heavy duty specialists, inc. · application air cleaner type/size air cleaner filter field life...

56 • Air Intake www.HvyDuty.com

Micron ratings are commonly used to convey filtration performance in liquid filtration. Because of this, we often are asked what our micron ratings are for a particular air filter or air cleaner. Typically, air cleaners and air filters are not assigned a micron rating.

To evaluate the life and efficiency performance of air filters, filtration manufacturers use standard industry recognized tests; i.e., SAE and ISO. These standards provide a basis for comparison among products, models and manufacturers. The test most commonly used is the SAEJ726 Air Cleaner Test Code (SAE = Society of Automotive Engineers).

The following is an excerpt from the SAEJ726 test code:

“Filter life is measured in total grams fed or in hours of lab life and is determined by testing at a standard test dust concentration of (1 gram/cubic meter or 0.028 grams/cubic foot) at either a constant or variable airflow. The end of the life testing is determined using the restriction method. When the predetermined restriction service point is reached, the test is stopped and the filter is weighed. The amount of test dust held by the filter is considered the capacity or life of the filter. The life of an air cleaner requires some additional consideration.”

Many of the Donaldson air cleaners have inertial separators included in the housing. These inertial separators remove up to 98% of the dust that is fed during one of these tests. Therefore, the inertial separator efficiency must also be evaluated.

Filtration efficiency is calculated by determining the increase in weight of an absolute filter (an absolute filter captures any dust that passes the test filter) located downstream of the test filter vs. the weight of the total dust fed.

Life & Efficiency Ratings

Particle Size Distribution by Weight % of Fine & Coarse Test DustThe fine test dust is used for testing primary dry, single stage air cleaners, which are most often used in on-road applications. Coarse test dust is used for two-stage air cleaners that typically use inertial separators and operate in very dusty applications.

...Donaldson air filters in Donaldson air cleaner housings have a 99.99+% minimum overall efficiency.

Filtration Efficiency

Common Contaminants by Micron SizeAlthough field conditions vary from one location to the next and from time to time, this test allows for a standard means of comparison and a laboratory method of evaluating air cleaner life and efficiency.

.01 0.1 1.0 10 100 1,000 10,000

Smog Clouds & Fog

Mist & Drizzle

Exhaust Soot

Dust

Rain

Particle Sizes in Microns

Particle Size (in microns)

Weight %Fine Coarse

0 - 5 39 ±2% 12 ±2%5 - 10 18 ±3% 12 ±3%10 - 20 16 ±3% 14 ±3%20 - 40 18 ±3% 23 ±3%40 - 80 9 ±3 % 30 ±3%

80 - 200 0% 9 ±3 %

HEAVY DUTYSPECIALISTS, INC.

9341 “G” Court • Omaha, NE 68127-1230Phone (402) 592-5400 • Toll Free (800) 642-2514 • Fax (402) 592-9659

www.HvyDuty.com Air Intake • 57

Typical Contaminant Holding Capacity and Life Range by Application ----Contaminant Capacity---- Application Air Cleaner Type/Size Air Cleaner Filter Field Life Range

On Highway Truck E Series / 13" (330mm) dia. 8 lbs. / 3.6 kg 8 lbs. / 3.6 kg 100,000-150,000 miles / 161,000 - 241,000 kmAgricultural Equipment F Series / 8" (203mm) dia. 14.5 lbs. / 6.6 kg 2.5 lbs. / 1.1 kg 300 - 2,000 hoursConstruction Equipment F Series / 16" (406mm) dia. 55 lbs. / 25 kg 8 lbs. / 3.6 kg 100 - 1,000 hours S Series / 16" (406mm) dia. 148 lbs. / 67 kg 7.5 lbs. / 3.4 kg 200 - 2,000 hoursMining Haul Trucks S Series / 29" (737mm) dia. 770 lbs. / 349 kg 38 lbs. / 17.2 kg 1,000 - 5,000 hours

The amount of contaminant an air filter can hold before servicing depends on... • air cleaner size and type • engine size and airflow • time of year • type and amount of contaminant • operating conditions • type of equipment • filter mediaIt’s easy to see why Donaldson recommends that you service your air cleaner based on airflow restriction measurements. Weigh your air filter the next time you change it based on restriction readings, and compare how close we are to predicting filter contaminant holding capacity.

