Crank Case Ventilation

7/27/2019 Crank Case Ventilation

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Owners Manual

Donaldson Spiracle

Crankcase Filtration Systems

Models: S040004 & S040005

Thank you for purchasing a Donaldson Spiracle CFS (Crankcase

Filtration System) to reduce diesel crankcase emissions.

This owners manual includes pre-installation instructions,

warranty activation procedures and maintenance procedures.

Doc. No. P478599 Rev 1


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Donaldson Spiracle Filtration System Owners Manual

Read each section carefully prior to installing your Donaldson Spiracle

Filtration System. To highlight important topics or steps regarding the

installation, operation and maintenance, pay special attention to the callouts in

the NOTE boxes.

Example:

NOTE Mount Spiracle at Proper Height

It is important to ensure the bottom of the Spiracle unitis positioned at least 6 (152mm) above the engine oildrain-back location to ensure free oil flow to the engine.

Consult your Donaldson distributor, dealer or Donaldson if you have

questions regarding the installation and warranty.

Contents

Introduction ........................................... 3

Pre-Installation Requirements ................. 3

What You Get With Your Assembly .................................. 3

Additional Hardware .......................................................... 3Selecting the Right Spiracle System ............................... 3

Spiracle Mounting Considerations .................................. 4

Typical Installation ............................................................. 4

Ensure Tubing/Connections are Leak-free..................... 5

Change Filter Routinely ..................................................... 5

Spiracle Filtration System Warranty ............................... 5

Activating the Warranty .................................................... 5

Spiracle Unit Installation ........................ 6

Locate and Mount the Spiracle Assembly ..................... 6Make Spiracle Inlet and By-pass Valve Connection .... 7

Connect Spiracle to the Air Intake System .................... 8

Connect Spiracle Drain to Engine Sump ........................ 8

System Checks.................................................................... 9

Activating the Warranty ........................ 10

Operation, Maintenance and Service Guidefor Spiracle Filtration Systems.............. 10

Add Filter Change to Maintenance Schedule ............. 10

Routine Filter Service Procedure .................................. 11Spiracle Filter Disposal Information .............................. 11

Actions and Improper Maintenance ThatMay Void Your Warranty ....................... 12


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IntroductionThe Donaldson Spiracle filtration systemis designed to eliminate emissions from opencrankcase vents on all diesel engines. In additionto reducing emissions, the Spiracle filtrationsystem eliminates underhood fumes, reduces

engine oil consumption, eliminates oil drips onroadways and helps maintain a cleaner enginecompartment.

Combustion chamber leakage past the pistonrings creates blow-by gases that are vented outthe crankcase vent. These gases contain severalunwanted constituents, such as hydrocarbons,diesel soot, engine oil and various engine oilcontaminants. Such emissions can range from 10to 25% of total engine emissions.

The Spiracle filtration system is effective ateliminating 100% of the crankcase emissionsover the varying flow and pressure ranges seen intodays engines, while preventing turbochargerand aftercooler fouling. Filter life is designed tocoincide with the engine manufacturers oil changeintervals or 500 hours, whichever comes first.

For optimum performance and warrantycoverage, follow Donaldsons installationrecommendations.

NOTE Follow installation requirements

Installations must meet Donaldson requirements toobtain full warranty coverage.

Pre-Installation RequirementsWhat you Get with Your Assembly

Part No. S040004Qty. Description

1 Assembly (housing and filter)

1 By-pass Valve 1 Mounting band 1 Check-valve, oil drain-back 1 Tubing, oil drain-back, " dia, 3' (0.91m) length 2 Clamps 1 Documentation package that includes this owner's

manual, a warranty registration card, warrantyand engine tag (for CARB requirement).

Part No. S040005Qty. Description

1 Assembly (housing and filter) 1 By-pass Valve 2 Mounting bands

1 Check valve, oil drain-back 1 Tubing, oil drain-back, " dia, 3' (0.91m) length 2 Clamps 1 Documentation package that includes this owner's

manual, a warranty registration card, warrantyand engine tag (for CARB requirement).

