MAHLE Pi 2105-057 User manual

Duplex Filter
Pi 210
Nominal pressure 25/63 bar (360/900 psi), nominal size up to 450
1. Features
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High performance filters for modern hydraulic systems
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■Modular system
■Compact design
■Minimal pressure drop through optimal flow design
■Visual/electrical/electronic maintenance indicator
■Threaded connections
■Change over valve on upstream side
■Ergonomic switch-over handle with safety lock and pressure
compensation
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■User-optimized one-hand-operation
■Equipped with highly efficient glass fibre Sm-x filter elements
■Beta rated elements according to ISO 16889 mulipass test
■Elements with high differential pressure stability and dirt holding
capacity
■NPT- and SAE-connections on request
■Worldwide distribution

Duplex Filter Pi 210 up to NG 450 2
2. Flow rate/pressure drop curve complete filter
.
y = differential pressure ∆p [bar]
x = flow rate V [l/min]

Duplex Filter Pi 210 up to NG 450 3
3. Separation grade characteristics
y = beta-value
x = particle size [µm]
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determined by multipass tests (ISO 16889)
calibration according to ISO 11171 (NIST)
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4. Filter performance data
tested according to ISO 16889 (multipass test)
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Sm-x elements with
max. ∆p 20 bar
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Sm-x vst elements with
max. ∆p 210 bar
Sm-x 3 β5(C) ≥200 Sm-x 3 β5(C) ≥200
Sm-x 6 β7(C) ≥200 Sm-x 6 β7(C) ≥200
Sm-x 10 β10(C) ≥200 Sm-x 10 β10(C) ≥200
Sm-x 25 β20(C) ≥200
Sm-x 25 β20(C) ≥200
values guaranteed up to
10 bar differential pressure values guaranteed up to 20 bar differential pressure
5. Quality assurance
MAHLE filters and filter elements are produced according to the following international standards:
Norm Designation
DIN ISO 2941 Hydraulic fluid power filter elements; verification of collapse/burst resistance
DIN ISO 2942 Hydraulic fluid power filter elements; verification of fabrication integrity
DIN ISO 2943 Hydraulic fluid power filter elements; verification of material compatibility with fluids
DIN ISO 3723 Hydraulic fluid power filter elements; method for end load test
DIN ISO 3724 Hydraulic fluid power filter elements; verification of flow fatigue characteristics
ISO 3968 Hydraulic fluid power filters; evaluation of pressure drop versus flow characteristics
ISO 10771.1 Fatigue pressure testing of metal containing envelopes in hydraulic fluid applications
ISO 16889 Hydraulic fluid power filters; multipass method for evaluation filtration performance of a filter element
6. Symbols

Duplex Filter Pi 210 up to NG 450 4
7. Order numbers
Example for ordering filters:
1. Housing design 2. Filter element
V=80 l/min, electrical indicator
Type: Pi 2108-069
Order number: 77810286
Sm-x vst 3
Type: Pi 2208 Sm-x vst 3
Order number: 77680200
7.1 Housing design
Nominal size
NG [l/min] Order number Type
with bypass
valve and
visual indicator
with bypass
valve and
electrical
indicator
with
visual
indicator
with
electrical
indicator
77810211 Pi 2105-057
77810229 Pi 2105-058
77810237 Pi 2105-068
50
77810245 Pi 2105-069
77810252 Pi 2108-057
77810260 Pi 2108-058
77810278 Pi 2108-068
80
77810286 Pi 2108-069
78204083 Pi 2111-057
78204091 Pi 2111-058
78204109 Pi 2111-068
110
78204117 Pi 2111-069
77774573 Pi 2115-057
77774565 Pi 2115-058
77774557 Pi 2115-068
150
77774540 Pi 2115-069
77774532 Pi 2130-057
77774524 Pi 2130-058
77774516 Pi 2130-068
300
77774508 Pi 2130-069
77774490 Pi 2145-057
77774482 Pi 2145-058
77774474 Pi 2145-068
450
77774466 Pi 2145-069
When filter with non bypass configuration is selected, the collapse pressure of the element must not be exceeded.

