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National Clean Diesel Campaign (NCDC)

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Donaldson Retrofit Technologies

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Donaldson's System: Series 6000 DOC & Spiracle
Verification Letter (PDF)  (2 pp, 90K, August 2003)
Amendment Letter (PDF)  (2 pp, 100K, April 2011)
Technology Engine
Model/Application
Retrofit Fuel, Max Sulfur (ppm) Reductions (%)
PMa NOx HC CO
Series 6000 DOC & Spiracle (closed crankcase filtration system). Baseline A.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 500 25 n/a 52 13
Series 6000 DOC & Spiracle (closed crankcase filtration system). Baseline A.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 33 n/a 26b 19
Series 6000 DOC & Spiracle (closed crankcase filtration system). Baseline B.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 28 n/a 50 23

a - Total PM reduction figures reflect reductions from both tailpipe and crankcase emissions.
b - Verification test results produced an average HC percentage reduction of 26%. However, the 95% confidence interval included zero so no reduction is assigned.

Baseline A - Baseline assumes an unmodified engine running on regular 2D (<500 ppm sulfur) fuel.
Baseline B - Baseline assumes an unmodified engine running on ultra-low sulfur diesel fuel (ULSD) (<15 ppm sulfur) fuel.

The following operating criteria must be met in order for appropriately retrofitted engines to achieve the above emissions reductions:

  1. The engine exhaust temperature must be at least 150° C during the duty cycle.
  2. The engine should be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer.
  3. The engine must be operated with a fuel that contains a sulfur content of no more than the level indicated above.

No discernible fuel economy penalty is expected when used in a compatible application.

The following operating criteria must be met for the Spiracle Closed Crankcase Filtration System in order for appropriately retrofitted engines to achieve the above emissions reductions:

  1. Blow-by rates must be measured and recorded on each vehicle prior to Spiracle installation before selecting the applicable Spiracle model based on the chart provided below.
  2. The filtered oil from Spiracle must be returned back to the engine oil sump. There is no catch bottle to be used with the Spiracle system.
  3. International DT444 engines require the installation of the Spiracle Boost using venturi technology to increase the turbo intake vacuum force acting to overcome the filter restriction.
  4. Spiracle systems require that the filter cartridge must be changed in accordance with the maintenance schedules noted below.

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Description Diesel Engine Application (5)
  Less than
400 HP (1)
Greater than
400 HP (1)
Blow-by Flow Rate 0-11 cfm 9-24 cfm
Metal Spiracle Part Number Replacement Filter Part Number S040004 P603746 (2)
or P607673 (3)
S040005 P603568 (2)
Plastic Spiracle Part Number Replacement Filter Part Number S040020 (3), (4)
P607673 (3)
 

Notes:

  • (1) HP rating is given as approximation of Spiracle sizing, but selection is based on blow-by flow rates.
  • (2) Filter change interval for P603746/S040004 and P603568/S040005: Every lube oil change or 500 hours, whichever comes first.
  • (3) Filter change interval for P607673/S040020 and P607673/S040004: 1000 hours or at 8” H20 if using indicator.
  • (4) Filter change interval for P607673/S040020 on Navistar DT444: 1000 hours or at 1” H20 if using indicator.
  • (5) Donaldson offers generic and custom installation kits. Generic kits include mounting brackets and connection fittings. Custom kits include generic components plus tubing and clamps.

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Donaldson's System: Series 6100 DOC
Verification Letter (PDF)  (2 pp, 60K, August 2003)
Technology Engine
Model/Application
Retrofit Fuel, Max Sulfur (ppm) Reductions (%)
PM NOx HC CO
Series 6100 DOC. Baseline A.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 26 n/a 49 38
Series 6100 DOC. Baseline B.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 20 n/a 66 41

Baseline A - Baseline assumes an unmodified engine running on regular 2D (<500 ppm sulfur) fuel.
Baseline B - Baseline assumes an unmodified engine running on ultra-low sulfur diesel fuel (ULSD) (<15 ppm sulfur) fuel.

The following operating criteria must be met in order for appropriately retrofitted engines to achieve the above emissions reductions:

  1. The engine must be operated with a fuel that contains a sulfur content of no more than 15 ppm.
  2. The engine exhaust temperature must be at least 150° C during the duty cycle.
  3. The engine should be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer.

