Operations Manual for

FM71012

Unit # 2529

FINAL DRIVE
FILTRATION UNIT

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 TABLE OF CONTENTS
1 Introduction 2
2 Calculation of Filtration Time 3
3 Specifications 4
4 System features 5
5 Explanation of Features 7
6 Park Brake 9
7 Element oil loading process for new elements 10
8 Set Up Prior to Operation 11
9 Operation Instructions 12
10 Filter Housings 17
11 Live Oil Sample Point 17
12 Filter Element Life 18
13 Element Removal & Refitting Procedure 19
14 Element Change Procedure 21
15 System Parts 23
16 Filter Housing Parts 28
17 Electrical Schematic 29
18 Electrical Parts 30
19 Warning 33

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1. INTRODUCTION
This mobile filtration system designed to filter the existing oil in mechanical drive rear ends using
the “Kidney Loop Filtration” process:-

“Kidney Loop Filtration” – a filtration process where the oil is pumped from its compartment
and directed through the filter element housings and returned to the same compartment of
the machine. The oil continues to circulate through this path until cleaned to an acceptable
level.

The system is equipped with one Suction and two Return hoses.

As described in the following information, the Suction hose is connected to the Differential drain
port and the Return hoses are connected to each of the Final Drive Fill ports.

This system pumps oil from the differential, through the filters and returns back into both final
drives not only cleaning the oil but also flushing as much residual contamination as is possible
from within the components.

2. CALCULATION OF FILTRATION TIME

It is critical to allow adequate filtration time to complete as many cycles of the oil volume as
possible.

Industry “best practice” recommends filtering the oil volume by a minimum of seven times to
ensure one pass of the oil in the compartment.

Filter Technology recommend, where possible, to complete the equivalent of 2 to 3 complete

passes, that is 14 to 21 times the volume of the compartment.

For example, for a compartment capacity of 800 litres:-

800L x 7 cycles = 5600 litres for one pass.

5600 L divide by 32L/min flow rate = 175 min. filtration time

= 2.9 hours filtration time from one pass

= 5.8 hours for 2 complete passes
= 8.7 hours for 3 complete passes

NOTE: The above calculation is based on the oil to be filtered being held at the recommended
temperature of 65°C. Some additional time will be required at the start of the job to heat the oil
if it is not already hot from service.

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3. SPECIFICATIONS

Model FM71012

Filter Housings 10 off

Replacement Kit FM21400

Power Supply 415Volts 63Amp

Flow Rate 38 L/min @ 65°C.

Variable Speed Drive set to
System Pressure Control
maintain 3 Bar (43.5 PSI)
Relief Setting 5 Bar (72.5 PSI)

Hose Length - Suction 1 x 1” Dia x 32ft long (10.0m)

Hose Length – Return 2 x ¾” Dia. x 39ft long (12.0m)

Manifold Heater 4500W

Particle Counter No

Blocked Filter Indication Yes

Park Brake Equipped Yes

Tyres Solid Rubber

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 Electrical
4. SYSTEM FEATURES Enclosure and
Control Panel
Filter Housings

Isolation
Switch
Power Supply
Cable and Plug

Manifold
Drain Port Live Sample
Port

Heater
Suction Hose

Park Brake

Return Hose
Fork Tynes

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 SYSTEM FEATURES

Tool Box

Oil
Temperature
Probe

Drip Tray Drain

Hour Run Meter Element Change

Light

Start Switch
Emergency-Stop

Heater On / Off Heater

Isolation Switch
Switch Temperature

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5. EXPLANATION OF FEATURES
System Control
When in operation, the system is managed by a Variable Drive Control System which monitors
element housing pressure and controls the pump speed to maintain element housing oil
pressure at the optimum value. This enhances oil flow whilst protecting the condition of the filter
elements.

During operation, it will be noticed that while the oil is cold, the pump speed will be noticeably
slow. As the oil circulates and heats to become more viscous, the pump speed is increased to
maintain optimum housing pressure and therefore oil flow.

In order to maximise filtration flow rate within the available service window, it is advantageous
to begin filtration as early as possible after the truck leaves service in order to prevent the oil
cooling too much.

