Our innovative products are solving complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment. Donaldson has the technical expertise, superior customer support and vast network of locations around the world to meet your toughest filtration needs - from initial system design through replacement products.
Engine Air Cleaners, Accessories & Service Parts
Table of Contents
Our innovative products are solving complex filtration challenges that improve people ' s lives, enhance engine and equipment performance and protect our environment. Donaldson has the technical expertise, superior customer support and vast network of locations around the world to meet your toughest filtration needs - from initial system design through replacement products.
Heavy Dust FLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 FLB Service Instructions . . . . . . . . . . . . . . . . . . . 92 EPB-ERB2 with Donaspin ™ Pre-Cleaner . . . . . 93 EPB-ERB2 with Strata ™ Pre-Cleaner . . . . . . . . 95 SPB2.....................................97 SRB.....................................100 SPB2-SRB Service Instructions . . . . . . . . . . . . 103 SSG Donaclone™ . . . . . . . . . . . . . . . . . . . . . . . . 104 SSG Service Instructions . . . . . . . . . . . . . . . . . . 110 STGDonaclone™.........................111 STG Service Instructions . . . . . . . . . . . . . . . . . . 117 Accessories Clamps, Worm-Drive Hose & T-Bolt . . . . . . . . . 120 Clamps, SealClamps ™ . . . . . . . . . . . . . . . . . . . . 121 Drop Down Tube Extension (Dust Dumpa) . . . 122 Exhaust Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . 124 In-LineCheckValve.......................126 In-LineSeparators........................127 Moisture Skimmer & Eliminator . . . . . . . . . . . . 128 Mounting Bands, Metal . . . . . . . . . . . . . . . . . . . 129 Pre-Cleaners, DonaSpin ™ . . . . . . . . . . . . . . . . . 130 Pre-Cleaners, Full-View . . . . . . . . . . . . . . . . . . . 131 Pre-Cleaners, TopSpin™. . . . . . . . . . . . . . . . . . . 132 Rain Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Restriction Indicators . . . . . . . . . . . . . . . . . . . . . 135 Rubber Elbows, Humps & Reducers . . . . . . . . 137 Silicone Charge Air Connectors . . . . . . . . . . . . 140 Vacuator ™ Valves . . . . . . . . . . . . . . . . . . . . . . . . 141 Maintenance And Servicing Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 144 Air Filter Inspection . . . . . . . . . . . . . . . . . . . . . . . 145 General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Service Parts . . . . . . . . . . . . . . . . . . . . . . . 147 Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . 153
Introduction Invented by Donaldson . . . . . . . . . . . . . . . . . . . . . . 2 Our Customers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Simple Facts on Air Filtration. . . . . . . . . . . . . . . . 10 Air Cleaner Models by Flow Direction. . . . . . . . 12 5 Easy Steps to Air Cleaner Selection . . . . . . . . 14 Air Cleaner Selection Chart . . . . . . . . . . . . . . . . . 16 Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . 17
Air Cleaner Models
PowerCore® Series PSD (Medium to Heavy Dust) . . . . . . . . . . . . . . . 19 PSD Service Instructions . . . . . . . . . . . . . . . . . . . 34 Light Dust DuraLite™ ECB, ECC, ECD . . . . . . . . . . . . . . . . . . 38 DuraLite Service Instructions . . . . . . . . . . . . . . . 42 EPB-ERB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 EPB-ERB2 Service Instructions. . . . . . . . . . . . . . 48 Medium Dust FKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FKB Service Instructions . . . . . . . . . . . . . . . . . . . 54 XRB......................................55 XRB Service Instructions . . . . . . . . . . . . . . . . . . . 59 EPB-ERB2 with Full-View Pre-Cleaner. . . . . . . . 60 EPB-ERB2 with TopSpin ™ Pre-Cleaner . . . . . . . 62 FPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FPG Alexin ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FPG + FPG Alexin™ Service Instructions . . . . . 76 FPG + FPG Alexin™ Mounting Bands. . . . . . . . . 77 FTGCycloflow™...........................78 FTG Service Instructions . . . . . . . . . . . . . . . . . . . 81 FRG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 FRG2 Service Instructions . . . . . . . . . . . . . . . . . . 88
Improve
Enhance
Protect
For a variation or a custom designed intake system, please call your current supplier of Donaldson products.
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
Ultra-Web ® Nanofiber Filtration Technology Donaldson has developed Ultra-Web media for usage in applications that operate in the highest level of protection. Ultra-Web media, a web-like filtering layer applied over specially-formulated cellulose media, traps submicron contaminant on the surface of the filter. This surface loading
prevents the contaminant from dispersing throughout the media and substantially increases the filter's efficiency. In field test, filters using Ultra-Web technology hold up to five times more contaminant compared to cellulose air filters
Scanning Electron Microscope image of Ultra-Web media magnified 1000 times.
Ultra-Web® Nanofiber Filtration Technology - a proven filter media with over 25 years in heavy-duty air filtration applications!
Over 90 million m² Ultra-Web media sold
Ultra-Web® and Cellulose Media at Same Magnification
Red circles represent the diameter of a 2 micron and a 5 micron particle. Cellulose media is used in most air filters.
Ultra-Web fibers have submi- cron diameters and small interfiber spaces, which result in more contaminant being captured on the surface of the media and low restriction.
Cellulose fibers are larger than Ultra-Web fibers, and have larger spaces between the fibers, causing contami- nant to load in the depth of the media and plug the airflow path; resulting in higher restriction and less capacity.
2 n Engine Air Cleaners, Accessories & Service Parts
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
PSD PowerCore ® Air Cleaners, Peak performance in Half the Space Air cleaners with original PowerCore filtration technology offer maximum design flexibility. You gain equal performance in significantly less space, freedom to design unique configurations to fit tight spots, and overall design simplicity.