No discernible fuel economy penalty is expected when used in a compatible application.

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Series 6100 DOC & Spiracle
Verification Letter (PDF)  (2 pp, 90K, August 2003)
Amendment Letter (PDF)  (2 pp, 100K, April 2011)
Technology Engine
Model/Application
Retrofit Fuel, Max Sulfur (ppm) Reductions (%)
PMa NOx HC CO
Series 6100 DOC & Spiracle (closed crankcase filtration system). Baseline A.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 32 n/a 14b 31
Series 6100 DOC & Spiracle (closed crankcase filtration system). Baseline B.
Environmental Technology Verification Logo
Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 28 n/a 42 34

a - Total PM reduction figures reflect reductions from both tailpipe and crankcase emissions.
b - Verification test results produced an average HC percentage reduction of 14%. However, the 95% confidence interval included zero so no reduction is assigned.

Baseline A - Baseline assumes an unmodified engine running on regular 2D (<500 ppm sulfur) fuel.
Baseline B - Baseline assumes an unmodified engine running on ultra-low sulfur diesel fuel (ULSD) (<15 ppm sulfur) fuel.

The following operating criteria must be met in order for appropriately retrofitted engines to achieve the above emissions reductions:

  1. The engine exhaust temperature must be at least 150° C during the duty cycle.
  2. The engine should be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer.
  3. The engine must be operated with a fuel that contains a sulfur content of no more than the level indicated above.

No discernible fuel economy penalty is expected when used in a compatible application.

The following operating criteria must be met for the Spiracle Closed Crankcase Filtration System in order for appropriately retrofitted engines to achieve the above emissions reductions:

  1. Blow-by rates must be measured and recorded on each vehicle prior to Spiracle installation before selecting the applicable Spiracle model based on the chart provided below.
  2. The filtered oil from Spiracle must be returned back to the engine oil sump. There is no catch bottle to be used with the Spiracle system.
  3. International DT444 engines require the installation of the Spiracle Boost using venturi technology to increase the turbo intake vacuum force acting to overcome the filter restriction.
  4. Spiracle systems require that the filter cartridge must be changed in accordance with the maintenance schedules noted below.

Top of page

Description Diesel Engine Application (5)
  Less than
400 HP (1)
Greater than
400 HP (1)
Blow-by Flow Rate 0-11 cfm 9-24 cfm
Metal Spiracle Part Number Replacement Filter Part Number S040004 P603746 (2)
or P607673 (3)
S040005 P603568 (2)
Plastic Spiracle Part Number Replacement Filter Part Number S040020 (3), (4)
P607673 (3)
 

Notes:

  • (1) HP rating is given as approximation of Spiracle sizing, but selection is based on blow-by flow rates.
  • (2) Filter change interval for P603746/S040004 and P603568/S040005: Every lube oil change or 500 hours, whichever comes first.
  • (3) Filter change interval for P607673/S040020 and P607673/S040004: 1000 hours or at 8” H20 if using indicator.
  • (4) Filter change interval for P607673/S040020 on Navistar DT444: 1000 hours or at 1” H20 if using indicator.
  • (5) Donaldson offers generic and custom installation kits. Generic kits include mounting brackets and connection fittings. Custom kits include generic components plus tubing and clamps.

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Series 6400 DOC & Spiracle
Verification Letter (PDF)  (2 pp, 90K, August 2011)
Technology Engine
Model/Application
Retrofit Fuel, Max Sulfur (ppm) Reductions (%)
PM NOx HC CO
Series 6400 DOC & Spiracle (closed crankcase filtration system). Highway, heavy-heavy and medium-heavy duty, 4 cycle, non-EGR, model year 1991 - 2003, turbocharged or naturally aspirated 15 28a n/a 50 23

a - Total PM reduction figures reflect reductions from both tailpipe and crankcase emissions.

Baseline assumes an unmodified engine running on fuel 15 ppm sulfur or less.