Isolation Switch
An Isolation Switch is located to the bottom right hand corner of the Control Panel.

START and EMERGENCY STOP Switches

These switches are provided for the routine starting and stopping of the system.

Heater Operation
The system is equipped with a 4500W heater built into the inlet manifold located under the
filters.

The Heater is automatically controlled by the Temperature Controller:-

o Upper Display – Existing oil temperature (measured at the element housing outlet).
o Lower Display – Pre-set to 65°C at which the heater will switch off.

This display will illuminate immediately on supply of power.

The oil temperature is measured on the outlet of the filter Element Housing outlet.

To protect against heating without oil flow, the heater will not operate unless the housing
pressure reaches a minimum value.

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An ON / OFF switch is provided. In the ON position, the switch itself will illuminate when the
Temperature Controller switches the heater ON. In the OFF position, the heater will not operate.
Hour Run Meter
The hour run meter indicates the total hours of operation to date.

Element Change Light

The Element Change Light will illuminate to indicate that the filter elements require change-out.
For further information, see Section 11. Filter Element Life.

Pressure Gauge
The pressure gauge provides the operator a visual display oil pressure in the filter element
housings.

Pressure Gauge

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6. PARK BRAKE SYSTEM

Push Tee Handle

back in direction
indicated.

Insert Lock Pin to

secure brake in the Set adjusting screw to apply
“On” position. the required pressure on tyre
when adjusting the brake.

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7. Oil Loading Process for New Elements

When the FM71012 is first delivered or during a usual service of the filtration unit there is a
procedure for the loading of the elements with oil to make the unit operational. If this procedure
is not followed the unit will consume an amount of oil that may deplete the volume of the
compartment to unsafe levels.

Once the filtration unit has been delivered or serviced the process to replenish the new elements
is as follows –
• The unit should be placed adjacent to the new oil drum or tote.
• Attach the unit to a power supply
• Place the unit into the kidney loop mode (if applicable)
• Use a suction device to evacuate the oil from the drum or tote
• Recirculate the oil through the unit back into the drum or tote
• The unit should be run until pressure of at least 3 bar has been reached this will ensure
that the unit has been purged of air and all the elements have been completely encased in
oil.
• Once these conditions have been achieved the suction hose should be removed from the
drum or tote and then the unit should be allowed to suck air to pump back as much oil as
possible to meet conditions that are usually meet in normal operation.
• After the unit has pumped as much oil out of its system that is practical it should be
stopped isolated and the hoses recoiled back onto the unit ready for general operation.

After all operations wheel

motor oil compartment levels
should be checked before the
truck is put back into service.

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8. SETUP PRIOR TO OPERATION
NOTE: Before opening the compartments to the atmosphere, thoroughly clean around all drain
and fill points and breather locations to prevent the ingress of dirt or dust whilst connecting
the system to the truck.

Before parking the truck in position in the workshop, position the final drives such that the Fill
ports are above the oil level of the compartment.

Install quick release couplings into the final drive Fill ports.

Move the truck into position in the workshop.

Wheel the system into position behind the truck to be filtered and lock the park brake to prevent
the unit rolling away.

Connect the Return hoses to the final drive Fill port couplings previously fitted to each final drive.

Connect the Suction hose to the drain port of the differential housing. This can be made easier
with the use of a transducer fitted to the breather while the differential drain plug is removed
and a quick release coupling or other adaptor is fitted to the drain port.

Ensure that the system isolation switch is in the OFF position.

Connect the power supply lead and switch ON the power supply to the system.

The system is now ready to begin filtration.

Hub Return Point

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9. OPERATION INSTRUCTIONS
1. Wheel unit into position near the Final drive to be filtered

2. Once the unit is in position lock the brake handle so the machine is secure and in no danger of
moving during the operation.
See Park Brake in Section 6

Push the tow handle

up and lock it into
position using the pin
supplied.

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3a. Plug the suction hose into the nominated take off point. This can be the drain plug using a
transducer on the breather while you remove the drain plug and screw in the quick release
couplings or an adaptor made up to go into the fill level plate in the back of the diff housing.

Suction Hose
Coupling in
the Drain

3b. Using a drop tube into the differential through a modified inspection plate

Pickup through a
modified inspection
plate

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4. Plug both return hoses into the final drive on either side of the machine.