PSD08, PSD09, PSD10 and PSD12 housings
See the PSD PowerCore® air cleaner section for all the details.
PowerCore® G2 Filtration Technology Big Performance, Small Footprint
The second generation of Donaldson PowerCore Filtration Technology is now available for engine air intake systems. PowerCore G2 Filtration Technology offers size reduction and geometric flexibility to overcome the tight space constraints resulting from today's complex emissions systems. In addition to size reduction, its customizable filtration performance also features lower restriction and longer filter life. For more information on PowerCore G2, please contact your Donaldson representative.
A
B
C
Conventional Cellulose Air Cleaner
Original PowerCore® Air Cleaner
60% smaller than A 30% smaller than B
Engine Air Cleaners, Accessories & Service Parts n 3
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
RadialSeal™ Sealing Technology The best, most reliable choice for your engine
Filters using Donaldson RadialSeal Technology are lighter weight and easier to service than other filter designs. Invented by Donaldson in the 1980s, the urethane seal compresses radially on the outside surface of the outlet tube to create a seal around the tube. In most applications, a safety element inside the main element seals radially to the inside of the outlet tube to provide an extra measure of protection. Filters equipped with RadialSeal Technology are easy to replace and provide leak-free seal even in adverse operating contitions such as extreme heat or cold. XRB Air Cleaners Smaller, Lightweight Alternative Two-Stage Air Cleaner The XRB family is ideal for light- to medium-duty diesel engine trucks, agriculture, construction, mining and industrial engine applications. The XRB air cleaner is smaller, lighter and easier to install and it effectively reduces contaminants, providing a high level of engine protection. Available in three diameter sizes.
New XRB Housings: left XRB08; middle XRB12; and right XRB10 (filters shown from XRB12 model).
See the XRB air cleaner section for all the details.
FKB Air Cleaners Smaller, Lightweight Alternative Two-Stage Air Cleaner
For smaller sizes of the XRB family, check out the FKB air cleaner family.
See the FKB air cleaner section for all the details.
FKB Housings and Filters: top center, FKB06; bottom left, FKB05; and bottom right, FKB04
4 n Engine Air Cleaners, Accessories & Service Parts
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
Drop Down Tube Extension (Dust Dumpa) Replacement to Your Existing Dust Cup Assembly
Air cleaners operate in extreme dust conditions (mining, construction and quarrying). In some cases, the dust is so concentrated that maintenance personnel have to empty the dust cups or check the Vacuator ™ Valves more frequently than they like. These two new drop tube accessory incorporates rubber connections that improve dust evacuation from the housing during normal vehicle vibration. The clear tube allows you to easily see what's happening during daily inspections without climbing up to open or check out the Vacuator Valve. Available for SSG and PSD PowerCore® air cleaner and also works on all other air cleaners with 76 mm drop tube. See the Accessories Section for more details.
New Dust Dumpa ship fully assembled. Left: Part No. X006561 / Part No. X006562 right.
SSG
PSD
Go Twice the Distance with Donaldson Endurance™ Air Filters
Donaldson Endurance™ high efficiency air filters, made using Donaldsons advanced Ultra-Web® nanofiber technology, deliver cost saving benefits:
• Longer filter life with submicron contaminant • Ideal for extended maintenance intervals • Longer engine life • Lower operating costs
Donaldson Endurance™ air filters are available for many popular Donaldson air cleaner housing models. Filters with Ultra-Web technology are easily to recognized because of the blue filter media. Finding a Donaldson Endurance air filter in this catalogue. If available for an air cleaner model, the Endurance air filters are listed in the service parts list with ES, Extended Service and HE, High Efficiency.
Engine Air Cleaners, Accessories & Service Parts n 5
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
Don't forget Intake Accessories
Engine Air Accessories are designed to solve our customer's specific problems - such as excessive moisture or noise - or simply help maintain your systems. • Inlet Hoods - protect air intake from large debris • Pre-cleaners - extend air filter life and boost system efficiency • Filter Gauges and Indicators - maximize filter life and reduce maintenance costs • Rubber Elbows and Connectors - minimize air intake flow resistance, reduce noise levels in severe operating condition • Vacuator™ Valves - automatically dispel dust and water from the air cleaner • Stack Caps - protects the exhaust stack from water and debris.
See the Accessories Section for all the details.
Donaldson TopSpin™ Pre-Cleaner Extend Filter Life in Heavy Dust Conditions
We recently upgraded the cover material of the TopSpin Pre-Cleaner to increase impact resistance . Before it was a see-through unit, now it is black . This new design will even more extend your primary air filter life, boost your system efficiency and extend your engine life! Donaldson TopSpin requires no maintenance and works great on all types of equipment, from crawler tractors to farm tractors to skid steer loaders.
See the Accessories Section for all the details.
6 n Engine Air Cleaners, Accessories & Service Parts
Designed to Fit
Manufactured to Perform
... solve complex filtration challenges that improve people's lives, enhance engine and equipment performance and protect our environment.
A New Generation of Hybrid Air Cleaners featuring Donaldson's Unique Design Concept
Air Cleaners equipped with Donaldson's Unique Design Concept ensure you
1) The best protection for your Engine:
Via a unique fit of the element into the access cover, • rotation of the element is prevented which improves durability of the radial seal. The unique interface between the primary element • and access cover assures best fit and function and is achieved only with the Donaldson original elements, discouraging use of low quality will-fit elements. New moulded polymer closed end cap works in • conjunction with the element retention system resulting in outstanding durability and safer manipulation of your element. A plastic liner outer instead of a metal one prevents • media pleat tip wear and improves handling protection. 2) The best protection for our Environment:
ERB2
FRG2
•
Reduced metal content.
