CCV3500 Series Closed Crankcase Ventilation System Contact Information: Parker Hannifin Corporation Racor Division P.O. Box 3208 3400 Finch Road Modesto, CA 95353 phone 800 344 3286 209 521 7860 fax 209 529 3278 [email protected]www.parker.com/racor www.parker.com/racorproducts Overview: The CCV3500 Series operates by filtering and coalescing contaminants from the crankcase gases. The filtered air from the CCV3500 Series is plumbed to the air intake system between the air filter and the turbocharger for re-combustion. The coalesced oil is collected in the filter sump, where a check valve holds it until it is released to the oil pan when the engine is shut down. A vacuum limiting valve protects the engine from excessive crankcase vacuum. Instruction Part Number 55395 Rev B Product Features: • Captures and returns oil to the crankcase reducing oil consumption and operating costs • Keeps engine compartment and components clean • Directs filtered air back to the intake system for re-combustion instead of polluting the environment • Improves reliability and maintainability of diesel engines
Overview:The CCV3500 Series operates by filtering and coalescing contaminants from the crankcase gases. The filtered air from the CCV3500 Series is plumbed to the air intake system between the air filter and the turbocharger for re-combustion. The coalesced oil is collected in the filter sump, where a check valve holds it until it is released to the oil pan when the engine is shut down. A vacuum limiting valve protects the engine from excessive crankcase vacuum.
Instruction Part Number 55395 Rev B
Product Features:• Captures and returns oil to
the crankcase reducing oil consumption and operating costs
• Keeps engine compartment and components clean
• Directs filtered air back to the intake system for re-combustion instead of polluting the environment
• Improves reliability and maintainability of diesel engines
Mounting Instructions
Installation Diagram
6.0 in.(15.2 cm)
4.3 in.(10.9 cm)
0.4 in.(1.0 cm)
Inlet
Oil Drain
6.0 in.(15.2 cm)
TOP BACK
CCV3550 and CCV3551(Intermittent Operation)
CCV3500 and CCV3501(Continuous Operation)
SumpDrain
Min. heightbetween bottomof CCV and topof check valvemust be 20 in.
(50.8 cm)
Drain must return to crankcase above oil level in oilpan.
Valve Cover
Turbo Charger
Air Filter
Oil Pan
Check Valve(45o max)
Inlet Drain
Inlet
Outlet
Valve Cover
Turbo Charger
Air Filter
Oil PanDrain must return to crankcase above oil level in oilpan.
Inlet
Outlet
Sump Drain
V
± 20º
V
± 20º
Outlet
Install Verticallywith not more than ± 20º tilt
Install Verticallywith not more than ± 20º tilt
Mount CCV3500 inlet, level •with, or above engine valve cover. This location provides greatest height between oil pan and filter, allowing captured oil to drain back to oil pan.
The CCV3500 is suitable for •operation in under-hood conditions, excessive temperatures should be avoided (exhaust manifold or turbocharger). If space is limited, install a heat shield between exhaust system and CCV3500.
Installation GuidelinesKeep hoses clear of hot spots.•
Install checkvalve (CCV55279 •- provided) in filter sump drain line. Do not exceed 45o from vertical. No checkvalve is required for inlet drain line.
Locate an unused dipstick •boss and/or other access to crankcase. Install filter sump drain line as low as possible into crankcase above oil level in oil pan (see diagram). Install inlet drain line in different unused access to crankcase.
Connect drain hose from •newly installed checkvalve to 3/8” filter sump drain barb on bottom of CCV3500 housing. Connect another drain hose to inlet drain barb on bottom of CCV3500 housing.
Remove bends in hoses that •may retain coalesced oil or condensed water vapor.
A minimum height of 4.5” (11.4 •cm) above CCV3500 must be available for servicing.
Continuous Operation
Mount CCV3500 inlet, level •with, or above engine valve cover. This location provides greatest height between oil pan and filter, allowing captured oil to drain back to oil pan.
The CCV3500 is suitable for •operation in under-hood conditions, excessive temperatures should be avoided (exhaust manifold or turbocharger). If space is limited, install a heat shield between exhaust system and CCV3500.
Keep hoses clear of hot spots.•
Locate an unused dipstick •boss and/or other access to crankcase. Install filter sump drain line as low as possible into crankcase above oil level in oil pan (see diagram). Install inlet drain line in different unused access to crankcase.
