contains information on the erection, operation, and maintenance of the
Filter based on the specifications of the unit when delivered from our factory. In case
post-delivery alterations have been made to the unit, we recommend that you contact
Filtrex S.r.l. or our local branch for an updated manual.

This manual makes reference to other pieces of literature, such as schematics and
drawings that are added to the manual as needed depending on the filter parameters
and configuration.

When ordering spare parts or requesting technical assistance, always state the serial
number of the Filter (see page I of this manual and name plate on unit).

Unless special permission has been granted by Filtrex S.r.l. do not attempt to repair or
dismantle the Filter or any of its components within the warranty period of the unit (with
exception of any dismantling necessary for the replacement of filter element). Failure to
seek the said permission will cause the guarantee on the said parts to be void!

Filtrex S.r.l. product liability does not cover technical modifications to the filter unit
unless Filtrex S.r.l. in writing has accepted such extension of liability.
CONVENTIONAL SIGNS USED IN THIS MANUAL:

A warning indicates either potential for malfunction

of the equipment or of the system and tells you
WARNING! how to avoid the problem.

A danger indicates a potential for damage to the

DANGER! equipment, to the system or personal injury.

STOP
A stop indicates that the filter shall be put out of
STOP! service.

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Page 3 of 21
2. CAUTIONS AND WARNINGS FOR HS&E HAZARDS

• The Filter does not require to be inspected daily.

• Fluid drained very often contain harmful substances that must not be drained to
ordinary sewers, but be collected in a special container and disposed of in
accordance with local regulations for chemical waste.

WARNING
Do not expose the pressure equipment to working pressure over
the Design Pressure.
Monitoring of the internal inlet pressure shall be considered by
the user.

WARNING
In order to avoid opening the cover when the filter is pressurized,
the user shall install on the inlet pipeline to the Filter,
downstream of any isolation valve, a pressure indicator.

WARNING
Do not expose the filter to working temperature over the Design
Temperature, otherwise it might be damaged. Monitoring of the
working temperature shall be considered by the user.

DANGER
Due to working temperature, pressure equipment insulation may
be considered by the user.

DANGER
When installing the filter, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.

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Page 4 of 21
3. INTRODUCTION

In many machining plants and for the trouble-free operation of all internal combustion
engines the removal of contaminants from a fluid process stream makes that fluid more
valuable and increases product yields. An ACP filter placed in a strategic location can
eliminate many costly problems, protecting moving parts from wear and also acting as a
monitor for the whole circuit.

The ACP system’s features are:

- Resolves the existing problems:

It greatly improves the quality of the oil being delivered to the engine’s moving parts
(crankshafts, bearings, cylinder’s liners, piston’s rings) and other oil wetted parts in
the equipment, thereby improving their reliability and longevity.

- Enhance the personnel’s life by reducing maintenance activity:

It virtually eliminates the requirements for a routinely planned maintenance on the

engines. No personnel’s manual cleaning is more reliable than the automatic
backwash.

- Improves the engine’s reliability and performance characteristics:

Human factor, and thus error, is completely eliminated since the filter, in standard
operating conditions, does not need intervention for twenty-thousand hours, as
compared to the few hours of a static filter.

- Minimizes the impact on the environment

Since there is no need to dispose of used filter cartridges.

- More advantages:

Simple construction and easy maintenance, does not require special tools, possible
emergency cleaning by manual hand wheel, monitoring of the pressure drop with
alarm for filter clogging, low operating costs, compact and lightweight. No external
electric panel, backwashing is performed by the same filtered fluid.