Additional HardwareAdditional hardware items are needed to completethe Spiracle system installation, including:

Qty. Description 2 Tubing Clamps: 1" (38mm)

2 Tubing Clamps: 1" (31mm)1 Tubing: 1" I.D. (31mm)

1 Tubing: 1" (25mm) I.D. Wire-ties to secure tubing

NOTE Components for Installation

Other components may be needed for your Spiracleassembly retrofit depending on your application.

Selecting the Right Spiracle System

Be sure you have selected the proper model.Application of the wrong model will affect filterefficiency and life. Check the application guidelocated on Donaldsons website,www.donaldsonexhaust.com, for sizingrecommendations by engine make, model andhorsepower rating before installing this unit.


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Spiracle Mounting ConsiderationsThe Spiracle filtration system will provide thelongest life when mounted independent of theengine due to vibration and movement typical

during engine operation.

Donaldson recommends mounting the assemblyon the firewall, fender or frame rail using existingor newly-fabricated brackets. Mounting bandsare included with the unit (1 with S040004 and 2with S040005). Consider serviceability and filterreplacement space requirements in choosing themounting location.

NOTE Mount Spiracle in a CoveredLocation

It is important to ensure the top of the Spiracle unit isnot directly exposed to rain or outside elements. Thisexposure can result in the malfunction of the regulatorvalve.


It is important to ensure the bottom of the Spiracle unitis positioned at least 6" (152mm) above the engine oildrain-back location to ensure free oil flow to the engine.

The Spiracle assembly must be mounted in avertical orientation (as shown below), plus orminus 10. Meeting these requirements will ensurethe coalesced oil can drain back to the enginefreely.

Typical InstallationThe Spiracle filtration system unit requires four

connections. A description of each follows:

1) Spiracle Inlet (from the crankcase vent)1" (31mm) diameter tubing is required toconnect the Spiracle inlet port to the Spiracleby-pass valve, then from the by-pass valve to thecrankcase vent. Retain the OEM breather whenpresent. An adapter may be required to connectbetween the OEM breather port and the Spiracleinlet. Do not allow any dips or sharp bends inthe tubing where coalesced oil can collect andblock flow from the crankcase vent. The tubingmust be able to withstand hot engine oil.

2) Spiracle Oil Drain-back Line (to engine sump)The bottom of the Spiracle housing must bepositioned at least 6" (152mm) above theengine-oil drain-back location. " (13mm)diameter tubing is provided to drain coalescedoil back to the engine oil sump. The check valve(" NPT) provided must be connected to adrain-back location and mounted vertically,plus or minus 45. Typical drain-back locationsinclude available engine block ports or dipstickmounting plates. An adapter may also be weldedonto an oil fill neck.

3) Spiracle Outlet (to engine intake)One inch (25mm) diameter tubing is requiredto connect to the Spiracle outlet port. Minimizethe tubing length and avoid sharp bends. Thetubing should be connected to the air intake ductbetween the air filter and the turbocharger. If anNPT port does not already exist, a 1" (25mm)tubing barb should be welded onto a metalintake duct. The weld must be leak-free andany debris must be removed before starting theengine to avoid damage.

Outlet

Oil Drain with

Check Valve

Over-center Latches

Mounting Band

InletBy-pass Valve

Hose to

Engine Intake

Mounting Bracket

Pressure

Regulating Valve

Hose to

Crankcase Vent

1

2

3

4


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4) By-pass Valve Mounting(in-line with inlet tube)Thisby-pass valve (see diagram)is used in the event of aplugged filter or malfunctionin the system. It allowsblow-by fumes to exit into

the atmosphere where theycan be detected by the user and the problem canbe addressed. The valve must mounted so thatit is within +/-30 of horizontal to prevent oilfrom building up in valve. The by-pass valve isinstalled using the 1 Spiracle inlet tubing.

NOTE Employ Oil-Resistant Tubing

Any tubing material used must be able to withstandhot engine oil. BunaN (Nitrile rubber) is anacceptable material.

