p. 1

technical filter booklet technical filter booklet 1 tips infos service

[close]

p. 2

i bring you the power of kolbenschmidt pierburg and trw engine components motor service group quality and service from a single source motor service group is the sales organisation for the worldwide aftermarket activities of kolbenschmidt pierburg it is one of the leading suppliers of engine components for the independent aftermarket including the premium brands kolbenschmidt pierburg and trw engine components our comprehensive product range allows our customers to procure engine components from a single source as a problem solver for dealers and garages motor service offers extensive services and the technical expertise that you would expect from the subsidiary of one of the largest automotive suppliers kolbenschmidt pierburg renowned supplier to the international automotive industry as long-standing partners to the automotive industry the companies in the kolbenschmidt pierburg group develop innovative components and system solutions with acknowledged competence in air supply and emission control for oil and water pumps for pistons engine blocks and engine bearings the products comply with the high demands and quality standards of the automotive industry low emissions reduced fuel consumption reliability quality and safety ­ these are the forces that drive innovation at kolbenschmidt pierburg 2nd edition 01.2010 article no 50 003 596-02 isbn 978-3-86522-209-1 edited by motor service technical market support layout and production motor service marketing die neckarprinzen gmbh heilbronn this document must not be reprinted duplicated or translated in full or in part without our prior written consent and without reference to the source of the material all content including pictures and diagrams is subject to alteration no liability accepted published by © ms motor service international gmbh liability all information in this brochure has been carefully researched and compiled nevertheless it is possible that errors have occurred information has been translated incorrectly information is missing or the details provided have changed in the intervening time as a result we are unable to provide any guarantee nor to accept any legal liability for the accuracy completeness currency or quality of the information provided we hereby waive all liability for any damages whether direct or indirect in nature and whether tangible or intangible resulting from the use or misuse of information or from incomplete or incorrect information in this brochure unless proven to be the result of deliberate intent or negligence on our part likewise we shall not be liable for damage arising because the engine reconditioner or mechanic does not have the necessary technical expertise the required knowledge of or experience in repairs the extent to which the technical methods and repair information described here will apply to future engine generations cannot be predicted and must be verified in individual cases by the engineer servicing an engine or the workshop operator 2 technical filter booklet

[close]

p. 3

table of contents table of contents 1 introduction 2 basics of filtration 3 dirt load and pressure difference 4 the filter medium 5 air filters 6 cabin filters 7 air dryer 8 fuel filters 9 urea filters 10 coolant filters 11 oil filters 12 gear oil filters 13 concluding remarks glossary page 4 7 9 10 12 16 24 25 30 31 32 36 37 38 technical filter booklet 3

[close]

p. 4

1 introduction they lead a life in the shadows but they are more important than any luxury accessories filters filters purify the substances that are necessary for proper engine operation neglecting replacement intervals or using poor quality filters often result in substantial costs down the line filtration has become very extensive in modern vehicles due to the constantly rising requirements on the engines high customer demands as well as stringent environmental regulations are further factors that have a great influence on the development of filter technology 1.2 ks filter classification the ks range of filters comprises air oil and fuel filters for passenger cars trucks and for utility vehicle applications according to the type of application the filters are classified as follows designation ac air cabin acc air cabin with activated carbon ad air dryer ap air panel ar air round cs coolant spin on fc fuel cartridge fp fuel pipe inline fs fuel spin-on filter type cabin filter standard cabin filter with activated carbon air dryer panel air filter round air filter coolant filters fuel filter cartridge fuel pipe filter spin-on fuel filter fuel filter cartridge metal-free oil filter cartridge hydraulic oil filter spin-on oil filter automatic transmission oil filter oil filter cartridge metal-free oil centrifugal filter 1.1 general remarks generally speaking filters have the function of preventing impurities and foreign matter from entering the inside ot the engine together with the air oil and fuel in engine technology different types of filters are used for the various substances to be filtered they differ with respect to their function structure and maintenance intervals there are numerous filtration methods dirt particles can be removed by using · fine-meshed plastic or metal sieves · fine-porous paper felt and fleece or · through centrifugal forces fx fuel metalfree oc oil cartridge oh oil hydraulic os oil spin-on ot oil transmission ox oil metalfree oz oil centrifuge 1.3 explanation of ks item numbers for filters kolbenschmidt uses two number ranges ­ in addition to the standard eight-digit ks number there is also a corresponding short number the short number is made up of three or four figures and two or three letters with the figures identifying the filter and the letters the filter type see 2 the eight-digit ks number appears on all documents e.g delivery notes and invoices the first five digits are always 50 013 or 50 014 while the last three or four figures identify the filter and correspond to the figures in the short number example oil filter insert 095-oc 50 013 095 cabin filter with activated carbon 4027-acc 50 014 027 4 technical filter booklet