What is the Purpose of a Safety Filter?Safety filter... secondary element... inner filter... spare filter? There are many names... Donaldson prefers to call it a “safety” filter.

A safety filter backs up the primary filter, and protects the clean air ducting while the primary is out of the housing during service. The engine should never be run with only a safety filter in place.The safety is NOT a spare filter! Its purpose is to protect the engine if something goes wrong with the primary (main) filter. Until then, all it does is take up space and add a little bit of restriction (1" to 2" H20).

What can go wrong with the primary filter? It may have hidden damage from shipping that you missed when you inspected it before installation; damage from cleaning (if you do); maybe even a manufacturing glitch; misinstallation by the mechanic (never happens, right?); a “will-fit” that doesn’t quite fit; or it’s the wrong part altogether and doesn’t fit at all into the housing.

Safety Filter (fits inside the Primary Filter)

Air CleanerHousing

Cover/ Dust Cup

Primary or Main Filter

All of these things happen more often than any of us like to think. Donaldson determined many years ago that a really good way to provide additional protection for large engines operating in heavy dust conditions was to add this “safety” filter to the air cleaner. There are some characteristics about the safety filter which you should be aware of, so you understand what it does and doesn’t do for your engine:

• is smaller, with less media;

• is more open and less efficient, for lower restriction;

• has less contaminant-holding capacity so that it will plug rapidly if any engine-damaging dust particles get past a damaged primary filter.

Protection against mistakes and reducing the need to open the clean air side of the system by 66% – compared to systems without a safety filter – is excellent insurance against contaminants entering your engine.

Most engine and equipment manufacturers set standards for filter contaminant holding capacity.

The standards generally reference an industry test procedure (i.e., SAE or ISO). These standards provide a basis for comparison among products, models and manufacturers. The standards do not directly translate to field conditions, but based on our experience and expertise, we can provide generalizations about the amount of contaminant an air filter can hold in typical applications.

How Much Contaminant Can a Donaldson Air Filter Hold?

Common Questions




Don’t remove filter for inspection. Such a check will always 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. Stick with the regular maintenance schedule, or, if you service by restriction, believe the gauge or restriction indicator. Get a new indicator if you don’t trust your current one.

Never rap a filter to clean it.Rapping hard enough to knock off dust damages the filter and destroys your engine protection. Deeply embedded dirt is never released by tapping. It is always safer to keep operating until you can change to a new filter.

Never judge the filter’s life by looking at it. Measure the airflow restriction.A dirty-looking filter may still have plenty of life left, while carbon contamination may not be visible to the eye. You can’t see the dirt that’s embedded deep within the filter paper. Your best bet for lowest filter maintenance costs and best engine protection is to follow a restriction indicator. It’s a smart, low-cost investment.

Never leave an air cleaner open longer than necessary.Your open air cleaner is a direct entry to the engine! Keep it protected during filter changes. Contaminants smaller than we can see will cause damage to a diesel engine. If the housing is not going to be reassembled immediately, cover the opening. The only way to be sure nothing got in, is to make sure nothing can get in!

Don’t ignore a worn or damaged gasket in the housing.If your air cleaner has a cover gasket, replace it with a new one. Always check to be sure that no piece of the old gasket remains in the housing and that the gasket is not worn. If your filter model calls for a new gasket with each use, never reuse the old one.

Don’t use a damaged or bunched filter. Never install a dented or punctured filter because it cannot protect properly against contamination. A dent can make a firm seal impossible or can indicate damaged media. A filter with bunched pleats saps engine power and fuel dollars.