NOTEMinimize Tubing

Lengths/Sharp Bends

Minimize tubing lengths and avoid sharp bends tothe Spiracle outlet port.

NOTEAvoid Dips and Valleys in

Tubing

Valleys or low spots in the interconnecting tubingshould be avoided to prevent condensed/coalescedoil from collecting and blocking flow paths. Blockedflow paths can result in increased crankcasepressure, which can lead to crankcase and oil panseal leaks.

NOTE Check Dipstick Seal

If the engine uses a sealed dipstick, make sure theseal is good or oil may be forced out of it.

Ensure Tubing/Connections are Leak-freeTo maximize effectiveness, interconnecting tubingand connections should be structurally sound

and leak-free. Inspect the tubing and connectionsregularly for damage, leaks, punctures or materialdefects, and replace defective components.

Change Filter RoutinelyThis assembly requires routing filter change. Youwill need to update your vehicle maintenancerecords to include a reminder to change theSpiracle filter on a routine basis.

Donaldson recommends that you change theSpiracle filter at every oil change or 500 hours ofoperation, whichever comes first.

A dirty filter, or one left unchanged, can alsoresult in low efficiency and fouling of theturbocharger and aftercooler. A plugged filtercan cause a pressure build-up in the crankcase,resulting in leaking crankcase seals and degradedengine performance.

NOTE Change Filter Regularly

The Spiracle filter must be replaced in accordance withengine manufacturers recommended oil change intervalor 500 hours of operation, whichever comes first.

Spiracle Filtration System WarrantyThe statement of warranty for the Spiraclefiltration system is in the documentation package.

Activating the Warranty

A Warranty Registration Card is included in thedocumentation packet. Furnish the informationrequested and answer all questions immediatelyafter completing the installation. Return thepostage-paid card to Donaldson to activate thewarranty.

NOTE Submit Warranty Information

Failure to complete the warranty information requestedby Donaldson within 30 days of installation of theemission control system may void this warranty.

By-pass Valve


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Spiracle Unit InstallationThe following section identifies installationprocedures for the Spiracle filtration system.

Review all pre-installation requirements before

proceeding with the installation.

Locate and Mount the Spiracle Assembly1) Identify prospective spaces for mounting the

Spiracle assembly and locate potential oil drain-back locations. The bottom of the Spiracleassembly should be at least 6" (152mm) higherthan the desired oil drain-back location. The unitmust be mounted vertical, plus or minus 10.Before selecting the best location, ensure the unitwill be accessible for service.


The bottom of the Spiracle assembly must be at least6" (152mm) higher than the oil drain-back location tofacilitate the draining of coalesced oil back to theengine sump.

NOTEMount Spiracle in a Covered

Location

It is important to ensure the top of the Spiracle unitis not directly exposed to rain or outside elements.This exposure can result in the malfunction of theregulator valve.

NOTEMount Spiracle Away from Hot

Surfaces

The Spiracle system and hoses must remain at least6" (152mm) away from the turbocharger, exhaustpipes, or other hot surfaces.

2) Secure the supplied mounting band(s) to anew or existing bracket on the firewall, fenderor other indepdendent structure. A custom-fabricated mounting bracket may be needed for

installation.3) Tighten mounting bolts securely.

Examples of different mountings:Example 1: Using existing mounting brackets

Example 2: Fabricated new mounting bracket


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Example 3: Mounted on an existing stanchion

Example 4: Mounted on back of cab stanchion

Example 5: Fabricated mount to existing power steering reservoir bracket

Make Spiracle Inlet and By-pass ValveConnection

1) Determine length and routing of Spiracle inlettubing needed to connect the current enginebreather port to the Spiracle inlet. Minimize thetubing length and avoid dips or sharp bendswhen determining routing.

2) The by-pass valve must also be installed in-line with the inlet tubing. The by-pass valve isnon-directional so either side may be installed

in-line with the breather port. This valve mustbe mounted so that it is within +/-30 fromhorizontal. This will prevent oil from building upwithin the valve.See image below.

