HEAVY MOTOR VEHICLE
AIR FILTER
Maintenance Practices
For trucks , Heavy & Construction equipment's
Developed by Nanda Kumar
Technical Trainer
Reference & Courtesy - Donaldson filtration Solutions
Air filter for trucks and Construction Equipment's
A particulate air filter is a device composed of fibrous or porous materials
which removes solid particulates such as dust, pollen, mold
and bacteria from the air. Filters containing an adsorbent or catalyst such
as charcoal (carbon) may also remove odors and gaseous pollutants such
as volatile organic compounds or ozone. Air filters are used in applications
where air quality is important, notably in building ventilation systems and in
engines.
Air Cleaner Evolution
Air Filter Service — Best Practices Tips and Maintenance Practices for Equipment Longevity!
Don’t remove an air filter from its housing simply to inspect it.
• Removing and replacing the same filter can
do more harm than good.
• Ridges of dirt on the gasket sealing surface
can drop on the clean filter side when the
gasket is released.
Follow the Air filter Clogged warning light in
dash board.
Clean or replace filter
Restriction measurement or Regular Maintenance
Ideally, service your air filter by restriction measurement or follow your regular
maintenance schedule.
• If you don’t trust your current
filter service indicator, getting a
new one is a good idea.
• Restriction indicators, mounted
on the air cleaner system are
recommended for keeping an eye
on restriction levels and
indicating when servicing is due.
• For testing of initial restriction
and confirming remaining filter
life, we recommend the greater
accuracy of a clock-type
restriction gauge or water
manometer.
Never hit a filter to try cleaning it.
• Rapping hard enough to
knock off dust damages the
filter and can place your
engine at risk for dust
ingestion.
• Deeply embedded dirt is
never released by tapping.
• It is always safer to keep
operating until you can
change to a new filter than
to try and tap out the dirt.
Do not clean a primary or safety filter instead of replacing it.
• Heavy-duty air filtration manufacturers do not
recommend any type of cleaning process to be
used on their products.
• Once an air filter has been cleaned or washed,
the Donaldson filter warranty is no longer valid.
• The dirt holding capacity of a filter is reduced
20 – 40% with each cleaning attempt.
• There is also the real risk of dirt reaching the
clean side of the filter if cleaning is attempted.
• The risk of filter damage from washing, tapping,
high pressure water, or compressed air cleaning
is very real.
• The potential savings from risky attempts at
filter cleaning won’t come close to offsetting
potential damage to engine components.
• Increased engine wear and damage is the result
of the ingression of contaminant over time.
Check any intake hoods and pre cleaner devices during maintenance routines.
• A missing inlet hood will
significantly shorten filter
life. If your unit had a
hood or pre-cleaner
originally, make sure you
replace it.
• Check openings and
tubes on pre-cleaners to
make sure they are not
plugged .
• Replace any units that
are damaged. Damaged
or dented units will not
operate properly.
Never leave an air cleaner open longer than necessary.
An open air cleaner with filter removed is a direct entry to the engine.
• Keep your engine protected
during filter changes.
• Contaminants that are smaller
than the eye can see can be
damaging to an engine.
• If the air cleaner housing is not
going to be reassembled
immediately, be sure to cover
the opening.
During filter change-Out
Check to ensure
that there is no
damage to the air
cleaner housing
itself.
Damaged filter
Don’t use a
dented
or
damaged
filter
Check for any air leaks in the ducting on both sides of the air cleaner.
An air leak
between the air
cleaner and the
engine gives dirt
a direct path
into the engine.
Do not judge the filter’s remaining life by looking at it.
A dirty-looking filter may still have plenty of life left.
• On the other hand, a clean-looking filter
can also be deceiving. You can’t see the
dirt that’s embedded deep within the
filter media, and carbon contamination
may not be visible to the eye.
• One of the best options for lowest filter
maintenance costs and best engine
protection is to monitor air filter life with
a restriction indicator.
• It’s a low-cost and smart investment.
• the filter shown looks ready for
replacement, but had not reached its
final servicing point.
Never Substitute filters
Never substitute
one filter with
another one that
has a different
model number.
DUPLICATE ORGINAL
Don’t ignore a worn or damaged gasket.
If your air cleaner has
a cover gasket, replace
it with a new one
when changing filters.
Avoid cross contamination during filter service.
• When a dirty filter is at its service point
— the inlet side of the filter is loaded
with contaminant — take these
precautions to eliminate contaminant
from getting on the outlet side of your
new filter or clean sealing surfaces
(gaskets or end caps).
• If you wear gloves during service,
remove them prior to handling the
new filter.