Replace missing or damaged parts.Check to ensure that there is no damage to the air cleaner housing that could cause a leak. Replace any missing or damaged Vacuator™ Valves and air cleaner fasteners. Never attempt to repair a damaged filter.

Never substitute an incorrect filter model number.Filters may look almost identical, but even a fraction of an inch difference in size can prevent a good seal or affect airflow. Selecting a filter by size may give you the wrong media and therefore affect service life and filter efficiency.

General Air Cleaner Service Tips



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Make sure the gasket6 seats evenlyIf you don’t feel the gasket seating evenly for a perfect seal, you don’t have protection. Recheck to see if the sealing surface in the housing is clean, and ensure that the filter is the correct model. It may be the wrong size for the housing.

Ensure air-tight fit on all7 connections and ductsCheck that all clamps and flange joints are tight, as well as the air cleaner mounting bolts. Seal any leaks immediately – leaks mean dirt is directly entering your engine.

Check for uneven4 dirt patternsYour old filter has valuable clues to dust leakage or gasket sealing problems. A pattern on the filter clean side is a sign that the old filter was not firmly sealed or that a dust leak exists. Identify the cause of that leak and rectify it before installing a new filter.

Press your fresh gasket5 to see that it springs backMake sure your new filter is made with a highly compressible gasket

that springs back (promptly) when finger pressure is released. A high quality gasket is one of the most important parts of the filter.

Remove the old1 filter gently“Baby” that dirty filter, until you get it clear of the housing. Accidentally bumping it while still inside means dropped dirt and dust that will contaminate the clean side of your filter housing, before the new filter element has a chance to do its job.

Always clean the inside� of the housing carefullyDirt left in the air cleaner housing spells death for your engine. Use a clean, damp cloth to wipe every surface clean. Check it visually to make sure it’s clean before putting in a new filter.

Always clean the gasket 3 sealing surfacesAn improper gasket seal is one of the most common causes of engine

contamination. Make sure that all hardened dirt ridges are completely removed, both on the bottom

and top of the air cleaner

housing.

Axial Seal Service InstructionsSingle-Stage Air Cleaners




Axial Seal Service InstructionsTwo-Stage Air Cleaners

F Series Cyclopac™ and Cycloflow™ Service Procedure

Change the Filter3 When restriction indicates that filter servicing is required, loosen the wing nut and remove the primary filter. Before installing the new filter, inspect the filter and gasket for shipping or storage damage. Wipe out the housing with a clean cloth. Carefully install new filter, wing nut and sealing washer. Always use Donaldson replacement filters, which have been engineered to fit the air cleaner and engine intake system exactly.

Cover the Inlet4 Don’t leave the air inlet exposed! If the new filter won’t be installed immediately, cover the opening to prevent stray contaminant from entering the induction system.

Safety Filter Service5 For maximum engine protection and air cleaner service life, replace the safety filter every third primary filter change or as indicated by the Donaldson Safety Signal® service indicator.

Reinstall the Dust Cup6 Be sure the dust cup is sealed 360° around the air cleaner body. Reset the restriction indicator to green.

Check Connections7 Ensure that all connections between the air cleaner and the engine are tight and leak-free.

Measure Restriction1 Measure the restriction of the air cleaner with a Donaldson restriction indicator, such as The Informer™, a service gauge, or water manometer at the restriction tap provided in the air cleaner or the transfer pipe. One of two conditions will exist:(1) If the reading indicates the maximum restriction (per engine manufacturer’s recommendations), change out the filter. (2) If the reading shows below the maximum, the filter still has life left and should not be serviced.

Empty the Dust Cup� Dust should not be allowed to build up closer than one inch from the baffle. On models equipped with a Donaldson Vacuator™ Valve, dust

cup service is cut to a minimum; all that is necessary is a quick check

to see that the Vacuator™ Valve is not inverted, damaged,

or plugged.



heavy duty specialists, inc. · application air cleaner type/size air cleaner filter field life...

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