3) Cut a short (3-6/ 76-152mm) section of 1 (32mm) tubing to be installed from the Spiracleunit to the by-pass valve inlet. Cut a secondsection of 1 (32 mm) hose to go from the by-pass valve to either the engine crankcase vent, orto a reducer where further hose will need to beinstalled to the engine crankcase vent. Use 1

(38mm) hose clamps to secure the hose sections.Tighten each clamp securely. Place the by-passvalve (with tubes) and into position, use wire tiesto prevent movement.

4) Attach the 5-6 (127-152mm) section of tubingto Spiracle inlet using 1 (38mm) tubingclamp. Tighten clamp securely.

5) Remove the drop tube from the OEM enginebreather port, if present. Attach the other endof the Spiracle inlet tubing to the OEM enginebreather port. An adapter may be requiredto transition between different diameterconnections. Secure the tubing to the crankcasebreather port using a 1" (38mm) tubing clamp

Example of connection to crankcase vent.


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Connect Spiracle to the Air Intake System1) Determine length and routing of tubing necessary

to connect Spiracle outlet to the air inductionpiping between the air filter and turbocharger.Minimize the tubing length and avoid sharpbends when planning routing.

NOTEVerify Existing NPT

is Greater Than 3/4" (19mm)

Make sure the existing NPT fitting is greater than3/4" (19mm) to ensure proper flow.

2) Locate NPT port on air intake piping.

a) If NPT port is present, remove the NPT plugand install 1" (25mm) diameter tubing adapter.

b) If no NPT adapter is found, weld 1" (25mm)diameter tubing adapter onto air intake piping.

3) Cut 1" (25mm) diameter Spiracle outlet tubing

to length and lay into position. Fasten tubingwith wire-ties to prevent movement.

4) Attach one end of tubing to Spiracle outlet using1 (31mm) tubing clamp.

5) Attach other end of Spiracle outlet tubing to airintake piping adapter using second 1" (31mm)tubing clamp.

6) Tighten both clamps securely.

Example 1: Existing NPT adapter on clean air duct.

Example 2: Tubing with beaded end welded onto intake pipe

NOTERemove Debris from

Clean Air Ducts

Welds on air intake piping must be leak-free to avoidengine contamination. Metal shavings and/or welding

debris must be removed from inside of clean air pipingafter installation. Disconnect clean air piping andremove any debris located inside before operatingengine.

Connect Spiracle Drain to Engine Sump1) Determine the location for oil drain-back.

Consider available unused engine block ports,dipstick holes or mounting plates, or weld "NPT adapter onto oil fill neck (see photos).

2) Install the threaded end of the check valvedirectly into the drain-back location with avertical orientation, plus or minus 45.

3) Determine length of drain-back tubing necessaryto connect the Spiracle bottom drain to thecheck valve. Minimize dips and sharp bends thatmay inhibit the flow of coalesced oil. Secure thetubing with wire-ties, if appropriate.

4) Connect one end of the " (13mm) diameterdrain tubing to the bottom of the Spiracle unit.Secure the tubing with a " (19mm) tubingclamp.

5) Attach the other end of the drain tubing to thecheck valve. Secure the tubing with the second" (19mm) tubing clamp.

6) Tighten both clamps securely.


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Examples of oil drain-back locations.

Example 1: Check valve installed on oil fill cap

Example 2: Check-valve adapter welded onto fill tube

Example 3: Check valve installed in existing engine block port.

Example 4: Unused dipstick drain hole used for Spiracle oil drainback.

System Checks1) Verify all bolts/fasteners/clamps are tight.

2) Start the engine and allow it to idle.

3) Check for leaks in the inlet, outlet, and drainlines and tighten connections as necessary.

4) Turn off engine.

5) If a weld leak exists, repair the leak.

6) To meet CARB requirements, permanentlyattach the product identification tag (suppliedin documentation package) in a clearly visiblelocation on the engine. CARB regulationsrequire a product identification tag bepermanently installed on the engine in a clear,visible location. Application of the engine tag i

not necessary for U.S. EPA regulations.