Connect newly installed drain •hose to 3/8” drain barb on bottom of CCV3550 housing.
Remove bends in hoses that •may retain coalesced oil or condensed water vapor.
A minimum height of 4.5” (11.4 •cm) above CCV3500 must be available for servicing.
Intermittent Operation
Replace filter when filter change indicator is fully extended into clear dome while engine is idling.
Shut down engine, allow five 1. minutes for filter to drain before proceeding.
Release spring clips and 2. remove cover.
Remove dirty filter and 3. pre-separator from housing, dispose properly.
Inspect drain line from inside 4. housing. Ensure there are no obstructions.
Remove O-ring from cover.5.
Filter ReplacementCarefully clean surfaces.6.
Lubricate new O-ring with 7. clean motor oil and install onto cover.
Place new pre-separator into 8. housing.
Place new filter into housing 9. on top of pre-separator. Push filter down to seat it in place.
Replace cover and secure 10. in place with spring clips. Reattach outlet hose, if removed.
Start engine and check for 11. leaks. Correct as necessary with engine off. CCV55304-08 (High Density)
Closed Crankcase Ventilation(CCV) Systems are used toprevent emissions fromcontaminating internal surfaces of the engine air induction system and prevent engine room environments from being coated with oily residue. Both functionsmaintain engine performanceand improve operating environment over the life of theengine. In cold weatherapplications, gases and vapors processed by the CCV system are affected by ambient conditions. The canister is cooled to ambient temperature and oil mist and water vapor particles traveling through the CCV system will then coalesce against the cold interior surfaces of the CCV
canister. This process introducesmicroscopic particles of oil andwater to each other. When theymix, an emulsification of thetwo liquids occurs. This emulsification turns the twoparticles into a creamy jelly-like substance. The mixture slowly builds up as cold air continually cools the canister and the process repeats itself. The emulsified oil-water mixture collect to a point where filter life is compromised and crankcase pressure will rise.
These heater kits prevent thisbuild-up and ensure filter life by warming the canister surfaces. The temperature of the canister is raised near to that of the
crankcase gases entering the CCV assembly. If the canister surfaces are as warm as the crankcase gases, then the oil and water mixture will not coalesce on the interior walls. Since no oil or water coalesces, no emulsification occurs.
CCV Heater Kits
CCV Assembly 120V AC Heater Kit 12V DC Heater Kit 24V DC Heater Kit Wattage
CCV3500 CCV55644 CCV55644-12 CCV55644-24 150
Note: Kits include heater band and insulation sleeve only. CCV assembly sold seperately.
Replacement Heater Kits
Filter
Pre-separator
Clean exterior of CCV canister 1. thoroughly. Adhesive is used to bond insulating sleeve to canister. Oily film present on canister surfaces will affect adhesion.
Wrap heater band around 2. CCV assembly and secure Velcro closure to fasten to canister.
Slide bottom piece of 3. insulation sleeve over heater band. Sleeve opening should
slide around bracket. Secure sleeve to CCV assembly with adhesive strips located along bottom of sleeve.
Slide top piece of insulation 4. sleeve over outside top of bottom insulation sleeve. Sleeve opening should align with CCV outlet. Secure Velcro closure to fasten sleeve together.
For AC models – Connect 5. power cord to appropriate
power source with 15 amp (minimum) circuit.
For DC models – Use wiring 6. diagram below for proper installation.
Allow enough slack in power 7. cord for element removal (servicing). When routing power cord, avoid rubbing areas and hot surfaces.
Heater Kit Installation Guidelines
Installation Diagram1 2 3 4
Wiring DiagramHeater Band
Green
Green/White
Red/White
Fuse BoxIgnition Switch
Battery
+ -Fuse
Black
Red
Resistor(See Notes)
Notes:Use resistor with 24V only1. Use 25 AMP fuse for 12V applications2. Use 15 AMP fuse for 24V applications 3.