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Page 5 of 21
4. CHARACTERISTICS OF THE FILTERING SET

The special shape of FILTREX ACP filters allows to get a light and efficient continuous
working and ensures a safe and easy replacement of the clogged filtering element.
The ACP filter mainly consists of:
• A housing provided with :
a) a main flanged connection to engine body with both inlet and outlet lines. The
direction of the fluid is marked on the above mentioned flanges.
b) a backwashing nozzle
c) other connections as requested by the process conditions.
d) a cover fixed to the housing by means of bolting.
• A filtering element is placed inside the housing with the appropriate filtration degree,
according to the customer’s requirement; its size is calculated according to the
design flow rate and normal pressure drop.
• An hydraulic motor with gear reducer for the rotation of the backwashing shaft during
the continuous cleaning of the filtering element.
• A differential pressure indicator with electric contacts.
• Optional accessories as :
¾ Differential pressure gauge or switch or transmitter
¾ Heating pocket
¾ Vent & drain valves
¾ Instruments root valves and/or manifolds
¾ Manual hand wheel for emergency cleaning
Refer to attached “General Arrangement Drawing” for actual scope of supply.
Other optional accessories are available on request.

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5. FILTER SECTIONAL DRAWING WITH PARTS LIST

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Page 7 of 21
 SELF-CLEANING FILTER PARTS LIST FOR ACP-702-50
(refer to sectional dwg. at page 7)
POS. DESCRIPTION FILTREX CODE Q.ty
0 Complete filter ACP-702-50 1
1 Gear reducer 2603/1 1
2 Gear shaft 1400 1
4 Thrust bearing flange fixing bolt 3198 4
5 Gear reducer flange/cover fixing bolt 987 4
6 Thrust bearing 1191 1
7 Backwash nozzle gasket See pos.27 1
7a Backwash shaft bushing gasket See pos.27 1
7b Backwash shaft bushing / nozzle gasket See pos.27 2
9 Self-cleaning filter cover 3272 1
10 Self-cleaning filter cover bolt 995 4
11 Backwash shaft tandem bushing 1453 1
12 Filtering element fixing bolt 1996 4
13 Self-cleaning filter cover gasket See pos.27 1
14 Self-cleaning filter body 2304 1
15 Self-cleaning filtering element type DH30XN101100 1
16 Backwash nozzle 3242 1
17 Self-cleaning filtering element gasket See pos.27 1
18 Backwash shaft bushing 1612 1
21 Differential pressure instrument S44P 1
22 Instrument root valve 1944 2
23 Hydraulic motor 1742 1
24 Hydraulic motor drain fitting 2617 2
25 Orifice 1416-3.5 1
26 Differential pressure gauge pipe fittings 2411 2
27 Complete gasket set (pos.7-7a-(2)7b-13-17) 3477 1
28 Backwash shaft tandem bushing kit (pos.7-7a-(2)7b-11) 3503 1

Please consider orifice (25) as manufacturer set up and do not modify or

eliminate it otherwise Filtrex will decline responsibility and/or guarantee.

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6. INSTALLATION OF THE FILTERING SET

To install the filtering set follow the following procedure step by step:
1. Identify the filter’s inlet and outlet. Position the filter in the line so that the fluid enters
the inlet connection in order to perform properly and to avoid damage to the system.

WARNING
Be sure that sufficient headroom is provided for easy removal of
the internal parts. This requires a clear height above the top (refer
to the attached “General Arrangement Drawing”). Clearance for
rigging equipment must also be considered.

2. Connect the filtering unit to the inlet/outlet piping, making sure that all closing means
(nuts, bolts, valves, etc.) are fast tightened. Inlet and Outlet piping should be carefully
aligned to avoid stressing the filter connections during installation. Installation of shut-
off valves on either side of the filter is recommended so that it can be independently
drained for filtering element change or inspection.

3. Connect all the remaining nozzles provided on the filter.

DANGER
During the installation of the filter, make sure that any oil or fuel
which leaks due to the improper handling cannot result in a fire
or injury.

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6.A INSTALLATION SCHEME - TYPICAL

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7. START-UP

To start the filtering set follow these usual operations:

1. Check that all valves installed on the vessel nozzles are in the relevant service
position.

2. Slowly introduce fluid to be filtered, to ensure the complete filling of the housing and
the complete utilization of the whole filtering surface.

WARNING
Before filling up the filter, make sure that all the valves connected
on vessel nozzles are in the relevant service position.