NOTE CARB Requirement

California ARB regulations require a productidentification tag be permanently installed on the enginein a clear, visible location.

7) Fill out and return the Warranty RegistrationCard (provided in the documentation packet).

Please contact Donaldson, at the phone numberprovided on the back cover, with any installationquestions or problems.


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Activating the WarrantyA Warranty Registration Card is included in thedocumentation packet. Furnish all informationrequested and answer all questions immediatelyafter completing the installation. Return toDonaldson via the postage-paid card.

NOTEComplete WarrantyRegistration Card

Failure to complete the warranty information requestedby Donaldson within 30 days of installation of theemission control system may void this warranty.

Operation, Maintenance andService Guide for SpiracleFiltration Systems

OperationUnder normal operation, the crankcase pressurein a diesel engine should be maintained betweenapproximately +/- 4" H

2O (this may vary from

engine to engine). High pressure can cause oilleaks in the crankshaft seals or oil pan gasket.Excess vacuum can cause contaminants to bedrawn into the engine.

The Spiracle filtration system has an integratedpressure-regulating valve that automaticallymaintains a neutral crankcase pressure. It closeswhen the intake vacuum is high (high engineload) and opens under high crankcase pressureconditions to relieve the pressure.

NOTEDo Not Tamper with

Regulating Valve

Do not tamper with pressure-regulating valve. Animproperly operating valve may cause excessivepressure or vacuum in the engine crankcase, resulting

in leaking seals and degraded engine performance.

The Spiracle assembly has two check valves toprevent the flow of engine oil from the enginesump: an integrated valve in the bottom of theassembly and a remote valve to be installed inthe drain-back location. If oil does not drainproperly from the assembly, verify that the unitwas installed properly, then clean each check valvewith diesel fuel or solvent.

Maintenance and ServiceDonaldson Spiracle filtration systems are designedand approved for use on most medium and heavy-duty truck and bus engines. To ensure efficientoperation of this product, the following preventivemaintenance procedures must be incorporated

into your regular vehicle maintenance routines.

During normally scheduled vehicle maintenance,inspect the Spiracle assembly, tubing, clamps,and mounting bracket. Look for leaks, structuralfailures (cracks), and loose connections. Repair orreplace any defective parts, as appropriate.

Add Filter Change into Maintenance ScheduleThe filter must be changed at the enginemanufacturers recommended oil change intervalor every 500 hours of operation, whichever comes

first.

NOTE Replace Filter Regularly

The Spiracle assembly is designed to have the filterreplaced at the engine manufacturers recommendedoil change interval or every 500 hours of operation,whichever comes first. Replace the filter regularly toavoid turbocharger and/or intercooler fouling.

Spiracle filtration systems are subject to shortenedservice life under the following conditions:

Improper engine maintenance. Engine operation with excessive oil consumption

and excessive blow-by due to worn piston rings.

Improper and oversized air cleaner, resulting ininsufficient vacuum at the spiracle outlet.

Engines with dual air cleaners may causeinsuffiicient vacuum at the Spiracle outlet.

To prevent the reoccurrence of short filter life,engine performance concerns must be resolvedbefore operating with a new Spiracle replacementfilter.

Use the following procedures to perform routineservice of the Spiracle filtration system.


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Routine Filter Service ProcedureReplace the Spiracle filter during regularlyscheduled oil changes or every 500 hours ofoperation, whichever comes first, in accordancewith the procedure below.

1.) Release over-center latches and separate upper

and lower sections of Spiracle assembly (lowersection is held in position with mountingband[s]). Lift the upper section of Spiracleassembly (still connected via inlet tube) out ofthe way.

2.) Remove old filter.

3.) Apply (rub) clean engine oil around the innerdiameter of new Spiracle filter seal to easeinstallation and improve sealing.

4.) Install the new filter (using a rotating motion) inupper section of Spiracle assembly by pushing itupward in the housing until fully seated on theseal tube.