Duplex Filter Pi 210 up to NG 450 5
7.2 Filter elements (a wider range of element types is available on request)
Nominal size
NG [l/min] Order number Type Filter material max. ∆p [bar] Filter surface [cm²]
77680135 Pi 2105 Sm-x 3 Sm-x 3 590
77943509 Pi 5105 Sm-x 6 Sm-x 6 590
77680325 Pi 3105 Sm-x 10 Sm-x 10 590
77680440 Pi 4105 Sm-x 25 Sm-x 25
20
590
77680192 Pi 2205 Sm-x vst 3 Sm-x vst 3 425
77943533 Pi 5205 Sm-x vst 6 Sm-x vst 6 425
77680382 Pi 3205 Sm-x vst 10 Sm-x vst 10 425
50
77680507 Pi 4205 Sm-x vst 25 Sm-x vst 25
210
425
77680143 Pi 2108 Sm-x 3 Sm-x 3 1150
77943517 Pi 5108 Sm-x 6 Sm-x 6 1150
77680341 Pi 3108 Sm-x 10 Sm-x 10 1150
77680457 Pi 4108 Sm-x 25 Sm-x 25
20
1150
77680200 Pi 2208 Sm-x vst 3 Sm-x vst 3 850
77943541 Pi 5208 Sm-x vst 6 Sm-x vst 6 850
77681190 Pi 3208 Sm-x vst 10 Sm-x vst 10 850
80
77680515 Pi 4208 Sm-x vst 25 Sm-x vst 25
210
850
77680150 Pi 2111 Sm-x 3 Sm-x 3 1700
77943525 Pi 5111 Sm-x 6 Sm-x 6 1700
77680333 Pi 3111 Sm-x 10 Sm-x 10 1700
77680456 Pi 4111 Sm-x 25 Sm-x 25
20
1700
77680218 Pi 2211 Sm-x vst 3 Sm-x vst 3 1275
77943558 Pi 5211 Sm-x vst 6 Sm-x vst 6 1275
77680390 Pi 3211 Sm-x vst 10 Sm-x vst 10 1275
110
77680523 Pi 4211 Sm-x vst 25 Sm-x vst 25
210
1275
77680168 Pi 2115 Sm-x 3 Sm-x 3 2425
77955099 Pi 5115 Sm-x 6 Sm-x 6 2425
77680358 Pi 3115 Sm-x 10 Sm-x 10 2425
77680473 Pi 4115 Sm-x 25 Sm-x 25
20
2425
77680226 Pi 2215 Sm-x vst 3 Sm-x vst 3 2010
77955123 Pi 5215 Sm-x vst 6 Sm-x vst 6 2010
77680408 Pi 3215 Sm-x vst 10 Sm-x vst 10 2010
150
77680531 Pi 4215 Sm-x vst 25 Sm-x vst 25
210
2010
77680176 Pi 2130 Sm-x 3 Sm-x 3 4620
77955107 Pi 5130 Sm-x 6 Sm-x 6 4620
77680366 Pi 3130 Sm-x 10 Sm-x 10 4620
77680481 Pi 4130 Sm-x 25 Sm-x 25
20
4620
77680234 Pi 2230 Sm-x vst 3 Sm-x vst 3 3800
77955131 Pi 5230 Sm-x vst 6 Sm-x vst 6 3800
77680416 Pi 3230 Sm-x vst 10 Sm-x vst 10 3800
300
77680549 Pi 4230 Sm-x vst 25 Sm-x vst 25
210
3800
77680184 Pi 2145 Sm-x 3 Sm-x 3 6865
77955115 Pi 5145 Sm-x 6 Sm-x 6 6865
77680374 Pi 3145 Sm-x 10 Sm-x 10 6865
77680499 Pi 4145 Sm-x 25 Sm-x 25
20
6865
77680242 Pi 2245 Sm-x vst 3 Sm-x vst 3 5600
77955149 Pi 5245 Sm-x vst 6 Sm-x vst 6 5600
77680424 Pi 3245 Sm-x vst 10 Sm-x vst 10 5600
450
77680556 Pi 4245 Sm-x vst 25 Sm-x vst 25
210
5600