[close]

p. 5

introduction 1 1.4 wear in an internal combustion engine whenever moving parts come into contact or mesh they cause friction which must be avoided as a suitable lubricant mineral or synthetic oil is used which forms a sliding film between the machine parts this ultra-thin separation film acts as a buffer to prevent a direct contact and to allow a sliding of the parts of course this lubrication is only possible if the oil does not contain contaminants even impurities of microscopic size may not be carried because as abrasive particles they enormously accelerate the abrasive wear of the engine parts critical spots within the engine are the cylinder barrels pistons piston rings valves gaskets crankshafts and connecting rod bearings impurities can enter the engine directly in the form of sand or sand particles with the fuel of the intake air in addition the engine creates its own contaminants in the form of fine metal abrasives residues of incomplete combustion or small fibres plastic or rubber particles these impurities also have a wear-enhancing effect on the system and may even cause operation failures sectional view of an internal combustion engine 1.5 wear of engine components due to impurities in the system new component damaged component huge wear to running surfaces of oil ring consequence elevated oil consumption strong scoring on the main bearing caused by an abrasive mass consisting of oil and dirt particles consequence engine failure technical filter booklet 5

[close]

p. 6

1 introduction new component damaged component used piston with cleat signs of wear strong abrasion of the graphite film on the piston body the missing sliding film may lead to piston malfunction or even piston seizing marked wear in the area of the 1st ring groove the elevated clearance leads to a lower compression causing a loss of power new cylinder sleeve with a clearly visible cross hatch this surface produced by using a honing tool improves the oil adhesion on the inside wall of the cylinder cylinder sleeve with scoring on the inside wall the honing pattern is not perceptible any more consequence elevated oil consumption 6 technical filter booklet

[close]

p. 7

basics of filtration 2 when talking of filtration in modern vehicles the main focus lies on depth filters these special filter elements are used if particles are to be removed from liquids oil and fuel or gases air at 100 the separation of particles is carried out in the depth structure of the medium on the surface of the individual fibres these impurities may include dust metal abrasion or soot particles resulting from an incomplete combustion process in addition to the solid particles the filters also have to remove water residues in the fuel pipes as well as oil drops which result from the blow-by-gas of the crankcase air vent ventilation/recirculation system 2.1 filtration effects a variety of different methods are used to separate dirt particles these effects will be explained in the following chapters they mainly depend on the size of the particle to be separated as well as on the properties of the liquid or gas containing them physical effects such as centrifugal or electrostatic forces also play a major role in the separation process in the following figures the filter medium is represented as an individual fibre perpendicular to the plane of the figure air oil and fuel move in a laminar flow around the fibre and are shown by simple path curves streamlines the barrier effect is the most important separation mechanism in the filtration of oil and fuel in air filtration the inertia and diffusion effects also play roles in addition to the barrier effect 2.2 inertia effect the inertia effect is based on the fact that dirt particles with a larger mass approaching the fibre leave their streamline path as a result of inertia and directly collide with the fibre stream lines dirt particle individual fiber axis perpendicular to the plane of the figure direction of flow stream lines inertia effect technical filter booklet 7

[close]

p. 8

2 basics of filtration 2.3 barrier effect in the barrier effect the particles can follow the streamline path due to their size but if they get too close to and come into contact with the fibre they adhere to it van-der-waals forces direction of flow stream lines smaller particle which can follow the stream lines individual fiber axis perpendicular to the plane of the figure stream lines barrier effect 2.4 diffusion effect the diffusion effect is used to filtrate very small dirt particles with a diameter of less than 0.5 µm they move on irregular paths brownian movement collide with a fibre more or less accidentally and adhere to it direction of flow stream lines individual fiber axis perpendicular to the plane of the figure stream lines diffusion effect 8 technical filter booklet

[close]

p. 9

dirt load and pressure difference 3 pressure difference p when using a new filter dirt particles first settle on the fibre surface with increasing contamination the thickness of this dirt layer increases and causes a decrease in the pore volume but with the pore volume decreasing and the flow remaining constant the pressure difference rises the course of the pressure difference p over the operating time or dirt load is shown in the diagram max pressure difference p latest time for filter replacement t1 operating time/dirt load pressure difference over time the rather slow increase in the pressure difference is a typical phenomenon with depth filters only when the pore volume of the filter is nearly exhausted does the pressure difference rapidly increase this is when the filter should be replaced the time t1 is specified in the data sheets by the car manufacturer smoke fog road dust pollen spores exhaust gases soot bacteria filters usually have to collect microscopic particles the following figure illustrates the different sizes of typical dirt particles which a filter has to deal with 0.01 µm 0.1 µm 1 µm 10 µm 100 µm dimensions of various particles in order to illustrate the dimensions of filtered particles even better dirt particles and pollens are shown in comparison with the cross-section of a human hair 1 2 3 4 5 6 7 human hair minimum human vision white blood corpuscle pollen dirt particle red blood corpuscle bacterium 70 µm 40 µm 25 µm 10 µm 7 µm 2 µm 1 2 5 3 4 6 7 proportions technical filter booklet 9