5.) Hold over-center latches up and position filter/upper section of assembly onto lower sectionof the housing. Align filter inside of sealing cupand push downward until filter is fully seated inbottom of housing.

6.) Fasten over-center latches to secure Spiraclesections together.

7.) Note engine mileage/hours in your maintenancerecords and schedule next filter replacementperiod.

8.) If there is moisture in the lower section of theSpiracle assembly, remove with a clean shoprag. Moisture can build up through the normal

combustion process.

NOTEUse Only DonaldsonReplacements Filters

Use only Donaldson replacement filters in the Spiracleunit. Do not operate the engine without a filter to avoid

turbocharger or aftercooler fouling.

Filter for S040004 Model is P603746Filter for S040005 Model is P603568

NOTE Do NOT Clean Spiracle Filters

Do not attempt to clean or recondition the filter.Reconditioned filters may provide low efficiency,resulting in fouled turbocharger and intercoolercomponents.

The oil dipstick may act as a pressure relief ventby dislodging from its fully installed position.If the dipstick is found dislodged, the filter mayneed service. Inspect the filter and replace if itappears dirty or plugged.

The Spiracle filtration system uses check valves toprevent engine oil in the sump from being drawninto the Spiracle filtration system. This preventsthe engine from drawing oil out of the sump andfrom a run-away engine in the event of an engineroll-over (from an accident or by other means).Inspect the Spiracle system, mounting bandsand interconnecting tubing in the event of anengine rollover. Replace the filter to ensure highefficiency and prevent turbo fouling.

Spiracle Filter Disposal Information

With proper use, Spiracle filters become loadedwith engine oil, combustion by-products, dieselparticulate matter, and engine wear debris. Thesematerials may be classified as hazardous waste incertain areas. Please dispose of the used Spiraclefilters in accordance with your local regulations.Treating the filter similar to a used oil filter willtypically meet local regulations.

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Donaldson Company, Inc.Minneapolis, MN55440-1299

www.donaldson.com

2006Printed in the U.S.A.Equal Opportunity EmployerDonaldson Company, Inc. reserves the right tochange or discontinue any model or specification atany time and without notice.

Actions and Improper Maintenance ThatMay Void Your WarrantyThe following conditions are considered to be abuse, neglect orimproper maintenance that may void your warranty.

Any other practice that would cause the

system to leak unfiltered flow to the engine,resulting in turbo charge or aftercoolerfouling

Tampering with the Spiracle pressureregulating valve

Any practice that would cause excessivepressure or vacuum in the crankcase

Failures or damage caused by mountingsystem failures

Physical damage caused by misuse, abuse orroad hazards including (but not limited to)dents, cuts, or fractures to the exterior orinterior of the Spiracle filtration system

Modifications, alteration or attemptedrepair of the Spiracle filtration system

Damage due to shipping

Failure to service the Spiracle system inthe event of an vehicle roll-over (from anaccident or by other means), including afilter element change and an inspection anddraining of lube oil from all tubing

Progressive engine failures that allow thepresence of fuel or coolant in the lube oilsump or blow-by gas stream in excess ofEngine manufacturers specifications

Misapplication or improper installation of

the Spiracle CCV filtration system (failureto adhere to Donaldson owners manual)

Failure to change the Spiracle element atevery engine manufacturers recommendedlube oil change or 500 hours (whichever ismore frequent)

Failure to perform routine and normalsystem maintenance practices during serviceintervals, including an inspection of alltubing connections and a tightening of allclamps as necessary to avoid contaminationof the engine through unfiltered leaks intothe air intake system connection

Failure to return the warranty registrationcard within 30 days of installation.

The use of a non-Donaldson Spiraclereplacement filter or the reuse of a cleanedSpiracle filter (Spiracle filters are notcleanable)

The operation of a Spiracle system (engineoperation) without a filter in place

Tampering with a filter resulting inbypassing either the first or second filteringstage

The use of a Spiracle replacement filter sizeother than that intended for the system

Crank Case Ventilation

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