87
8685
30
Specifications
CCV3500 CCV3501
Max. Flow Rate 3 CFM (85 LPM) 3 CFM (85 LPM)
Max. Engine Rating 125 HP (93 KW) 125 HP (93 KW)
Height 7.0 in. (17.8 cm) 7.0 in. (17.8 cm)
Opening Width 7.0 in. (17.8 cm) 7.0 in. (17.8 cm)
Depth 6.3 in. (16.0 cm) 6.3 in. (16.0 cm)
Weight 2.3 lbs (1.0 kg) 2.3 lbs (1.0 kg)
Service Clearance 4.6 in. (11.7 cm) 4.6 in. (11.7 cm)
High Density Element CCV55304-08 CCV55304-08
Inlet/Outlet 3/4” hose 3/4” hose
Pressure Regulator Integral Integral
Bypass Indicator Integral Non-Bypass
Return Fitting 1/4” NPT 1/4” NPT
Swivel Fitting #6 JIC (2 pcs) #6 JIC (2 pcs)
Oil Drain Hose I.D. 0.375 in. (3/8”) 0.375 in. (3/8”)
Operating Temperature -40o to +255oF (-40o to +124oC)
CCV3550 CCV3551
Max. Flow Rate 3 CFM (85 LPM) 3 CFM (85 LPM)
Max. Engine Rating 125 HP (93 KW) 125 HP (93 KW)
Height 7.0 in. (17.8 cm) 7.0 in. (17.8 cm)
Opening Width 7.0 in. (17.8 cm) 7.0 in. (17.8 cm)
Depth 6.3 in. (16.0 cm) 6.3 in. (16.0 cm)
Weight 2.3 lbs (1.0 kg) 2.3 lbs (1.0 kg)
Service Clearance 4.6 in. (11.7 cm) 4.6 in. (11.7 cm)
High Density Element CCV55304-08 CCV55304-08
Inlet/Outlet 3/4” hose 3/4” hose
Pressure Regulator Integral Integral
Bypass Indicator Integral Non-Bypass
Return Fitting 1/4” NPT 1/4” NPT
Swivel Fitting #6 JIC (2 pcs) #6 JIC (2 pcs)
Oil Drain Hose I.D. 0.375 in. (3/8”) 0.375 in. (3/8”)
Operating Temperature -40o to +255oF (-40o to +124oC)
CCV3500, CCV3501, CCV3550 & CCV3551Replacement Parts
A
1
B
2
Part No. Description
1. CCV55304-08 Filter Replacement - High Density (Kit includes A and B)
2. CCV55279 Check Valve
Note: CCV3500 - Continuous Duty with Bypass CCV3501 - Continuous Duty with Non-Bypass
CCV3550 - Intermittent Duty with Bypass CCV3551 - Intermittent Duty with Non-Bypass
All products manufactured or distributed by Racor are subject to the following, and only the following, LIMITED EXPRESS WARRANTIES, and no others: For a period of one (1) year from and after the date of purchase of a new Racor product, Racor warrants and guarantees only to the original purchaser-user that such a product shall be free from defects of materials and workmanship in the manufacturing process. The warranty period for pumps and motors is specifically limited to ninety (90) days from date of purchase. A product claimed to be defective must be returned to the place of purchase. Racor, at its sole option, shall replace the defective product with a comparable new product or repair the defective product. This express warranty shall be inapplicable to any product not properly installed and properly used by the purchaser-user or to any product damaged or impaired by external forces.
THIS IS THE EXTENT OF WARRANTIES AVAILABLE ON THIS PRODUCT. RACOR SHALL HAVE NO LIABILITY WHATSOEVER FOR CONSEQUENTIAL DAMAGES
FLOWING FROM THE USE OF ANY DEFECTIVE PRODUCT OR BY REASON OF THE FAILURE OF ANY PRODUCT. RACOR SPECIFICALLY DISAVOWS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED INCLUDING, WITHOUT LIMITATION, ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE (EXCEPT FOR THOSE WHICH APPLY TO PRODUCT OR PART THEREOF THAT IS USED OR BOUGHT FOR USE PRIMARILY FOR PERSONAL, FAMILY, OR HOUSEHOLD PURPOSES), WARRANTIES OF DESCRIPTION, WARRANTIES OF MERCHANTABILITY, TRADE USAGE OR WARRANTIES OR TRADE USAGE.
Warning
Failure or improper selection or improper use of the products and/or systems described herein or related items can cause death, personal injury and property damage. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product
and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the applications are met. The products described herein, including with limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.
The following statement is required pursuant to proposition 65, applicable in the State of California: ‘This product may contain a chemical known to the State of California to cause cancer or reproductive toxicity’.