[close]

p. 10

4 the filter medium since paper is the number one filter medium in motor vehicle technology it will be examined more closely in the following chapter this brochure does not include a detailed description of filtration methods using fine-meshed sieves felt or fleece fabrics the types of timbers most often used to produce filter paper are oak maple and alder among the hardwoods spruce and ceder woods predominate in the range of softwoods depending on the application high quality filter paper differs in the composition of the fiber and pore structure as well as in its fineness the three most important filter media are cotton cellulose and plastic fibers 4.2 forming in order to accommodate a maximum filter surface in a cartridge the paper is formed during heat treatment in this operating procedure a certain pleat shape is forced onto the paper by making use of the paper`s thermoplastic behavior between 20 und 100 °c so that the pleat shape is preserved even during curing this pleat geometry makes it possible to obtain an effective filter surface area of approx 10 m² in a truck filter cartridge for example in order to prevent the pleats from sticking to each other in the engine environment pleat spacers are formed into the paper another possibility consists in giving each pleat a corrugation thus preventing the paper from bridging 4.1 requirements on the filter paper the requirements on the filter medium are · a high pulsation stability at any dynamic load · insensitiveness to water e g in case of heavy rain or spray engine oils crankcase gases and fuel vapors · a high thermal stability since the filter element may be exposed to temperatures of up to 80 °c during operation in order to counteract these mechanical climatic and thermal loads the filter papers are impregnated the paper is soaked in modern synthetic resins and then subjected to a heat treatment during this process the pore volume pore size and fiber structure of the original material must remain unchanged pleat geometry 10 technical filter booklet

[close]

p. 11

the filter medium 4 4.3 quality testing of filter papers the filter paper is subjected to rigid quality controls one of the most important test procedures is the so-called bubble test putting it simply this test consists of soaking the test paper with a precisely defined liquid and subjecting it to different test pressures exact documentation of the test conditions is very important the first air bubble can mathematically be assigned to the largest pore when the test piece is completely covered with air bubbles this indicates the average distribution of pore sizes the reason large pores require low pressure loads small pores require high pressure loads this method is also used to determine the pressure difference the test is relatively simple to execute but its results are still very exact it has to be kept in mind however that the test only provides comparative values with other papers in addition separation tests with test particles are carried out direct method according to din iso 5011 the following figure shows the test set-up for the determination of the degree of separation and the dust capacity of filter elements 1 air flow 2 1 2 3 4 5 6 7 8 9 10 inlet pipe dust injector casing for dust addition outlet pipe pressure meter absolute filter volume flow meter volume flow control device suction blower filter 3 5 10 6 7 8 9 4 air flow test set-up to determine the separation degree technical filter booklet 11

[close]

p. 12

5 air filters when talking about air filters inlet filters in today`s engine technology the main focus lies on the so-called dry filters the generic term for a variety of exchangable paper filters dry filters are based on the opposite operating principle than wet or oil bath filters where liquids are used to separate dust particles from the inlet air the paper filter has gained acceptance mainly because it can ensure higher and above all stable separation degrees for all load ranges additional advantages are the easy maintenance and the independence of the installation position from the environmental standpoint too the paper filter is increasingly gaining acceptance this amount of dust together with the lubricant can form an abrasive mass which inevitably leads to a considerable wear of the pistons piston rings and cylinder barrels 5.2 consequential damage a failure to replace air filters in time leads to a richer fuel-air mixture and thus to a higher emission of pollutants as well as a lower engine performance fine dust particles that pass the filter paper contribute to siltation in the engine and may deposit on the air mass sensor this component is installed on the cleanair side of the inlet filter and is responsible for proportioning the amount of fuel increasing fuel consumption if dirt particles get into the inside of the combustion chamber the life-time of the engine is reduced since the plain bearings pistons piston rings and cylinder barrels wear out due to the increased abrasive effect 5.1 task function it is the general task of air filters to purify the inlet air and to muffle the inlet noise of the engine another function especially in passenger cars ­ consists in pre-heating the inlet air and controlling the temperature this regulation is essential for the operating behavior of the engine and the composition of exhaust gases a short numerical example will illustrate the capacity and importance of the filter element depending on the landscape weather conditions soil and road properties and the use of the vehicle the amount of dust per m³ of air may range from 1 to 10 mg on unpaved roads or on construction sites it may even reach 40 mg assuming that a supply of approximately 14 kg of air is necessary for the complete combustion of one liter of fuel spark ignition engine one gets an idea of how many dust particles have to be filtered out the dirt film which has settled on the filter during a mileage of 15,000 km is clearly visible minute dirt particles settle in the depth structure of the filter paper consequences richer fuel-air mixture elevated pollutant emission lower engine performance 12 technical filter booklet

