AIR STARTER

INSTALLATION AND MAINTENANCE

INFORMATION

DAIHATSU DIESEL MFG.CO.,LTD.

TECHNICAL DEPARTMENT

MORIYAMA, JAPAN

&4#90$; S.OMURA
TYPE 150TLPF88L54 %*'%-'&$; T.KIMURA
LIST No. INB000045A
DATE 18th, Jul. 2011 #22418'&$; M.MIZUNO

REVISION
 LUB. OIL AUTO BACKWASHING FILTER
OPERATING AND MAINTENANCE MANUAL

DAIHATSU DIESEL MFG.CO.,LTD.

TECHNICAL DEPARTMENT

OSAKA, JAPAN

DRAWN BY Y.KAJI
TYPE ACP-702-50＆703-50 CHECKED BY T.KIMURA
LIST No. INB000001D M.TAKEUCHI
DATE 5th, Oct. 2006 APPROVED BY M.MIZUNO
B:Revised 20th, Mar. 2007 S.O.
C:Revised 7th, July. 2009 Y.K.
REVISION D:Revised 3th, Jan. 2010 Y.K.

(1/21)
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

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

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
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 no 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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
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.

- Improves the engine’s reliability and performance characteristics:

Human factor, and thus error, are completely eliminated since the filter 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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
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) two main flanged connections, one for the inlet and the other one for the outlet.
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 request; its size has been calculated according to the
design flow rate and normal pressure drop.
• An hydraulic motor with gear reducer for the rotation of the backwashing arm during
the continuous cleaning of the filtering element.
• A differential pressure indicator with electric contacts.
• Optional accessories as :

Differential pressure gauge or switch or transmitter

Heating pocket

Vent & drain valves

Instruments root valves and/or manifolds

Manual hand wheel for emergency cleaning
Refer to attached “General Arrangement Drawing” for actual limit of supply.
Other optional accessories are available on request.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 6 of 21
5. FILTER SECTIONAL DRAWING WITH PARTS LIST

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 7 of 21
 SELF-CLEANING FILTER PARTS LIST FOR ACP-702-50
(refer to sectional dwg. at page 6)
POS. DESCRIPTION FILTREX CODE Q.ty
0 Complete filter ACP-702-50 1
1 Gear reducer 1742 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 2603/1 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-7b-13-17) 3477 1

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

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

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 8 of 21
 SELF-CLEANING FILTER PARTS LIST FOR ACP-703-50
(refer to sectional dwg. at page 6)
POS. DESCRIPTION FILTREX CODE Q.ty
0 Complete filter ACP-703-50 1
1 Gear reducer 1742 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 DH30XN101180 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 2603/1 1
24 Hydraulic motor drain fitting 2617 2
25 Orifice 1416-3.8 1
26 Differential pressure gauge pipe fittings 2411 2
27 Complete gasket set (pos.7-7a-7b-13-17) 3477 1

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

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

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 9 of 21
6. INSTALLATION OF THE FILTERING SET

To install the filtering set follow these usual operations:

1. Identify the vessel inlet and outlet. Position the vessel 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 require 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 vessel is recommended so that it can be
independently drained for filtering element change or inspection.

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

WARNING

A vigorous backwash flow is necessary for proper operation of

the filter. It is therefore important to prevent back-pressure by
having a short, vented, free-flowing backwash line with a minimum
of bends, elbows or vertical risers. The backwash line Ø has to be
no smaller than the size indicated in the attached “General
Arrangement Drawing”.

4. Connect power source to all the electrical components included in the scope of
supply.
5. Connect the earthing lug (when provided) to the general earthing system.

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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 10 of 21
6.A INSTALLATION SCHEME - TYPICAL

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 11 of 21
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. Energize the controls.

3. Open the vent connection (if provided) on filter cover.

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

5. Close the vent connection (if provided) when air is expelled and fluid begins to flow.

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

6. Insert the vessel 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
After start-up phase the status of the filtering element shall be
checked, in order to verify that no damages have been occurred.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 12 of 21
8. OPERATION
8.A FILTRATION AND CLEANING PHASE

The filter works with continuous back-washing using its own process fluid; the
backwashing fluid is fed back into the circulation tank again.
The fluid enters from the inlet flange (A) and flows through all the sectors of the filtering
element (C) except three (inside-outside filtration). The filtered fluid is collected in
chamber (D) and exits from the outlet flange (B).
While all the filtering sectors except three 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 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

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 13 of 21
 The pressure gradient thus 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 at the outlet is not lower than 2 barg
downstream the filter.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 14 of 21
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 and whether a by-pass treatment unit is installed.
In order to maintain trouble-free operation, the following aspects are to be observed
during maintenance :

9.1 The filter must be switched 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 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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 15 of 21
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 switched off for all maintenance work.

10.2 Isolate the heating line . (*)

10.3 Open the by-pass line. (*)

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

10.5 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

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 16 of 21
10.A SELF-CLEANING FILTERING ELEMENT

For ordinary maintenance operations the following tools are required :

- Fork wrench
- T Socket head screw

10.A1 Empty the filter 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 (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, or for big filter size, provide
an adequate lifting device and place it in a safe and clean area, paying attention
that the backwash nozzle (16) will not be 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 Check the allowance between the filtering element (15) and the backwash nozzle
(16) does not exceed 0.2 mm.

WARNING
If the allowance exceeds 0.2 mm, the above components have to
be replaced.

10.A7 Check the allowance between the bushings (11) and (18) and the backwash
nozzle (16) does not exceed 0.2 mm.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 17 of 21
 WARNING
If the allowance exceeds 0.2 mm, the relevant components have
to be replaced.

10.A8 Dip the filtering element (15) into the clean gasoil for a few hours.

10.A9 After dipping the filtering element, clean them thoroughly from the outside to the
inside with a clean compressed air .

10.A10 Prior to be installed the filtering element (15) shall undergo a visual examination
and if damaged shall be replaced.

WARNING
Damaged filtering elements must not be used again.

10.A11 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.A12 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.

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 18 of 21
 PICTURE No. 1 PICTURE No. 2

PICTURE No. 3 PICTURE No. 4

PICTURE No. 5 PICTURE No. 6

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 19 of 21
11. TROUBLESHOOTING

FAULTS POSSIBLE CAUSE INTERVENTIONS/REMEDIES

Wait for normal operating
Viscosity too high due to low temperature
conditions
Check backwashing oil treatment
High solids loading in process fluid
unit for operability
High Shorten backwash line, eliminate
Differential Backwash piping elbows, upwards pipe runs,
Pressure restriction due to valves, etc.

Clogged filtering elements Clean the filtering element

Check if nozzle (J) or back-
Backwashing fluid volume too low
washing piping are clogged

Fluid Bolts not tightened Check bolts tightness

Leakage
Gaskets damaged Replace damaged gaskets

Obstruction between
filtering element and Remove obstruction
The hydraulic motor backwash arm
is blocked
Misalignment of
Backwash Check backwash arm alignment
backwash arm
arm not
rotating Operate the filter for a proper time
The operating fluid pressure is < 2 barg
with pressure 5-6 bar and remove in
downstream the filter
this way the clogging

Oil quantity is too low Increase the oil quantity

Control Check functionality and calibration of

Differential pressure switch improperly adjusted
problems the instrument

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 20 of 21
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 Anulare, 2
20090 Milano San Felice ITALY
Tel +39-02-75.33.841
Fax +39-02-75.31.383
E-mail info@filtrex.it

OM.05-DH
Rev. 07 ACP Automatic Filter
29/01/10 OPERATING AND MAINTENANCE MANUAL DEC 08
Page 21 of 21