6. Put the filter into the operating process condition.

STOP
It is very important to consider that, during this start up phase or
after important works (long time not running period), the filter is
submitted to particularly heavy conditions as it must provide the
elimination of impurities such as lints, piles, metallic slags and/or
STOP
other contaminants that are by chance introduced in the system.
It is therefore important to keep carefully under control the ∆p of
the filter, to prevent the ∆p increase reaching the alarm value. If
the alarm value is reached, the filter must be taken out of service.
Dismantle the filtering element and clean it (see section
“Inspection and cleaning of the filtering element”).

WARNING
In case of high differential pressure after start-up phase, the
status of the filtering element shall be checked, in order to verify
that no damages have occurred.

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8. OPERATION
8.A FILTRATION AND CLEANING PHASE

The filter works on continuous back-washing basis, using its own process fluid; the
backwashing fluid is fed back into the sump tank again.
The fluid enters from the inlet flange (A) and flows through all the sectors of the filtering
element (C) (inside-outside filtration). The filtered fluid is collected in chamber (D) and
exits from the outlet flange (B).
While all the filtering sectors of the filtering element (C) provide the filtration of the fluid,
the sector in front of the nozzle (F), driven by the hydraulic motor (E), is cleaned by the
backwash flow spilled from the filtered fluid in chamber (D) (outside-inside backwash).
The impurities are carried away by the same backwash fluid, through the nozzle (F) to
the backwash outlet nozzle (J).

E
C

D x
x
x
x

J
F
Drawing for reference only

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 The pressure gradient produced (operating pressure with respect
to the free discharge – atmosphere) results in an extremely
efficient cleaning action.

WARNING
For the correct automatic operation of the filter it is mandatory
that the pressure on the backwash line is not lower than 2 Bar (g).

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9. MAINTENANCE
Even with automatic filters, inspection and maintenance must be performed at regular
intervals.
It is extremely important to remember that in spite of a continuous back-washing the
mesh may become clogged over the course of time, depending on the quality of the
fluid.
In order to maintain trouble-free operation, the following aspects are to be observed
during maintenance :

9.1 The filter must be turned off for all maintenance work.

9.2 Check filter and connections for leaks.

9.3 Check for the correct rotation of the backwash shaft by means of the gear motor.

After every cleaning make sure that the backwash shaft rotates
freely.

9.4 Carry out a careful visual check of the filter status every 8.000÷12.000 hours of
operation or two years, whichever the earlier. If necessary, proceed to clean the
filter (refer to section 10 “Inspection and cleaning of the filtering unit”.

STOP
STOP Should a higher differential pressure occur beforehand, the filter
must be checked and, if necessary, cleaned.

9.5 It is recommended to replace the filter element after four years operation.

9.6 Carry out a careful visual check of the gaskets.

It is advisable to replace all the gaskets during any overhaul.

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10. INSPECTION AND CLEANING OF THE FILTERING UNIT

Refer to section 5 “Filter Sectional drawing with parts list”

For the inspection and cleaning of the filtering element proceed as follows:

10.1 The filter must be turned off for all maintenance work.

10.2 Close the closing devices at the filter inlet and outlet. (*)

10.3 To proceed with the inspection, refer to the hereafter descriptions.

WARNING
Before dismantling any filter parts and discharging the fluid,
make sure that the filter is not pressurized.

(*) If existing

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10.A SELF-CLEANING FILTERING ELEMENT

For ordinary maintenance operations the following tools are required :

- Fork wrench
- T Socket head screw (supplied).

10.A1 Empty the filter by removing the drain plug positioned on the bottom of the
vessel.

10.A2 Unscrew the hydraulic motor drain fitting (24) (see picture No. 1), remove the
filter cover bolts (pos.10) (see picture No. 2) and screw two of them in the
threaded holes positioned on the same cover bolts circle in order to slightly raise
the filter cover (9) (see picture No. 3).