Plug the return hoses

into the final drives on
the right and left side
of the Haul Truck.

5. Unroll the power lead and plug it into a power source and turn it ON.

Plug the power lead into a power source.

6. Turn the isolation switch to the ON position
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 Turn Isolation switch
to the ON Position.

7. The unit is ready to start so release the Emergency Stop button and press the Green Start
button on the front of the Stainless Steel Box

To Start, release
the Stop button
and press the Start
button.
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8. The machine is fitted with a pressure driven variable drive which is set at 50 PSI. As the oil heats
up the pump speed will increase. Maximum flow rate of unit is 32LPM.

Variable Drive is
driven of pressure
automatically.

9. The system has a heater built into the bottom manifold under the filters and is also
automatically controlled, the max temperature is set at 65°C. The temperature of the oil is
controlled by the temperature controller unit.
Temperature
Controller unit

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10. Allow the unit to run for the time period available. See Section 2. Calculation of Filtration
Time for recommended filtration times.

When finished, depress the red stop button to stop the system. Follow Set-up steps in reverse
order to disconnect the system.

Check oil levels and ensure all drain and fill port plugs are correctly tensioned prior to returning
unit to service.

10. FILTER HOUSINGS

The system is equipped with ten filter housings, each containing four filter elements.

See Section 13. Element Change Procedure for details on changing used elements.

11. LIVE OIL SAMPLE POINT

One live oil sample point is provided on the pump outlet, before the filters – this location
provides a representative sample of the oil condition in the compartment.

NOTE: As a matter of good practice, when taking any live oil sample, always drain off at least
200ml of oil to flush the sample valve and remove and “dead zone” oil from behind the sample
valve.

Live Oil Sample point –

located below the electrical
enclosure.
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12. FILTER ELEMENT LIFE
The elements should be changed when:-

o The pressure on the gauge rises above 4.5 Bar / 65 PSI with the system at full operating
temperature of 65°C
o 500 hours is the recommended maximum element life.

Initially, depending on existing oil cleanliness levels, element life may be shorter as residual
contamination is removed from each compartment.

NOTES

1. The Orange Light on top of the electrical box is to indicate that the elements may require
changing. It will activate when the filter inlet pressure exceeds 5 bar
2. As cold oil (< 65°C) is difficult to pump through the filter elements, housing pressure will
increase to and remain above 5 bar until operational temperature is achieved.
3. The control system includes a timer which will allow enough time for the oil to reach
operational temperature before the light circuit is activated. This avoids a situation which
may otherwise falsely indicate that the filter elements have become blocked and require
change-out.

The elements must be changed if the Orange Light on top of the electrical box is illuminated.

When the elements become blocked with contamination, the oil does not return to tank
unfiltered. Rather, the housing pressure will increase until the 5 bar relief opens and oil travels
back to the inlet side of the pump.

Effectively, this means that the same quantity of oil simply circulates around through the pump.
As a result, oil flow through the elements is severely reduced and effective filtration results will
not be achieved.

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13. ELEMENT REMOVAL & REFITTING PROCEDURE

1. Using a clean rag or paper towel, clean away any dirt etc from around the lids of the filter
housings.

2. Rotate the housing lid “Tee” handle anti-clockwise until the thread can be felt to have
disengaged in the housing, see Fig 1.

3. Lift the filter assembly only slightly and reposition off-centre so that the centre tube is
not engaged in the housing, see Fig. 2. Do not remove element assembly from housing
at this stage.

4. Place a drain tray under the drain port, see Fig 4, or connect a waste evacuation hose to
the drain port. Allow housings to drain accordingly.

5. Repeat steps 1 to 3 at remaining housings so all can drain ASAP. This will be more
effective if the oil is warmer but is worth doing in any case.

6. With a spill container in position, withdraw the used element assemblies from the
housings and place them in the spill container to drain further.

7. Change elements on the assembly as per Section 13. Element Change Procedure

8. Insert the clean element assemblies into the housing slowly, being careful not to displace
any oil still in the housing causing spillage.

9. Locate the threaded end of the Return tube into the base of the element housing and
rotate clockwise to pull the lid into position. Note that there is a “lead” into the base to
make it easier to align and engage the thread, see Fig 3.