See the ERB2, FRG2 and SPB2 Air Cleaner Section for more details on these next generation products.
SPB2
Built with Donaldson Technology.
Engine Air Cleaners, Accessories & Service Parts n 7
Designed to Fit
Manufactured to Perform
the following customers rely on Donaldson
Agco, Case New Holland, Claas, Deutz, Fendt, John Deere, Landini, Manitou, Massey Ferguson, McCormick, Renault Agriculture, SAME, Valtra...
BMC, Carrier Transicold, DAF, Daimler, EvoBus, FIAT, Ford Otosan, Freightliner, International, Isuzu, Iveco, MAN, Paccar, Renault Truck, Scania, Thermo-King, Vanhool, VDL Bus, Volvo... AtlasCopco, Bobcat, Case New Holland, Daewoo, Doosan, Dynapac, Fermec, Fiat-Kobelco, Furukawa, Hitachi, JCB, Komatsu, Liebherr, Linde, MCFE, Merlo, Sandvik, Terex, Toyota, Volvo CE...
Cummins, Detroit Diesel, Honda, Isuzu, Iveco, John Deere, KHD, Komatsu, Kubota, MAN Engines, Mercedes Benz, Perkins, Scania, Sisu, Steyr Motors, Yanmar Diesel...
Manitou, Hyster, JCB, Jungheinrich, Komatsu, Linde, Toyota...
8 n Engine Air Cleaners, Accessories & Service Parts
Donaldson Engine
Aftermarket Warranty for Filtration and Exhaust Products
Donaldson warrants its Aftermarket products against failure due to defects in materials and workmanship for the period specified under Terms and Conditions for the particular product. Donaldsons obligation under this warranty cov- ers replacing the failed product, including trans- portation charges, only. If the Donaldson product failure is the sole and direct cause of damage to the equipment on which the product was proper- ly installed, Donaldson will reimburse reasonable costs to restore the equipment to the condition it was in immediately before the failure. This warranty does not cover failure due to mis- application, misuse, abuse, neglect, rust through and corrosion (mufflers), improper service prac- tices or non-Donaldson approved modifications. Engine and equipment manufacturers’ warran- ties remain in effect when Donaldson products are used.
Donaldson must be notified in writing of any claims covered by this warranty within one year of the date of failure. Donaldson, at its discre- tion, will either physically visit the site where the alleged failure has been found or, request that all parts, Donaldson and other relevant parts, be shipped prepaid to its General Office, in care of the Product Lab or as otherwise specified. Terms & Conditions Warranty coverage begins at the date of installa- tion to the original end-user, and expires after the indicated period or kilometres, whichever occurs fi rst. More detailed information can be found in the Donaldson Europe Operating Guide or can be received upon request.
Warranty Length by Product Filtration Products Warranty Period
Air Cleaner Housing & Accessories Liquid Filter Assemblies & Accessories
1 year 1 year
Air & Liquid Filters
Maximum 1 year
Exhaust Products
Warranty Period
Exhaust Assemblies On-Road Exhaust Assemblies Off-Road
2 years - 300.000 kilometers 1 year - 1500 working hours
Exhaust Accessories
1 year
Brochure No. F116006 (11/08)
Engine Air Cleaners, Accessories & Service Parts n 9
Simple Facts
on Air Filtration
... common terms and definitions.
Two-stage Air Cleaners
Why an Air Intake System?
Air is a critical component of combustion for a diesel engine. If the air reaching the engine is not clean, the engine will lose efficiency and have engine wear. The engine will run longer and more efficiently with a proper air intake system that is designed to keep the engine intake air as clean as possible by removing par- ticulate matter or debris that would cause engine wear and ultimately failure.
Air entering a two-stage air cleaner is first pre-cleaned before reaching the main element. The air may either be sent through pre-cleaner tubes or cleaned by centrifugal flow around the filter. Depending on the type of pre-cleaner, the pre-cleaner removes between 75-98% of the contaminate from the air before the air reaches the main element. Two stage air cleaners are recommended for use in medium- and heavy dust environments, such as in agricultural, construction, and mining applications.
Components Air Intake System
Inlet Stack
Mounting Band
Bellow
Element types
Clean Air Duct
Main Element Is the filter element in the air cleaner that removes around 99,9% + of the air's dust. The air flows through the main element first. Safety Element Is an optional element that protects the engine during servicing of the main element and in case of a leak in the main element.
Air Cleaner
Vacuator ™ Valve
Air Cleaner Types
One-Stage Air Cleaners
Main Element
Safety Element
Air Cleaners in which the air goes through the inlet and directly to the main element are considered one- stage air cleaners. One-stage air cleaners are typically used where there is less contaminate in the environment, such as in on-road applications.
10 n Engine Air Cleaners, Accessories & Service Parts
Simple Facts
on Air Filtration
... common terms and definitions.
Technologies
Dust Concentration Dust concentration expresses the mass of dust in a specified volume of air. Typical ambient conditions are around 0,1 milligrams per cubic meter (mg/m ³ ). Dirt road conditions are around 10 miligrams per cubic meter (mg/m ³ ). Laboratory Life This is the life of an air filter, until a defined restriction, tested at a constant dust concentration (mg/m ³ ) following an ISO 5011 laboratory test procedure to determine performance and allow comparison with other air filter models. Field Life This is the life of an air filter, till a defined final restriction, during its usage in the field. Differential Pressure The difference in pressure between two points, generally between the inlet and outlet of an air cleaner. To be measured in pascal (Pa). Pascal The SI unit to express a pressure, to be used instead of mm H 2 O. Pa (pascal) - kPa (kilopascal) - mbar (milibar) - daPa (decapascal)
RadialSeal™ RadialSeal refers to Donaldsons sealing technology, which uses the urethane end caps and the cleaners outlet tube to created the seal. This is the preferred method of sealing. Axial Seal The Axial Seal sealing method requires a force between air filter and air cleaner that provides enough compression on the gasket between the parts to create a seal.