Duplex Filter Pi 210 up to NG 450 6
8. Technical specifications
Design: line mounting filter
Nominal pressure: Pi 2115 - Pi 2145 25 bar (360 psi)
Pi 2105 - Pi 2111 63 bar (900 psi)
Test pressure: Pi 2115 - Pi 2145 33 bar (470 psi)
Pi 2105 - Pi 2111 82 bar (1170 psi)
Temperature range: -10 °C to +120 °C
(other temperature ranges on request)
Bypass setting: ∆p 3.5 bar ±10 %
Filter head material: GAL
Filter housing material: AL/St
Sealing material: NBR/AL
Maintenance indicator setting: ∆p 2.2 bar ±10 %
Electrical data of maintenance indicator:
Maximum voltage: 250 V AC/200 V DC
Maximum current: 1 A
Contact load: 70 W
Type of protection: IP 65 in inserted
and secured status
Contact: normally open/closed
Cable sleave: M20x1.5
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The switching function can be changed by turning the electric upper
part by 180° (normally closed contact or normally open contact). The
state on delivery is a normally closed contact. By inductivity in the
direct current circuit the use of suitable protection circuit should be
considered. Further maintenance indicator details and designs are
available in the maintenance indicator data sheet.
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We draw attention to the fact that all values indicated are avera-
ge values which do not always occur in specific cases of applicati-
on. Our products are continually being further developed. Values,
dimensions and weights can change as a result of this. Our specia-
lized department will be pleased to offer you advice.
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We recommend you to contact us concerning applications of our fil-
ters in areas governed by the EU Directive 94/9 EC (ATEX 95). The
standard version can be used for liquids based on mineral oil (cor-
responding to the fluids in Group 2 of Directive 97/23 EC Article 9).
If you consider to use other fluids please contact us for additional
support.
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Subject to technical alteration without prior notice.
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9. Dimensions
All dimensions except “C” in mm.
Type A B C* D E F G SW H I K L M N O P R Weight [kg]
Pi 2105 78 38 G1 200 258 80 27 66 139 168 M8x16 52 81 85 100 16 2.6
Pi 2108 78 38 G1 276 334 80 27 66 139 168 M8x16 52 81 85 100 16 2.9
Pi 2111 78 38 G1 358 416 80 27 66 139 168 M8x16 52 81 85 100 16 2.6
Pi 2115 78 40 G1½ 269 327 110 32 109 165 280 M10x20 62 140 140 210 19 7.1
Pi 2130 78 40 G1½ 386 444 110 32 109 165 280 M10x20 62 140 140 210 19 8.0
Pi 2145 78 40 G1½ 501 559 110 24 109 165 280 M10x20 62 140 140 210 19 16.0
*SAE flange connections (3000 PSI) on request

Duplex Filter Pi 210 up to NG 450 7
10. Installation, operating and maintenance instructions
10.1 Filter installation
When installing the filter make sure that sufficient space is availa-
ble to remove filter element and filter housing. Preferably the filter
should be installed with the filter housing pointing downwards. The
maintenance indicator must be visible.
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10.2 Connecting the electrical maintenance indicator
The electrical indicator is connected via a 2-pole appliance plug ac-
cording to DlN EN 175301-803 with poles marked 1 and 2.
The electrical section can be inverted to change from normally open
position to normally closed position or vice versa.
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10.3 When should the filter element be replaced?
1 . Filters equipped with visual and electrical maintenance indica-
tor:
During cold starts, the indicator may give a warning signal.
Press the red button of the visual indicator once again only af-
ter operating temperature has been reached. lf the red button
immediately pops up again and/or the electrical signal has not
switched off after reaching operating temperature, the filter ele-
ment must be replaced after the end of the shift.
2 . Please always ensure that you have original MAHLE spare ele-
mentsinstock:Disposableelements(Sm-x)cannotbecleaned.
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10.4 Element replacement
Note: Themaintenanceindicatormonitorsthefiltersideinoperation,
which is identified by the position of the switching lever catch. The
flow transfer valve must be switched prior to filter servicing. Now the
signal of the maintenance indicator is cancelled and the red button
can be depressed again.
1 . Operate and hold pressure equalizing lever located in the swit-
ching lever. Swivel switching lever. Engage the catch. Place
through or drip pan underneath to collect leaking oil.
2 . Loosen vent screw of the filter side not in use by 2-3 turns; ma-
ximum back out against safety stop.
3 . Unscrew filter bowl by rotating same counter clockwise and
clean with a suitable medium.
4 . Remove filter element with a side-to-side motion.
5 . Check o-ring on the filter housing and the spigot for damage.
Replace, if necessary.
6 . Make sure that the order number on the spare element corre-
spondstotheordernumberofthe filter name-plate.Removethe
plastic bag and push element over the spigot in the filter head.
7 . Completeinstallationby screwing on the housing,turning clock-
wise until it comes to a full stop. Back off the housing 1/8 to 1/2
turn.
8 . To refill the filter chamber, operate only the pressure equalizing
lever long enough for the medium to emerge bubblefree from
the vent bore. Tighten vent screw. Check filter for leaks by ope-
rating the pressure equalizing lever once again.
11. Spare parts list
Order number for spare parts
Position Type Order number
Seal kit for housing
Pi 2105 - Pi 2111
NBR 79761271
FPM 79761289
EPDM 79761297
Pi 2115 - Pi 2145
NBR 79761230
FPM 79761248
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EPDM 79761255
Seal kit for maintenance indicator
NBR 77760309
FPM 77760317
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EPDM 77760325
Maintenance indicator
Visual PiS 3098/2.2 77669971
Electrical PiS 3097/2.2 77669948
Electrical upper section only 77536550