[close]

p. 13

air filters 5 5.3 passenger car air filter design air filters for passenger cars come in two different designs as panel filters and as round filters round and oval elements the type of filter which is suitable for any specific case mainly depends on the application of the basic rules of filter technology for their position in the vehicle the spot with the lowest possible dust or water supply is chosen the filter elements have a high separation degree which is independent of the load their replacement is simple and is determined by the maintenance dates specified by the vehicle manufacturer there is a wide range of engines on the market and each vehicle requires filters which exactly fulfill the requirements of the engine and installation space ks offers air filters with suitable designs for virtually any vehicle filter casings and filter elements are optimally matched and adjusted to the engine type and its inlet system a special design for a panel filter is shown in the picture below in addition to the filter paper the filter is protected by a fleece for rough filtration this design is predominantly used in areas with a heavy dust load ap air filter panel ap air filter circular ap air filter circular for trucks air filter panel with protective fleece 5.3.1 commercial vehicle air filter design due to the higher flow rate and less critical sealing of the filter casing periphery cylindrical round filters with a steel or plastic mesh are predominantly used in commercial vehicles these filters are divided into single-stage and two-stage air filters in contrast to single-stage filters two-stage filters are equipped with a cyclone-type cleaner as a pre-separator the cyclone cleaner takes advantage of the effects of centrifugal forces the air stream is set into rotation by a specifically designed rotor disk with so-called baffles due to the centrifugal forces the dirt particles are precipitated towards the wall of the casing from there they are either routed to the outside or are collected in a collector tank depending on the design of the filter this pre-separator helps to prolong the service life both filter types are usually integrated in one casing the two-stage filter is mainly used in construction and agricultural machines technical filter booklet 13

[close]

p. 14

5 air filters especially in construction machines some filters are equipped with an additional secondary element safety element it is used to protect the engine when the main element is damaged or being serviced the secondary element may not be inserted without the main filter and should be exchanged with every third replacement of the the main element in commercial vehicles the air intake is often located above or beside the driver`s cabin this helps keeping the amount of dust in the intake air as low as possible and thus extends the maintenance intervals in modern trucks the filter casings are frequently designed larger than necessary for filtration this measure helps reduce the intake noise considerably since these filters combine the tasks of filtration and suppression of noise they are called silenced filters a two-stage air filter for a commercial vehicle is shown in the following figure it consists of a deflector baffle 1 t he main filter element 2 and a safety element 3 the intake air enters the filter through the outer shell and the purified air leaves it through the interior 1 3 2 multi-stage commercial vehicle air filter 5.4 mounting instructions for filter replacement please keep in mind the following advice when replacing an air filter · never exchange the air filter with the engine running · make sure that no dirt particles get into the air ducts when removing the old filter p bar · do not try to clean the old filter by using compressed air · choose the right filter serious damages may otherwise occur on the engine due to different sealing and permeation properties · follow the instructions given by the manufacturer when installing the new filter · bevor installation clean the cover and casing of the new filter using a clean and soft cloth do not use a brush or other instruments that might whirl up dirt particles · examine all gaskets for damages even small cracks or deformations can lead to considerable contamination if in doubt replace the gaskets · place the filter element in the center of the system · when mounting the cover make sure that there is no gap between the cover and the casing because unfiltered air may otherwise enter the combustion chambers max differential pressure p important note in case of frequent rides on very dusty roads the air filter cartridge must be exchanged more often than prescribed under normal circumstances multi-stage filter single-stage filter time different service lives 14 technical filter booklet

[close]

p. 15

air filters 5 5.5 handling mistakes the filter may not be cleaned by using compressed air under any circumstances this would press the microscopic dirt particles even further into the depth structure of the filter paper resulting in an even lower flow rate in addition the filter paper may tear due to the high air pressure when handling the filter also pay attention that a the paper pack and b the sealing area are not destroyed for this reason the filter should not be beaten in case of insufficient sealing or cracks in the filter paper foreign matter will enter the inside of the engine and may cause serious damages spoiled or deformed filters see pictures may not be fitted under any circumstances technical filter booklet 15

[close]