• If you don’t use gloves, wash or clean
your hands before handling the new
filter.
• Keep your new filter in its box until
The clean side of your air filter can vary
your ready to replace.
depending on the application. Some filters • If product box has layers of
load on the outer surface (shown above — contaminant, take care that the
referred to as standard flow), and some load
contaminant doesn’t get on the new
on the inside surfaces of the filter (referred to
as reverse flow) filter as you remove it from the box.
Installing filters
• No cover pressure is required
to hold the seal in place and
one should NEVER use the
service cover to apply
pressure.
• Forcing a cover could damage
the housing, filter and
fasteners and void the
warranty.
• If the service cover presses
against the filter before the
cover is fully in place, remove
the cover, push the filter
further into the air cleaner by
hand and then the cover will
go on with no extra force.
Filter service & maintenance records
• Vehicle and engine manufacturers
provide filter maintenance practices for
the equipment they sell. Make sure to
follow their recommendations for
routine filter service. Being able to
show/reveal your maintenance records
for potential warranty claims is essential.
• Like all components, air intake systems
have evolved and older styles and filters
have different maintenance procedures.
Make sure your maintenance personnel
are familiar with the proper service
techniques.
• Log or track your filter changes.
Whether your are going to service by
miles, hours or restriction.
• Many maintenance shops find it
helpful to record the date of filter
change directly on the filter.
Inspect the entire air induction system
• The last step to any air filter service, is to
inspect and tighten all air cleaner system
connections.
• Immediately replace or repair any visible
holes or damaged components.
• Inspect all air ducting for worn spots or
damage — elbows, connections and
seals.
• Check all clamps, making sure they’re
secure and tight.
• Inspect your pre-cleaners or inlet hoods
(if equipped).
• Annual replacement of air cleaner system
gaskets is recommended.
• Reset manual filter indicators.
• Record action items taken in your filter
service records.
VOLVO Filters old & New Types
• Volvo trucks old type filters
maximum life 6 times of air blow
cleaning with 1 to 1.5 bar air
pressure .(Note : Each air cleaning the micron rated pores of the filter open up to a bigger size
leading contamination into the system is the need for replacement after 6 cleaning intervals)
• Volvo trucks new type filter
maximum life 24 months,
• do not clean by air blowing.
• Clean only by surface tapping to a
wooden flat surface .
The most accurate method to verify airflow restriction.
• Replace the filter only when the
restriction level has reached the
maximum LIFE TIME OR LIMIT
recommended by the engine or
equipment manufacturer.
• Restriction indicators & warning
signs that are mounted on the air
Air filter Clogged warning light cleaner system & dash board are
in dash board.
recommended for keeping an eye
on restriction levels and indicating
when servicing is due.
Air filter Cleaning only when the clog indicator indicates
AIR FILTER CHANGE INDICATORS
• Knowing when to change the air filter of your machine is
very critical.
• Replacing air filters too soon, increases maintenance
cost. While replacing an air filter too late, reduces airflow
and engine performance.
• Visual Inspection of an air filter is not a satisfactory way
of determining when a filter needs replacing.
• An air filter change indicator is the most reliable way to
determine when an air filter needs replacing.
• OEM recommended change point for air filter cleaning is
(20-30" H2O or 4.9 – 7.4 kPa filter restriction).
Advantages of Air Filters Indicators:
1. Maximize filter life.
2. Reduce maintenance cost by avoiding unnecessary filter
changes.
3. Helps in managing maintenance intervals by Indicating
the remaining life of the filter.
4. Improve engine performance by indicating when a filter
change is required.
Air filter Cleaning
Inner Filter or Secondary air filter Outer Filter or Primary air filter
• Clean filter using “Air under pressure” dry air is used on a dry air filter.
• The pressure should not exceed 40PSI (276kPa) at a distance of not closer than 50 mm
(2 inches).
• Direct the compressed air through the primary filter from the clean side, running the
nozzle up and down the filter pleats the dust particles outside.
• Secondary air filters should never be cleaned since the secondary filter is the last
barrier to contaminant before it reaches your engine/equipment. The useful life of a
secondary air filter is equivalent to three changes of the primary air filter or one year of
continuous service, whichever occurs first.
Rubber Vacuator Valves
Don’t take chances with Rubber Vacuator Valves
which can admit dirt instead of expelling it.
• Replace any missing or damaged Vacuator Valves and any air cleaner fasteners.
• Make sure the valve is flexible and not inverted, damaged or plugged. Replace it if
damaged or if it looks like any of these images. A damaged or missing Vacuator Valve will
disrupt the designed flow of air through the air cleaner
Thank you