Filtration Terms
Dust Capacity Dust capacity is the amount of contaminant that will be collected on a filter before final restriction level - as set by the engine manufacturer - is reached. Efficiency Efficiency is the percentage of dust that the air cleaner with a filter removed from intake air. Donaldson air cleaners have a 99,7% efficiency level. Restriction Restriction represents the resistance to the flow of air through the air cleaner system. Typical unit is kilopascal (kPa). Air cleaners with clean filters should have restrictions between 0,5 and 4 kPa. Filter media Filter media is the material in the filter that removes the contaminate. Conventional media is made from cellulose fibers combined with resins to keep the fibers together.
1 mm H 2 O
= 9,80665 Pa
1000 Pa 100 Pa
= 1 kPa = 1 mbar = 1 daPa
10 Pa
Airflow Requirements Air is as critical to the operation of an engine as it is to the working of the human body. Like lungs, an engine draws air from the atmosphere. The amount of air required by engine depends on the type of engine, whether there is a turbocharger, and the amount of horsepower of the engine. The airflow requirement is a specification of the engine that should be given by the engine manufacturer.
Engine Air Cleaners, Accessories & Service Parts n 11
Air Cleaner Selection
by Flow Direction
Donaldson has air cleaner housings that work in a variety of dust conditions and air flow patterns (A - D, and G). For improved filtration reliability and quicker filter service compared to older axial seal style air cleaners, Donaldson recommends installing either PowerCore air cleaners or radial seal style air cleaners whenever possible.
Light Dust - ECB Disposable, one-stage, dry air cleaner, small, lightweight and unitized (housing and filter in one). For 2-3 cylinder, high-vibration engines. Can be vertically or horizontally mounted. Handles airflows of 6-90 m³/min. Used on light-duty applications. Page 38-42. Heavy Dust - SPB2 Two-stage full-plastic air cleaner with built-in high efficiency pre-cleaner. Body diameter of 13". Handles airflows of 6-22 m³/min. Designed for heavy-duty equipment. To be used with an exhaust ejector. Page 97-99. Medium Dust - XRB The radial seal, plastic, two-stage air cleaner. with side inlet for horizontal installation. Body diameters in 8", 10" and 12". Mount under hood or behind cab. Handles airflows of 7,5-18 m³/ min. Used on off-road equipment operating in medium-dust conditions. Page 55-59. Light, Medium & Heavy Dust - ERB2 One-stage hybrid air cleaner. Body diameters in 10", 11", 13" and 15". Handles airflows of 8-65 m³/min. Used on light-, medium- and heavy-duty applications, always combined with a pre-cleaner. Page 43-48.
Flow Direction Legend B = Air in the Side, Out the End
C = Air in the End, Out the Same End D = Air in the End, Out the Opposite End G = Air in the Side, Out the End
B Airfl ow Air in the Side, Out the End
Light and Medium Dust - FKB A compact housing high dust holding capacity, and comparable airflow to FPG. Two-stage filtration, side inlet, horizontal installation. Body diameters in 4", 5” and 6". Mount under hood or behind cab. Handles airflows from 2-6 m³/min. Used on off- road equipment operating in medium-dust conditions. Page 50-54. Light, Medium & Heavy Dust - EPB One-stage full-plastic air cleaner. Body diameters in 7" and 8". Handles airflows of 2-7 m³/min. Used on light-, medium- and heavy-duty applications, always combined with a pre-cleaner. Page 43-48. Heavy Dust - FLB Two-stage air cleaner with scavenge exhaust system. Body diameters in 6", 8", 10" and 12". Handles airflows of 3-17 m³/min. Designed for heavy-duty equipment. To be used with an exhaust ejector. Page 90-92. Heavy Dust - SRB Two-stage hybrid air cleaner with built-in high efficiency pre-cleaner. Body diameters in 9", 10", 11" and 13". Handles airflows of 4-18 m³/min. Designed for heavy-duty equipment. To be used with an exhaust ejector. Page 100-103.
C Airfl ow Air in the End, Out the Same End
Light Dust - ECC Disposable, one-stage, dry air cleaner, small, lightweight and unitized (housing and filter in one). For small 2-3 cylinder, high-vibration engines. Can be vertically or horizontally mounted. Handles airflows of 1-26,5 m³/min. Used on off-road equipment operating in medium-dust conditions. Page 38-42.
12 Engine Air Cleaners, Accessories & Service Parts
D Airfl ow Air in the End, Out the Opposite End
Medium to Heavy Dust - PSD Two-stage air cleaner with built-in high efficiency pre-cleaner using the PowerCore™ Filtration Technology. Smaller, compact with built-in mounting brackets. Can be vertically or horizontally mounted. Handles airflows of 6-30 m³/ min. Body diameters in 8", 9", 10" and 12". Designed for medium- and heavy-duty equipment. Can be used with Vacuator™ Valve on the pre-cleaner or continuously scavenge of the pre-cleaner by an exhaust ejector or air blower cooling. Page 19-35.
Light Dust - ECD Disposable, one-stage, dry air cleaner, small, lightweight and unitized (housing and filter in one). For small 2-3 cylinder, high-vibration engines. Can be vertically or horizontally mounted. Handles airflows of 1-23 m³/min. Used on light-duty applications. Page 38-42.