10.A3 Lift the cover / filtering element assembly by hands and place it in a safe and
clean area, paying attention that the backwash nozzle (16) is not raised together
with the cover / filtering element assembly (see picture No. 4).

WARNING
Take care not to damage the filtering element (15), the backwash
nozzle (16) and the gaskets (13) and (17).

10.A4 Remove the fixing bolts (12) of the filtering element (15) (see picture No. 5).

10.A5 The filtering element (15) can be now easily disconnected by hands from the
cover (9) (see picture No. 6).

10.A6 Dip the filtering element (15) into the clean gasoil for a few hours.

10.A7 After dipping the filtering element, clean it thoroughly from the outside to the
inside with clean compressed air .

10.A8 Prior to be installed, the filtering element (15) shall undergo a visual examination
and if damaged shall be replaced.

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 WARNING
Damaged filtering elements must not be used again. Damaged filter
elements can be easily recognised by their oval/convex shape

10.A9 Re-assemble the filtering element (15) in the reverse sequence to that described
under points above and insert the cover / filtering element assembly inside the
filter body without forcing.

10.A10 Fasten the bolts (10) and the hydraulic motor drain fitting (24).

DANGER
Inspection to the filtering elements involves the risk of
contaminating the main lubricating circuit, therefore it is
necessary to operate with the utmost care and cleanliness.

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 PICTURE No. 1 PICTURE No. 2

PICTURE No. 3 PICTURE No. 4

PICTURE No. 5 PICTURE No. 6

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11. TROUBLESHOOTING
FAULTS POSSIBLE CAUSE INTERVENTIONS/REMEDIES
Wait for normal operating
Viscosity too high due to low temperature conditions and fluid temperature
increase.
Check oil treatment unit of sump
High solids loading in process fluid
tank.
Shorten backwash line, eliminate
Backwash piping elbows, upwards pipe runs,
restriction due to valves, etc.
High
Differential Clean the filtering element (see
Pressure paragraph 10 above)
Visually check for abnormalities in
Clogged filtering elements
the shape of the filter element and
stretching of the internal filter
mesh
Check if nozzle (J) or back-
Backwashing fluid volume too low
washing piping are clogged

Backwash arm not rotating see below countermeasures

Check bolts tightness and

Bolts not tightened
Fluid connections.
Leakage Check for damaged gaskets – in
Gaskets damaged
case, replace.
Obstruction between
filtering element and Remove obstructions.
The hydraulic motor backwash arm
is blocked
Misalignment of Dismount filter and check for free
backwash arm rotation of backwash arm.
Disconnect the backwash from the
circuit and check for free discharge,
Backwash Modified and/or clogged backwash line turning of nut on top of reducer and
arm not differential pressure back to normal
rotating values.
Check for obstructions before filter
inlet.
Check the oil pump operational
Oil quantity is too low
conditions.
Check engine’s oil pressure alarms.
Check oil level gauge in sump tank.
Check for continuous rotation of
nut on top of reducer
Check for proper position of root
Control valves.
Differential pressure switch malfunctioning
problems Check the switch activation when
the needle is in the red sector

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12. SPARE PARTS

FILTREX filters are so easy to operate and so accurately manufactured that there is no
need of special spare parts for the ordinary maintenance.

It is advisable to use Filtrex Genuine spare parts; only in this way customers are sure of
exact interchangeability of spare parts and enables them to claim under the
manufacturing warranty stipulated with the purchase order.

Please refer to Filtrex Code (see Section 5 “Filter sectional drawing with part list” for
identification code) to order the spare parts required.

For Two years ordinary maintenance it is advisable to keep in store the spare parts
listed on page I of this manual

For any further information or eventual request of intervention of highly skilled

personnel, please apply to the manufacturing firm at the following address:

FILTREX S.r.l.
Via Rubattino, 94/B
20134 Milano ITALY
Tel +39-02-75.33.841
Fax +39-02-75.31.383
E-mail [email protected]

When requesting for spare parts or asking for clarifications on already delivered
filters, please always mention the filter’s serial number.

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13. TEST REPORT

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