The following operating criteria must be met for appropriately retrofitted engines to achieve the above emissions reductions:

  1. The engine must be operated on ultra-low sulfur diesel fuel (ULSD) of 15 ppm or less.
  2. The engine exhaust temperature must be at least 150° C during its duty cycle.
  3. The engine must be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer.
  4. The vehicle may not be equipped with an oil burning system and lube oil or other oils may not be mixed with the fuel
  5. The engine must not have been originally certified or equipped with a diesel oxidation catalyst or diesel particulate filter.
  6. Spiracle™ must be installed and maintained as described in the April 1, 2011 EPA approval

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Donaldson’s Semi-Active Electric Filter for Non-Road Applications (NR-SEF) System
Verification Letter (PDF)  (2 pp, 90K, December 13, 2013)
Technology Engine
Model/Application
Fuel, Max Sulfur (ppm) Reductions (%)
PM NOx HC CO
Semi-Active Electric Filter for Non-Road Applications (NR-SEF) System Nonroad, model year 1996-2010, with power rating between 100 and 400 hp and particulate matter (PM) certification levels less than 0.25 g/bhp-hr 15 90 n/a 95 90

The following criteria must be met in order for appropriately retrofitted engines to achieve the aforementioned emission reductions:

  1. The engine must be operated on ultra-low sulfur diesel fuel (ULSD) of 15 ppm or less.
  2. The engine must be a model year 1996-2010 nonroad engine with power rating between 100 and 400 hp and particulate matter (PM) certification levels less than 0.25 g/bhp-hr.
  3. A Donaldson approved dealer will install the Donaldson Emissions Device Monitor with the NR-SEF System to constantly monitor backpressure and temperature on all vehicles equipped with this diesel particulate filter.
  4. For active regeneration, owners are periodically required to plug in their NR-SEF System to the Regeneration Control Station.
  5. The engine must be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer. Crankcase oil burning systems may not be used with this diesel particulate filter.
  6. The vehicle may not be equipped with an oil burning system and lube oil or other oils may not be mixed with the fuel.
  7. The engine must not have been originally certified or equipped with a diesel particulate filter.
Donaldson’s Low NO2 Diesel Particulate Filter for Non-Road Applications (NR-LNF DPF) System
Verification Letter (PDF)  (2 pp, 90K, December 2013)
Technology Engine
Model/Application
Fuel, Max Sulfur (ppm) Reductions (%)
PM NOx HC CO
Low NO2 Diesel Particulate Filter for Non-Road Applications (NR-LNF DPF) System Non-road, Tier 1 or Tier 2 diesel engines certified with a maximum PM level of 0.25 g/bhp-hr with power rating 75 ≤ Kilowatts < 450 (100.6 ≤ Horsepower < 603.4) 15 90 n/a 95 90

The following criteria must be met in order for appropriately retrofitted engines to achieve the aforementioned emission reductions:

  1. The engine must be operated on ultra-low sulfur diesel fuel (ULSD) of 15 ppm or less.
  2. The NR-LNF DPF System requires an exhaust temperature profile sufficient for regeneration. For engines with certification levels of 3.0 to 8.0 g/bhp-hr NOx and 0.01 to 0.11 g/bhp-hr PM, a duty cycle with a Weighted Average Temperature (WAT) at or above 250°C or at least 40% above 245°C (Category 1). For the engine group with emission certification of 5.0 to 8.0 g/bhp-hr NOx and 0.11 to 0.25 g/bhp-hr PM, a duty cycle with a WAT at or above 320°C or at least 40% above 320°C (Category 2). For the engine group with emission certification of 3.0 to 4.99 g/bhp-hr NOx and 0.11 to 0.25 g/bhp-hr PM, a duty cycle with a WAT at or above 362°C or at least 40% above 372°C (Category 3).
  3. Donaldson approved dealer shall perform an engine pre-assessment that assures the engine is at a minimum operating condition to prevent excess soot build up and that checks the maximum flow rate necessary for installation. The dealer will provide the owner with a copy of the pre-assessment.
  4. Donaldson approved dealer will install the Donaldson Emissions Device Monitor with the NR-LNF DPF System to constantly monitor backpressure and temperature on all vehicles equipped with this diesel particulate filter.
  5. The NR-LNF DPF System can be applied to engines with a maximum PM certification level of 0.25 g/bhp-hr.
  6. The engine must be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer.
  7. The vehicle may not be equipped with an oil burning system and lube oil or other oils may not be mixed with the fuel.
  8. The engine must not have been originally certified or equipped with a diesel particulate filter.

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