G Airfl ow Air in the Side, Out the End
Medium Dust - FPG The first fully plastic air cleaner in our two-stage filtration line. Built-in pre- cleaner. Tangential inlet, with or without safety element, body diameters from 4", 5", 7", 8" and 10". Handles airflows of 0,5- 12 m³/min. Can be mounted horizontal, vertical or at an angle. Used on medium- duty applications. Page 64-69 / 76-77. Medium Dust - Alexin FPG Two-stage full-plastic air cleaner with built-in pre-cleaners. Tangential inlet, with or without safety element, body diameters from 6", 8", 9" and 10". Handles airflows of 1,5-12 m³/min. Can be mounted horizontal, vertical or at an angle. Used on medium-duty applications. Page 70-77. Medium to Heavy Dust - FRG2 Two-stage hybrid air cleaner which is available in body diameters of 10", 11", 13", 15" and 18". Horizontal mount required. Handles airflows from 6,5-51 m³/min. Used in medium- to heavy-duty duty applications. Page 82-88. Heavy (Severe) Dust - STG Two-stage - high airflow - air cleaner with built-in Donaclone™ tube pre-cleaner. Two styles available - one with a peripheral inlet and another with a tubular inlet. Handles airflows from 11-50 m³/min. Can be mounted vertically or horizontally. Used on heavy-duty applications. Page 111-117.
Heavy (Severe) Dust -SSG These new models are replacing our older SRG models. Donaldson's largest two-stage engine air cleaner, designed for the engines on large equipment. Handles airflows of 48-135 m³/min. The best protection for 500 to 2000 horsepower diesel engines. This new model uses radial seal sealing technology for filter retention. Used on heavy-duty applications. Page 104-110. Medium to Heavy Dust - FTG Two-stage air cleaner with built-in pre-cleaner. Body diameter of 21". Handles airflows of 32-59 m³/min. Used in medium- to heavy-duty duty applications. Page 78-81.
Engine Air Cleaners, Accessories & Service Parts n 13
Five Easy Steps to
Air Cleaner Selection
(1) Determine the Airflow Requirements of the Engine
Additional Consideration
There are 2 different formulas to estimate the airflow (m ³ /min) required by the engine. One formula is based on Engine Displacement (Formula A). The other is based on Engine Horse Power (Formula B).
1. Please be aware that when you have High Pulsation engines the air inflow to the air cleaner is influenced by this pulsation. We recommand that you review the application and if necessary multiply the airflow - found by one of above formula - by the pulsation factor (PF). PF Table 2,1 for 1 cylinder engine natural aspirated. 1,5 for 2 cylinder engine natural aspirated. 1,2 for 3 cylinder engine natural aspirated. 1,0 for 4 and more cylinder engine natural aspirated. 2. No pulsation factor needs to be considered for turbo charged engines. 3. Donaldson ECB, ECC, ECD Duralite ™ (see page 38-42) and the FPG057505 Air Cleaners (see page 67) are not subject to the pulsation factor due to the fact that we use a specially developed High Pulsation media for these products. Example A tractor is equiped with a 40 HP(SAE), 3 cylinder, 4 stroke natural aspirated diesel engine of 2 litres run- ning at 2600 RPM.
Formula A =
Airflow = Engine Displacement x RPM x VE = m ³ /min. 1000 x CF
Engine Displacement • Size of the engine expressed in litres (swept volume) . RPM = Revolutions per minute • VE = Volumetric Efficiency • VE Table 0,85 for 4 stroke natural aspirated diesel engine 1,60 for 4 stroke turbo charged diesel engine 1,85 for 4 stroke turbo charged after cooled diesel engine
1,40 for 2 stroke scavenge blower diesel engine 1,90 for 2 stroke turbo charged diesel engine
•
CF = Cycle Factor = 2 for 4 stroke engine
1 for 2 stroke engine
Formula B =
Airflow = HP(SAE) x SA = m³/min.
Formula A =
Airflow = 2 x 2600 x 0,85 = 2,21 m ³ /min. 1000 x 2
• •
HP(SAE) = Horse Power
SA = Specific Airflow per Horse Power
SA Table 0,057 m ³ /min. for 4 stroke natural aspirated diesel engine 0,065 m ³ /min. for 4 stroke turbo charged/after cooled engine 0,093 m ³ /min. for 2 stroke scavenge blower diesel engine 0,102 m ³ /min. in for 2 stroke turbo charged diesel engine
Formula B =
Airflow = 40 x 0,057 = 2,28 m ³ /min.
In High Pulsation application multiply your answer by FP table which in this case is 2,21 m ³ /min. x 1,2 = 2,652 m ³ /min.
14 n Engine Air Cleaners, Accessories & Service Parts
Five Easy Steps to
Air Cleaner Selection
For example, a truck of less than 8 ton will probably see light-dust, whereas dumpers used on construction sites would almost always be surrounded by an extremely heavy-dust concentration of large dirt particles. To deter- mine the type of environment and the dust concentration level your machine works in, you can use the table below. (2) Determine the Type of Machine and its Environment
Environment
Applications
Dust concentration (mg/m ³ )
Light-Duty
On-Highway Trucks (< 8T), Lift Truck, Pumps for use in generators, compressors, marine, small engines and railroad.
1-5
(On-Road, Marine)
+ carbon, soot, oil vapeur
Medium-Duty
Mixed operating Trucks (8 -16T),
5-15
(Light Construction,
Farm Tractor, Lift Truck,
Agricultural, Compressors)
Mobile Compressor, Skid Steer.
Medium- to Heavy-Duty
Combines and Harvesters, Earth Moving Equipment, Loader, Dozer, Grader, Excavator, Artic Dumper.
15-20
Heavy-Duty
Scraper, Dumper, Track type dozer,
(Construction, Mining)
Mining Equipment,
20-50
Rail Road (Middle East).
Extra Heavy-Duty
Special equipment, Military.