10. As the lid engages the housing, take care to ensure the lid seal aligns and enters the
housing correctly.

11. Continue to rotate the “Tee” handle until the lid has pulled up firm on the housing.

12. Rotate the “Tee” handle 180° to apply final tension to the lid seals.

13. Clean away any spillage.

14. Repeat process on other housings.

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Fig. 1 Element assembly
screwed into
housing base.

Oil in housing can

Fig. 2 now drain back to
reservoir.

Element assembly
unscrewed and
repositioned off-centre
as shown.

Fig. 3
“Lead” into
thread

Fig. 4

Housing Drain
Port

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14. ELEMENT CHANGE PROCEDURE

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Page 22 of 33
15. SYSTEM PARTS

Item FTA Part Number Technical Description Qty

1 FM3204 Filter Housing No 4 - Industrial 10

2 FM0063 Pressure Gauge ¼” BSP Bottom Entry c/w FTA logo 1
3 FM0064 Pressure Gauge Mounting Bracket x ¼ "BSP 1
4 FMP3010 Live Sample Point 1
5 FMM6012 Live Sample Dust Cover 1
6 FM0348 Relief Manifold 1
7 FM0339 Outlet Manifold 1
8 FM0368 Heated Inlet Manifold with Red Lid 1
9 FME1047 855 RPM Motor 1
10 FMP1102 44.3cc Pump 1
11 FME2016 4500 Watt 415 Volt Heater Element 1
12 FMM3007 Reel craft Hose Reel 10 metres 1” Hose 1
13 FMM1000 Fallshaw Wheels Solid Rubber 4
14 FMP5007 Quick Release Couplings 1'' Male 1
15 FMP5006 Quick Release Couplings 1'' Female 1
16 FMP3056 Check Valve 5 Bar x 1" 1
17 FME4005 Pressure Switch High 1
18 FME4004 Pressure Switch Low 1
19 FMM3003 Reel craft Hose Reel with 12 Metres ¾” Hose 2
20 FMP5005 Quick Release Coupling ¾“ Male Return Hose 2
21 FMP5004 Quick Release Couplings ¾”' Female Return Hose 2
22 FME2065 Temperature Sensor 1
23 FME4031 Pressure Sensor 1

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SYSTEM PARTS
2
1

13 19 19

12

20
21
20
14
21 15

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SYSTEM PARTS

4
6

11
8

22

16
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SYSTEM PARTS

10

10

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 23

18 17

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16. FILTER HOUSING PARTS

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17. ELECTRICAL SCHEMATIC

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18. ELECTRICAL PARTS

Item FTA Part Number Description Qty

1 FME3003 VVVF Drive – 1.1 kW 1

2 FME6200 24 Volt VDC Transformer 1
3 FME6292 Emergency Stop 1
4 FME6311 Circuit Breaker - 16AMP Heater 1
5 FME6310 Circuit Breaker – 10AMP Variable Drive 1
6 FME6300 Element Change Light Timer 1
7 FME6189 Wilco Industrial 4 Pin 63Amp Plug 1
8 FME6228 Heater Contactor 1
9 FME6264 Amber Light 24VDC 1
10 FME6289 Control Switch – Illuminated - Blue 1
11 FME6250 Hour Run Meter 1
12 FME4081 Temperature Controller - 24VDC 1
13 FME6284 Start Switch 1
14 FME6260 Isolation Switch 1
15 FME6275 Stainless Steel Box 1
16 FME6313 Circuit Breaker – 32AMP Main Breaker 1

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ELECTRICAL PARTS
2

4 5

16
14

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ELECTRICAL PARTS

11 9
13

15

14
12

10

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19. WARNING

This unit has a

variable drive. It
cannot be
insulation
resistance tested
by usual means.
Please contact Filter Technology Australia for
testing procedure.
Filter Technology Australia

Office: Tel: +61 2 4966 1833

44 Bonville Ave, Thornton NSW 2322 Fax: +61 2 4966 1933
Toll Free Australia: 1800 626 899
Postal:
PO Box 101, Thornton NSW 2322 Email: info@filtertechnology.com.au

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