50-100
Note: These figures are only indications.
(3) Select an Air Cleaner Series
You can do this by using the Air Cleaner Selection Overview on page 12-13. This correlates the Airflow Requirements of your engine (which you calculated under step 1) with the Dust Concentration level of your envi- ronment (which you calculated under step 2). Once you have selected your Air Cleaner Series you can look in the catalogue for the specific Air Cleaner Model according to the Air Flow Requirements your engine needs. You can do this by refering to the Air Flow Restriction Curves. If there are 2 air cleaner models that fit your parameters, choose the one with the lowest restriction to ensure maximum service life from that air cleaner seriers. (4) Choose a SPECIFIC Air Cleaner Model (5) Choose Intake Accessories Accessories are an integral and important part of the entire air intake filtration system. See the Accessories Section for more details.
Engine Air Cleaners, Accessories & Service Parts n 15
Engine Protection for
All Dust Conditions
...Donaldson offers a full line of air cleaners for a wide variety of applications and operating environments
16 n Engine Air Cleaners, Accessories & Service Parts
Air Filtration
Conversion Factors
Weight 1 kg = 2,205 lb = 35,27 Oz 1 lb = 0,4536 kg = 16 Oz 1 Oz = 0,02835 kg = 0,0625 lb Pressure 1 mm H 2 O = 9,80665 Pa 1 bar = 100 kPa = 14,5 psi 10 mbar = 1 kPa = 0,145 psi 10 psi = 68,95 kPa = 0,6895 bar 1 “Hg = 345,4mm H2O = 3,321 kPa Air Weight Air weight at 0°C = 1,293 kg/m ³ Air weight at 20°C = 1,205 kg/m ³ Air weight at 25°C = 1,184 kg/m ³
Temperature °C = (°F – 32) x 5/9 °F = (°C x 9/5) + 32
Power HP = KW x 1,341 (metric) KW = HP x 0,745 (metric)
Flow rates 1 l/min. = 0,0353 cfm 1 m ³ /min. = 35,3147 cfm 1m ³ /h = 0,5886 cfm 1 English gallon/min. = 0,1605 cfm Length 1 m = 1000 mm = 39,37 inch = 3,281 ft. 1 inch = 25,4 mm = 0,0254 m = 0,08333 ft. 1 ft. = 304,8 mm = 0,3048 m = 12 inch Volume 1 m ³ = 1000 litres = 35,31 ft. ³ = 61024 inch ³ 1 ft. ³ = 28,32 litres = 0,02832 m ³ = 1728 inch ³ 1 litre = 0,2642 US gallon = 0,2201 Engl gallon 1 US gallon = 3,785 litres = 231 inch ³ 1 English gallon = 4,546 litres = 277 inch ³
Engine Air Cleaners, Accessories & Service Parts n 17
Engine Protection All Conditions in
Like Never Before!
Innovative vehicle designs call for new engineering solutions plus know-how from your suppliers. We have both – and are ready to help you solve your space or configuration problems.
PowerCore filters in round, obround, and rectangular configurations.
PowerCore® Filtration Technology
Why was it developed? Vehicle design is moving from classic to aerodynamic. This means less under-hood space, highly stylized, cost effective designs, greater operator visibility, higher horsepower engines with greater airflow and other emission requirements with hotter engines…
Therefore Donaldson developed PowerCore® Filtration Technology, to do more in less space and to allow system optimization.
What is it about?
• Proprietary air filtration technology developed to improve engine protection. • Revolutionary, fluted media design for improved air filtration. • PowerCore® media is visually unique. • PowerCore filters can be designed, based on an approved matrix, in obround (racetrack) and round shapes. • High density media packaging technology. • Built with Donaldson Technology. • Backed by extensive lab and field testing
How does it work?
Fluted channels are alternately sealed: air enters an open flute and is forced to exit through an adjacent flute Contaminants stay inside the filter - and won’t drop back into an unprotected air filter housing.
Clean air travels on to your engine
Filter media is formed into flutes - these flutes are layered to give tight, rugged structure to the fi lter
Dirty air travels in and is filtered in one pass through the media
20 n Engine Air Cleaners, Accessories & Service Parts
PowerCore® Filtration Technology
With PowerCore, you will gain…
Greater Efficiency The straight-through fluted design of PowerCore Filtration Technology is three times more efficient than average conventional pleated filters. Engine Protection No media movement, expansion, contraction or bunching, with less dust and dirt passed on to the engine.
Lower Shipping and Inventory Costs PowerCore filters are lighter and take up less shelf space being so compact - in fact as much as half of a conventional filter.
Improved Handling and Maintenance Lighter and smaller, changing filters is a snap.
Improved Environment Protection Non-metal filters – both main and safety (where applicable).
Contaminant Encapsulation Dust and dirt won’t dislodge during servicing.
System Design Flexibility Multiple horizontal and vertical installation positions.
Equal or Better Performance in a Small Package The freedom to design unique configurations to fit tight spots and overall design simplicity. Donaldson Reliability Backed by nearly a century of innovation and experi- ence. Donaldson supplies air filtration products to almost every vehicle manufacturer.
Dust Holding Capacity Gain over 100% more dust holding capacity in a given volume.
Built-In Pre-Separation and Mounting Brackets To eliminate the need to purchase separate.
PowerCore filters in round, obround, and rectangular configurations.
Engine Air Cleaners, Accessories & Service Parts n 21
PSD Air Cleaner
Excellent Performance in Half the Space The PSD PowerCore® Air Cleaner is a two-stage air cleaner with built-in high efficiency pre-cleaner using PowerCore Filtration Technology. PSD PowerCore Air Cleaners are designed especially for on and off road equipment operating in medium to heavy dust environments. Can be used with Vacuator™ Valve on the pre- cleaner or continuously scavenge of the pre-cleaner by an exhaust ejector or air blower cooling. See page 124-125 for all available Exhaust Ejectors.
Applications
• Equipment operating in medium to heavy dust conditions with engine airflow ranges up to 30 m³/min. • Obround housing shape allows for a narrow or wide mounting orientation. Models have either end or side filter service access • Sustained temperature tolerance: to 82°C
D080069 - Horizontal
D080070 - Vertical
Features
Mounting Flexibilty The PSD air cleaner is available with two separate drop tube in orientations and built- in mounting brack- ets on the 2 long sides of the housing. The ohter three PSD models (09, 10 and 12) offer even more mounting flexibility with built- in brackets on three sides of the main body housing.
• More compact at a given performance level than standard pleated filters • Non-metal filters - both main and safety (where applicable) • Improved engine protection: no media movement, expansion, contraction or bunching • Improved contaminant encapsulation: dust and dirt stay contained in filter during service • Improved filtration efficiency: - Three times more efficient than the average conventional pleated filter - PowerCore Filtration Technology with high efficiency pre-cleaner tubes improve engine protection • Improved handling and maintenance: lighter and smaller, changing filters is a snap • Easily serviced with clamp-on cover design • Can be used with scavenge line or Vacuator™ Valve depending on housing orientation • Built in mounting brackets eliminate the need to purchase separate mounting bands • Indicator thread size = 1/8-27NPT (Male) for PSD08/PSD09/PSD10 1/8-27NPT (Female) for PSD12
D090074 - Horizontal
D090073 - Vertical
D100030 - Horizontal
D100029 - Vertical
22 n Engine Air Cleaners, Accessories & Service Parts
PSD Air Cleaner
PSD 08 - Service Access on Inlet End
PSD 09-10-12- Service Access on Side
Straight
Indicator
90°
Engine Air Cleaners, Accessories & Service Parts n 23
PSD Air Cleaner
PSD 08 - Specifications
'
+
*
$
&
)
(
%
Air Cleaner Model No.
Airflow Range
Dimensions (mm)
m³/min.
A
B
C
D
E
F
G
H
D080069 (H) D080070 (V)
up to 6
With Vac Valve
89
380 257 159 100 117
191
76
D080069 (H) D080070 (V)
up to 8,5
With Scavenge Flow
(H) Horizontal / (V) Vertical Installation
To Scavenge or Not Scavenge…
PSD air cleaners are designed to operate with or without aspiration, otherwise known as scavenging. Scavenging is accomplished by introducing a secondary airflow to the drop tube on the air cleaner (generally through the use of an ejector or ejector muffler). This flow pulls the separated contaminant from the precleaner and inserts it into the exhaust stream. The advantages to scavenging are: • Higher pre-cleaner efficiency (resulting in longer filter service life) • Completely self-servicing (no regular maintenance needed on pre-cleaner) • Drop tube can be located in variety of orientations (not just straight down as is necessary on non-scavenged systems) Aspirating an intake system through the use of a scavenging device adds more components (an ejector and some plumb- ing) to the overall system, but will enhance the separator efficiency of the pre- cleaner and consequently extend the filter service life. Conversely, the PSD air cleaner and precleaner will function adequately without scavenge, with the result being less filter service life than with the use of scavenging.
24 n Engine Air Cleaners, Accessories & Service Parts
PSD Air Cleaner
PSD 09 - 10 - 12 Specifications
PSD09
PSD10
K
PSD12
Air Cleaner Model No.
Airflow Range
Dimensions (mm)
m³/min.
A
B
C
D
E
F
G
H
K
With 10% Scavenge Flow
433 433 458 458 533 533 477 477 502 502 577 577 429 429 529 529 505 505 605 605 496 496 596 596
D090073 (V) D090074 (H) D090099 (V) D090098 (H) D090101 (V) D090100 (H) D090086 (V)* D090087 (H)* D090088 (V)* D090089 (H)* D090090 (V)* D090091 (H)* D100029 (V) D100030 (H) D100031 (V) D100032 (H) D100124 (V)* D100123 (H)* D100122 (V)* D100121 (H)* D120035 (V) D120036 (H) D120037 (V) D120038 (H)
6-10 6-10 7-11 7-11 9-13 9-13 6-10 6-10 7-11 7-11 9-13 9-13
102 102 102 102 102 102 102 102 102 102 102 102 127 127 152 152 127 127 127 127 152 152 152 152
110 110 135 135 180 180 110 110 135 135 180 180 110 110 210 210 110 110 210 210 168 168 268 268
362 362 362 362 362 362 362 362 362 362 362 362 375 375 375 375 375 375 375 375 430 430 442 442
130 130 130 130 130 130 130 130 130 130 130 130 110 110 110 110 110 110 110 110 110 110 110 110
180 180 180 180 180 180 180 180 180 180 180 180 254 254 254 254 254 254 254 254 306 306 306 306
174 174 174 174 174 174 218 218 218 218 218 218 165 165 165 165 241 241 241 241 160 160 160 160
100 100 100 100 100 100 100 100 100 100 100 100 110 110 110 110 110 110 110 110 154 154 154 154
76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5 76,5
12-18 12-18 18-25 18-25 12-18 12-18 18-25 18-25 23-27 23-27 27-30 27-30
76 76 76 76
(H) Horizontal / (V) Vertical Installation
* 90° Outlet
Engine Air Cleaners, Accessories & Service Parts n 25
PSD Air Cleaner
PSD PowerCore® - Service Parts
Orientation
Service Parts
Service Parts
Air Cleaner Model No.
Air Cleaner Installation Horizontal
Orientation Drop Tube Horizontal
Orientation Outlet
Access Cover Assy
U-Clip, Mounting (x4)
Main Element P608533 P608533 P608665 P608665 P787281 P787281 P608675 P608675 P608665 P608665 P787281 P787281 P608675 P608675 P608677 P608677 P608667 P608667 P608666 P608666 P608676 P608676 P608666 P608666 P608676 P608676
Safety Element P600975 P600975 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P606121 P601560 P601560 P601560 P601560 P601560 P601560 P601560 P601560 P607557 P607557 P607557 P607557
9HUVLRQ Version
NEW D080069 NEW D080070
- -
Straight Straight
P785236 P785237
P786050 P786050
Vertical
Vertical
NEW D090073 NEW D090074 NEW D090099 NEW D090098 NEW D090101 NEW D090100 NEW D090086 NEW D090087 NEW D090088 NEW D090089 NEW D090090 NEW D090091
Vertical
Short Short
Vertical
Straight Straight Straight Straight Straight Straight
P785651 P785651 P785978 P785978 P786989 P786989 P785651 P785651 P785978 P785978 P786989 P786989
P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517 P784517
Horizontal
Horizontal
Vertical
Medium
Vertical
Horizontal
Medium Horizontal
Vertical
Long Long Short Short
Vertical
Horizontal
Horizontal
Vertical
Vertical
90° 90° 90° 90° 90° 90°
Horizontal
Horizontal
Vertical
Medium
Vertical
Horizontal
Medium Horizontal
Vertical
Long Long
Vertical
Horizontal
Horizontal
D100029 D100030 D100031 D100032
Vertical
Short Short Long Long Short Short Long Long Short Short Long Long
Vertical
Straight Straight Straight Straight
Upon request Upon request Upon request Upon request Upon request Upon request Upon request Upon request Upon request Upon request Upon request Upon request
Horizontal
Horizontal
Vertical
Vertical
Horizontal
Horizontal
NEW D100124 NEW D100123 NEW D100122 NEW D100121
Vertical
Vertical
90° 90° 90° 90°
Horizontal
Horizontal
Vertical
Vertical
Horizontal
Horizontal
D120035 D120036 D120037 D120038
Vertical
Vertical
Straight Straight Straight Straight
Horizontal
Horizontal
Vertical
Vertical
Horizontal
Horizontal
Accessories used on all PSD Air Cleaners
Vacuator™ Valve Accessories used on all PSD Air Cleaners
P112803 for the European PSD Range / P158914 for the US PSD Range - See page 27. When making use of a reducer, see page 141 for all available Vac Valves P784790 for the PSD Range. See page 126 for all available Check Valves. P112803 for the European PSD Range / P158914 for the US PSD Range - See page 27. When making use of a reducer, see page 141 for all available Vac Valves ø 32 = P783747 ø 38 = P783746 ø 50 = P783748 ø 25 + 90° = P786685 ø 32 + 90° =P784019 (PP) ø 32 + 90° =P784834 (PA) ø 38 + 90° = P786778 P784790 for the PSD Range. See page 126 for all available Check Valves. ø 32 = P783747 ø 38 = P783746 ø 50 = P783748 ø 25 + 90° = P786685 ø 32 + 90° =P784019 (PP) ø 32 + 90° =P784834 (PA) ø 38 + 90° = P786778 See page 124-125 for all available Exhaust Ejectors
Adapter Straight
Check Valve Vacuator™ Valve
Adapters Check Valve
Ejectors Adapters
Adapter 90°
Media used on PSD PowerCore® Standard Air Cleaners All PSD Standard Air Cleaners are equiped with White Media, Blue Ultra-Web® Media is optional. Contact your Donaldson representative for more info. Media used on PSD PowerCore® Standard Air Cleaners All PSD Standard Air Cleaners are equiped with White Media, Blue Ultra-Web® Media is optional. Contact your Donaldson representative for more info. See page 124-125 for all available Exhaust Ejectors Ejectors
26 n Engine Air Cleaners, Accessories & Service Parts
PSD Air Cleaner
PSD Extended Product Line
For the PowerCore™ Air Cleaner Range, Donalson now offers you more alternatives - an extended product line. These new alternatives provide you more flexibility and mounting options. A new range of accessories is also available (see page 26).
Standard PSD PowerCore® Line
PSD08 Extended Product Line - Features
US Models
European Models
PSD08
D080020 D080026
D080069 D080070 PSD09 PSD09 D090073 D090074 D090099 D090098 D090101 D090100 D090086 D090087 D090088 D090089 D090090 D090091 PSD10 D100029 D100030 D100031 D100032 D100124 D100123 D100122 D100121 PSD12
New New
• Lower initial restriction • Mounting brackets on both sides to increase mounting options • Drop tube diameter enlarged (same as PSD10 & 12) • Possibility to fix different scavenge adapters > straight & 90° • Possibility to integrate check-valve into scavenge tube of pre-cleaner • 4 latches on service cover to improve accessibility & serviceability
D090019 D090020
New New New New New New New New New New New New
- -
D090021 D090022
PSD09 Extended Product Line - Features
- - - - - - - - - - - - - -
• Lower initial restriction • Next to the short and long PSD09 we offer now a medium version • Drop tube diameter enlarged (same as PSD10 & 12) • Possibility to fix different scavenge adapters > straight & 90° • Possibility to integrate check-valve into scavenge tube of pre-cleaner • Optional 45° latch position on the cover • New version with 90° outlet tube • Male indicator tab with thread 1/8 27 NPT
Existing Existing Existing Existing
New New New New
PSD10 Extended Product Line - New features
D120035 D120036 D120037 D120038
- - - -
Existing Existing Existing Existing
• New version with 90° outlet tube
Engine Air Cleaners, Accessories & Service Parts n 27
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